Running gear, axles, steering

Chapter overview

• Technical data
  1
• 1 Safety information
  1
• 1.2 Safety precautions when working on subframe
  1
• 1.3 Safety precautions when working on the cooling system
  1
• 1.4 Safety precautions when working on a high-voltage system
  2
• 1.5 Safety precautions when working in the vicinity of high-voltage components
  2
• 2 Repair instructions
  4
• 2.1 Leaks at shock absorbers
  4
• 2.2 Noises from shock absorbers
  4
• 2.3 Checking shock absorbers when removed
  5
• 2.4 Steering rack
  5
• 2.5 Gaskets and seals
  6
• 2.6 Nuts and bolts
  6
• 2.7 Electrical components
  6
• 3 Evaluating accident vehicles
  7
• 3.1 Check list for evaluating running gear on accident vehicles
  7
• 4 Disposal
  9
• 4.1 Releasing gas and draining front gas-filled shock absorbers
  9
• 4.2 Releasing gas and draining rear gas-filled shock absorbers
  11
• Front suspension
  12
• 1 Front axle
  12
• 1.1 Overview of fitting locations – front axle
  12
• 2 Subframe
  13
• 2.1 Assembly overview – subframe
  13
• 2.2 Assembly overview – anti-roll bar
  14
• 2.3 Removing and installing subframe without steering rack
  14
• 2.4 Removing and installing subframe with steering rack
  17
• 2.5 Removing and installing anti-roll bar
  19
• 2.6 Removing and installing coupling rod
  21
• 2.7 Repairing thread in longitudinal member
  22
• 2.8 Fixing subframe in position
  22
• 2.9 Taking up weight of front axle with scissor-type assembly platform
  24
• 3 Suspension strut, upper suspension link
  27
• 3.1 Assembly overview - suspension strut, upper suspension link
  27
• 3.2 Removing and installing suspension strut
  29
• 3.3 Repairing suspension strut
  32
• 4 Lower suspension link, swivel joint
  38
• 4.1 Assembly overview - lower suspension link, swivel joint
  38
• 4.2 Removing and installing lower suspension link
  40
• 4.3 Checking swivel joint
  41
• 4.4 Removing and installing swivel joint
  42
• 4.5 Renewing bonded rubber bush for lower suspension link
  44
• 4.6 Removing and installing shield for suspension link
  53
• 5 Wheel bearing
  54
• 5.1 Assembly overview – wheel bearing assembly
  54
• 5.2 Removing and installing wheel bearing housing
  57
• 5.3 Removing and installing wheel bearing unit
  60
• 5.4 Loosening and tightening wheel bearing threaded connection on outside
  62
• Rear suspension
  64
• 1 Rear axle
  64
• 1.1 Overview – rear axle
  64
• 1.2 Removing and installing rear axle
  66
• 1.3 Taking up weight of rear axle with scissor-type assembly platform
  71
• 1.4 Lowering rear axle
  76
• 1.5 Securing vehicle to support arms of lifting platform
  79
• 2 Subframe
  82
• 2.1 Assembly overview – subframe
  82
• 2.2 Fixing subframe in position
  84
• 2.3 Renewing subframe mountings
  86
• 2.4 Renewing motor mountings
  106
• 2.5 Renewing gearbox mounting
  116
• 3 Anti-roll bar
  126
• 3.1 Assembly overview – anti-roll bar
  126
• 3.2 Removing and installing anti-roll bar
  128
• 3.3 Removing and installing coupling rod
  128
• 4 Suspension link, track rod
  130
• 4.1 Assembly overview - transverse link
  130
• 4.2 Assembly overview - transverse link
  132
• 4.3 Assembly overview – spring control arm
  134
• 4.4 Assembly overview – track rod
  136
• 4.5 Removing and installing upper transverse link
  137
• 4.6 Removing and installing lower rear spring control arm
  139
• 4.7 Removing and installing lower suspension link
  141
• 4.8 Removing and installing track rod
  142
• 4.9 Removing and installing stone deflector for spring control arm
  143
• 5 Suspension strut, shock absorber, spring
  145
• 5.1 Assembly overview - suspension strut, shock absorber, spring
  145
• 5.2 Removing and installing shock absorber
  147
• 5.3 Repairing shock absorber
  150
• 5.4 Removing and installing spring
  153
• 6 Wheel bearing assembly, trailing arm
  159
• 6.1 Assembly overview – wheel bearing assembly
  159
• 6.2 Removing and installing wheel bearing housing
  161
• 6.3 Removing and installing wheel bearing unit
  163
• 6.4 Raising wheel bearing assembly to unladen position
  165
• 7 Drive shaft
  167
• 7.1 Assembly overview – drive shaft
  167
• 7.2 Removing and installing drive shaft
  169
• 7.3 Dismantling and assembling drive shaft
  176
• 7.4 Loosening and tightening threaded connections of drive shaft
  183
• 7.5 Checking outer constant velocity joint
  184
• Self-levelling suspension
  187
• 1 Electronically controlled damping system
  187
• 1.1 Overview of fitting locations - electronically controlled damping system
  187
• 1.2 Assembly overview – body acceleration sender
  189
• 1.3 Assembly overview - electronically controlled damping control unit J250
  189
• 1.4 Removing and installing electronically controlled damping control unit J250
  190
• 1.5 Removing and installing front body acceleration senders G341/G342
  191
• 1.6 Removing and installing rear left body acceleration sender G699
  192
• 2 Vehicle level sender
  194
• 2.1 Assembly overview – front vehicle level senders
  194
• 2.2 Assembly overview – rear vehicle level senders
  194
• 2.3 Removing and installing front vehicle level senders G78/G289
  195
• 2.4 Removing and installing rear vehicle level sender
  197
• Wheels, tyres, vehicle geometry
  198
• 1 Wheel alignment
  198
• 1.1 Notes for wheel alignment
  198
• 1.2 Conditions for testing
  199
• 1.3 Test preparations
  199
• 1.4 Specifications for wheel alignment
  201
• 1.5 Setting vehicle to initial position for wheel alignment
  202
• 1.6 Wheel alignment procedure
  203
• 1.7 Necessity of wheel alignment
  204
• 1.8 Adjusting camber at front wheels
  205
• 1.9 Adjusting camber on rear axle
  206
• 1.10 Adjusting toe at rear axle
  207
• 1.11 Adjusting front axle toe
  208
• 1.12 Wheel runout compensation
  209
• 1.13 Vehicle data sticker
  209
• 1.14 Checking maximum steering wheel angle
  210
• Steering
  212
• 1 Steering wheel
  212
• 1.1 Assembly overview – steering wheel
  212
• 1.2 Removing and installing steering wheel
  213
• 2 Steering column
  215
• 2.1 Assembly overview – steering column
  215
• 2.2 Checking steering column for damage
  217
• 2.3 Handling and transporting steering column
  217
• 2.4 Removing and installing steering column
  218
• 2.5 Removing and installing intermediate steering shaft
  222
• 2.6 Removing and installing control unit for electronic steering column lock J764
  223
• 3 Steering rack
  228
• 3.1 Assembly overview – steering rack
  228
• 3.2 Removing and installing steering rack
  231
• 3.3 Removing and installing boot
  234
• 3.4 Removing and installing track rod
  237
• 3.5 Removing and installing track rod ball joint
  239
• 3.6 Repairing steering rack
  241