Running gear, axles, steering

Chapter overview

• Technical data
  1
• 1 Safety information
  1
• 1.1 Safety precautions when working on high-voltage system
  1
• 1.2 Safety precautions when working in the vicinity of high-voltage components
  2
• 1.3 Safety measures when working on vehicles with a start/stop system
  2
• 1.4 Safety precautions when working on subframe
  2
• 1.5 Safety precautions when tow-starting or towing
  2
• 2 General information
  3
• 2.1 Tyre types
  3
• 3 Repair instructions
  4
• 3.1 Checking shock absorbers when removed
  4
• 3.2 Rules for cleanliness
  4
• 3.3 General repair instructions
  4
• 3.4 Contact corrosion
  5
• 3.5 Gaskets and seals
  5
• 3.6 Nuts and bolts
  6
• 3.7 Routing and attachment of lines
  6
• 3.8 Raising wheel bearing assembly to unladen position
  6
• 4 Evaluating accident vehicles
  10
• 4.1 Check list for evaluating running gear on accident vehicles
  10
• 5 Disposal
  12
• 5.1 Releasing gas and draining front gas-filled shock absorbers
  12
• 5.2 Releasing gas and draining rear gas-filled shock absorbers
  12
• 6 Classification of dangers of the high-voltage system
  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 with steering rack
  24
• 2.3 Repairing subframe
  33
• 2.4 Removing and installing anti-roll bar
  33
• 2.5 Renewing anti-roll bar bushes
  35
• 2.6 Removing and installing coupling rod
  35
• 2.7 Fixing subframe in position
  36
• 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
  50
• 4 Lower suspension link, swivel joint
  54
• 4.1 Assembly overview - lower suspension link, swivel joint
  54
• 4.2 Removing and installing lower suspension link
  54
• 4.3 Checking swivel joint
  56
• 4.4 Removing and installing swivel joint
  57
• 4.5 Renewing bonded rubber bush for lower suspension link
  59
• 5 Wheel bearing
  64
• 5.1 Assembly overview – wheel bearing assembly
  64
• 5.2 Removing and installing wheel bearing housing
  64
• 5.3 Removing and installing wheel bearing unit
  69
• 6 Drive shaft
  75
• 6.1 Assembly overview – drive shaft
  75
• 6.2 Removing and installing drive shaft
  77
• 6.3 Dismantling and assembling drive shaft
  82
• 6.4 Loosening and tightening threaded connections of drive shaft
  88
• 6.5 Checking outer constant velocity joint
  90
• 6.6 Repairing intermediate shaft
  91
• Rear suspension
  95
• 1 Rear axle
  95
• 1.1 Overview – rear axle
  95
• 1.2 Removing and installing rear axle
  96
• 2 Anti-roll bar
  104
• 2.1 Assembly overview - anti-roll bar
  104
• 2.2 Removing and installing anti-roll bar
  105
• 2.3 Renewing anti-roll bar bushes
  108
• 2.4 Removing and installing coupling rod
  109
• 3 Suspension strut, shock absorber, spring
  112
• 3.1 Assembly overview - suspension strut, shock absorber, spring
  112
• 3.2 Removing and installing shock absorber
  118
• 3.3 Removing and installing leaf spring
  119
• 3.4 Removing and installing bonded rubber bushes for leaf spring
  124
• 3.5 Removing and installing axle beam stop buffer
  132
• 3.6 Removing and installing spring hanger for leaf spring
  132
• 3.7 Removing and installing support spring
  133
• 4 Wheel bearing assembly, trailing arm
  135
• 4.1 Assembly overview – wheel bearing assembly
  135
• 4.2 Removing and installing wheel bearing housing
  138
• 4.3 Removing and installing wheel bearing unit
  140
• Self-levelling suspension
  150
• 1 Vehicle level sender
  150
• 1.1 Assembly overview - front vehicle level senders
  150
• 1.2 Assembly overview - rear vehicle level senders
  150
• 1.3 Removing and installing front right vehicle level sender G289
  152
• 1.4 Removing and installing rear right vehicle level sender G77
  152
• Wheels, tyres, vehicle geometry
  154
• 1 Wheels, tyres
  154
• 1.1 Removing tyre from wheel
  154
• 1.2 Fitting tyres
  154
• 1.3 Wheel change
  155
• 1.4 Specified torques for wheel bolts
  160
• 1.5 Pressing tyre off wheel rim
  161
• 1.6 Tyre sealant disposal
  161
• 1.7 Models with breakdown set
  162
• 2 Tyre Pressure Monitoring System
  163
• 2.1 System description – Tyre Pressure Monitoring System
  163
• 2.2 Overview of fitting locations - tyre pressure monitoring system
  163
• 2.3 Assembly overview - tyre pressure sensor
  164
• 2.4 Removing and installing Tyre Pressure Monitoring System control unit J502
  166
• 2.5 Removing and installing tyre pressure sensors G222/G223/G224/G225
  166
• 3 Wheel alignment
  169
• 3.1 Notes for wheel alignment
  169
• 3.2 Conditions for testing
  170
• 3.3 Test preparations
  171
• 3.4 Specifications for wheel alignment
  178
• 3.5 Wheel alignment procedure
  183
• 3.6 Necessity of wheel alignment
  197
• 3.7 Explanatory notes on production control numbers (PR no.)
  198
• 3.8 Adjusting camber at front wheels
  199
• 3.9 Adjusting camber on rear axle
  199
• 3.10 Adjusting toe at rear axle
  200
• 3.11 Adjusting front axle toe
  200
• 3.12 Wheel runout compensation
  201
• 3.13 Vehicle data sticker
  201
• 3.14 Checking maximum wheel lock
  201
• 3.15 Bringing steering to straight-ahead position on steering rack
  202
• 4 Vibration due to wheels/tyres - causes and rectification
  203
• 4.1 Causes of rough running
  203
• 4.2 Conducting a road test before balancing wheels
  203
• 4.3 Balancing wheel
  204
• 4.4 Vibration control system
  208
• 4.5 Checking radial and lateral runout of wheels and tyres
  208
• 4.6 Checking radial and lateral run-out on wheel rim
  209
• 4.7 Matching wheels and tyres
  210
• 4.8 Determining flat spots on tyres
  211
• 5 Adaptive cruise control
  213
• 5.1 Calibrating adaptive cruise control, Crafter
  213
• 5.2 Calibrating adaptive cruise control, MAN TGE
  217
• 6 Front camera for assist systems
  222
• 6.1 Calibrating front camera for assist systems, Crafter
  222
• 6.2 Calibrating front camera for assist systems, MAN TGE
  229
• Steering
  243
• 1 Steering wheel
  243
• 1.1 Assembly overview – steering wheel
  243
• 1.2 Removing and installing steering wheel
  243
• 2 Steering column
  246
• 2.1 Assembly overview – steering column
  246
• 2.2 Checking steering column for damage
  247
• 2.3 Handling and transporting steering column
  247
• 2.4 Removing and installing steering column
  248
• 2.5 Removing and installing intermediate steering shaft
  250
• 3 Steering rack
  253
• 3.1 Assembly overview – steering rack
  253
• 3.2 Checking steering rack for damage
  254
• 3.3 Handling and transporting steering rack
  254
• 3.4 Removing and installing steering rack
  254
• 3.5 Removing and installing boot
  263
• 3.6 Removing and installing track rod
  265
• 3.7 Removing and installing track rod ball joint
  268
• 3.8 Repairing steering rack
  270
• 3.9 Removing and installing steering rack mountings
  271
• 4 Sensors
  275
• 4.1 Removing and installing steering angle sender G85
  275