Running gear, axles, steering

Chapter overview

• Technical data
  1
• 1 Safety information
  1
• 1.1 Safety measures when working on vehicles with a start/stop system
  1
• 1.3 Safety precautions when working on subframe
  1
• 2 General information
  2
• 2.1 Running gear
  2
• 2.2 Steering
  2
• 2.3 Tyre types
  2
• 3 Repair instructions
  3
• 3.1 Checking shock absorbers when removed
  3
• 3.2 Rules for cleanliness
  3
• 3.3 General repair instructions
  4
• 3.4 Contact corrosion
  4
• 3.5 Gaskets and seals
  4
• 3.6 Nuts and bolts
  5
• 3.7 Electrical components
  5
• 3.8 Routing and attachment of lines
  5
• 3.9 Raising suspension to unladen position (vehicles with coil springs)
  6
• 4 Evaluating accident vehicles
  11
• 5 Disposal
  13
• 5.1 Releasing gas and draining front gas-filled shock absorbers
  13
• 5.2 Releasing gas and draining rear gas-filled shock absorbers
  14
• Front suspension
  15
• 1 Front axle
  15
• 1.1 Overview of fitting locations – front axle
  15
• 2 Subframe
  16
• 2.1 Assembly overview – subframe
  16
• 2.2 Removing and installing subframe without steering rack
  20
• 2.3 Removing and installing subframe with steering rack
  23
• 2.4 Repairing subframe
  24
• 2.5 Removing and installing anti-roll bar
  35
• 2.6 Removing and installing coupling rod
  36
• 2.7 Repairing thread in longitudinal member
  37
• 2.8 Fixing subframe in position
  37
• 2.9 Lowering subframe
  42
• 3 Suspension strut, upper suspension link
  46
• 3.1 Assembly overview - suspension strut, upper suspension link
  46
• 3.2 Removing and installing suspension strut
  46
• 3.3 Repairing suspension strut
  53
• 4 Lower suspension link, swivel joint
  57
• 4.1 Assembly overview - lower suspension link, swivel joint
  57
• 4.2 Removing and installing lower suspension link
  58
• 4.3 Checking swivel joint
  61
• 4.4 Removing and installing swivel joint
  61
• 4.5 Renewing bonded rubber bush for lower suspension link
  63
• 5 Wheel bearing
  71
• 5.1 Assembly overview – wheel bearing assembly
  71
• 5.2 Removing and installing wheel bearing housing
  71
• 5.3 Removing and installing wheel bearing unit
  78
• 6 Drive shaft
  83
• 6.1 Assembly overview – drive shaft
  83
• 6.2 Removing and installing drive shaft
  87
• 6.3 Loosening and tightening threaded connections of drive shaft
  94
• 6.4 Removing and installing drive shaft heat shield
  96
• 6.5 Dismantling and assembling drive shaft
  97
• 6.6 Checking outer constant velocity joint
  107
• 6.7 Checking inner constant velocity joint
  109
• Rear suspension
  112
• 1 Rear axle
  112
• 1.1 Overview – rear axle
  112
• 1.2 Removing and installing rear axle
  113
• 2 Axle beam
  118
• 2.1 Assembly overview – axle beam
  118
• 2.2 Removing and installing axle beam
  120
• 3 Subframe
  123
• 3.1 Assembly overview – subframe
  123
• 4 Anti-roll bar
  124
• 4.1 Assembly overview – anti-roll bar
  124
• 4.2 Removing and installing anti-roll bar
  125
• 4.3 Removing and installing coupling rod
  128
• 5 Suspension link, track rod
  130
• 5.1 Removing and installing track rod
  130
• 6 Suspension strut, shock absorber, spring
  132
• 6.1 Assembly overview - suspension strut, shock absorber, spring
  132
• 6.2 Removing and installing shock absorber
  133
• 6.3 Removing and installing spring
  135
• 7 Wheel bearing assembly, trailing arm
  138
• 7.1 Assembly overview – wheel bearing assembly
  138
• 7.2 Assembly overview - trailing arm
  139
• 7.3 Removing and installing wheel bearing unit
  141
• 7.4 Removing and installing trailing arm with mounting bracket
  145
• 8 Drive shaft
  149
• 8.1 Assembly overview – drive shaft
  149
• 8.2 Removing and installing drive shaft
  151
• 8.3 Dismantling and assembling drive shaft
  156
• 8.4 Loosening and tightening threaded connections of drive shaft
  156
• 8.5 Checking outer constant velocity joint
  158
• 8.6 Checking inner constant velocity joint
  158
• Self-levelling suspension
  159
• 1 Vehicle level sender
  159
• 1.1 Assembly overview – front vehicle level senders
  159
• 1.2 Assembly overview – rear vehicle level senders
  159
• 1.3 Removing and installing front vehicle level senders G78/G289
  160
• 1.4 Removing and installing rear vehicle level senders G76/G77
  162
• Wheels, tyres, vehicle geometry
  163
• 1 Wheels, tyres
  163
• 1.1 Removing tyre from wheel
  163
• 1.2 Fitting tyres
  164
• 1.3 Wheel change
  166
• 1.4 Balancing wheels
  170
• 1.5 Specified torques for wheel bolts
  173
• 1.6 Pressing tyre off wheel rim
  173
• 1.7 Tyre sealant
  174
• 1.8 Tyre sealant disposal
  174
• 1.9 Alloy wheels with metal valves
  175
• 1.10 Models with breakdown set
  175
• 2 Tyre Pressure Monitoring System
  176
• 2.1 System description – Tyre Pressure Monitoring System
  176
• 3 Wheel alignment
  178
• 3.1 Notes for wheel alignment
  178
• 3.2 Conditions for testing
  178
• 3.3 Test preparations
  179
• 3.4 Specifications for wheel alignment
  180
• 3.5 Wheel alignment procedure
  182
• 3.6 Necessity of wheel alignment
  183
• 3.7 Adjusting camber at front wheels
  184
• 3.8 Adjusting camber on rear axle
  185
• 3.9 Adjusting toe at rear axle
  185
• 3.10 Adjusting front axle toe
  185
• 3.11 Wheel runout compensation
  186
• 3.12 Vehicle data sticker
  187
• 3.13 Checking maximum steering wheel angle
  188
• 4 Vibration due to wheels/tyres - causes and rectification
  189
• 4.1 Causes of rough running
  189
• 4.2 Conducting a road test before balancing wheels
  189
• 4.3 Balancing wheel
  189
• 4.4 Vibration control system
  190
• 4.5 Checking radial and lateral runout of wheels and tyres
  190
• 4.6 Checking radial and lateral run-out on wheel rim
  191
• 4.7 Matching wheels and tyres
  192
• 4.8 Determining flat spots on tyres
  193
• Steering
  195
• 1 Steering wheel
  195
• 1.1 Assembly overview – steering wheel
  195
• 1.2 Removing and installing steering wheel
  195
• 2 Steering column
  197
• 2.1 Assembly overview – steering column
  197
• 2.2 Checking steering column for damage
  198
• 2.3 Handling and transporting steering column
  198
• 2.4 Removing and installing steering column
  199
• 2.5 Removing and installing control unit for electronic steering column lock J764
  204
• 3 Steering rack
  206
• 3.1 Assembly overview – steering rack
  206
• 3.2 Removing and installing steering rack
  208
• 3.3 Removing and installing bellows
  215
• 3.4 Removing and installing track rod
  217
• 3.5 Removing and installing track rod ball joint
  221
• 3.6 Repairing steering rack
  223
• 4 Sensors
  226
• 4.1 Removing and installing steering angle sender G85
  226