Running gear, axles, steering - front and four-wheel drive

Chapter overview

• Technical data
  1
• 1 Checklist for evaluating running gear of accident vehicles
  1
• 2 General information
  3
• Front suspension
  4
• 1 Appraisal of accident vehicles
  4
• 2 Repairing front suspension
  5
• 3.1 Modifications to the pendulum support
  11
• 3.2 Modified screw for pendulum support
  12
• 4.1 Removing and installing swivel joint
  18
• 4.2 Removing and installing wishbone
  20
• 4.3 Removing and installing subframe
  21
• 4.4 Removing and installing front anti-roll bar to model year 2000
  23
• 4.5 Removing and installing front anti-roll bar from model year 2001
  25
• 4.6 Repairing nut in longitudinal member/body
  28
• 4.7 Modified subframe connection to body
  29
• 4.8 Aligning subframe to body
  30
• 5 II - Removing and installing wheel bearing, suspension strut, drive shaft
  31
• 5.1 Pressing front wheel bearing out and in with wheel bearing housing installed
  35
• 5.2 Removing and installing wheel bearing housing
  39
• 5.3 Removing and installing suspension strut
  42
• 5.4 Repairing front suspension strut
  45
• 6 Removing and installing drive shafts
  48
• 6.1 Removing and installing drive shafts on vehicles with manual gearbox 006
  48
• 6.2 Removing and installing drive shafts on vehicles with automatic gearbox 099
  50
• 6.4 Removing and installing drive shafts on vehicles with manual gearbox 02N
  56
• 6.5 Removing and installing drive shafts on vehicles with automatic gearbox 09B
  58
• 7 Repairing drive shafts
  62
• 7.2 Checking outer constant velocity joint
  67
• 7.3 Checking inner constant velocity joint
  67
• 7.4 Repairing drive shaft from model year 2001
  69
• 7.5 Repairing drive shaft with triple roller joint AAR 3300i
  75
• Rear suspension
  82
• 1 Appraisal of accident vehicles
  82
• 2 Repairing rear suspension
  83
• 2.1 Assembly overview - rear axle beam, front-wheel drive
  83
• 2.2 Assembly overview - rear axle beam, syncro
  87
• 2.3 Removing and installing rear wishbone
  91
• 2.4 Repairing welded nut in longitudinal member/sill
  94
• 2.5 Repairing thread in cross member
  96
• 2.6 Aligning axle beam to vehicle
  97
• 2.7 Removing and installing shock absorber/spring
  98
• 3 Repairing rear wheel bearing
  100
• 3.1 Pressing rear wheel bearing out and in with V.A.G 1459 B
  103
• 4 Removing and installing rear drive shaft
  109
• 4.1 Removing
  109
• 4.2 Installing
  109
• 5 Repairing rear drive shaft
  111
• 5.1 Checking inner constant velocity joint
  114
• Wheels, tyres, vehicle geometry
  116
• 1 Appraisal of accident vehicles
  116
• 2 Tightening torques for wheel bolts
  117
• 2.1 Modified wheel bolts from model year 2001
  117
• 3 Wheel alignment
  118
• 3.1 General
  118
• 3.2 Test prerequisites
  119
• 3.3 Test preparations
  120
• 3.4 Measuring ride height
  120
• 3.5 Specifications for wheel alignment, vehicles with front and four-wheel drive
  122
• 3.6 Overview - wheel alignment procedure
  122
• 3.7 Measuring vehicle longitudinal inclination
  124
• 3.8 Adjusting toe
  124
• 3.9 Checking left and right-hand wheel lock
  124
• 4 Wheels, tyres
  126
• 4.1 Models with breakdown set
  126
• 4.2 Assembly overview - breakdown set
  126
• 4.3 Renewing bottle with tyre sealant
  127
• 4.4 Removing a tyre
  129
• 4.5 Fitting a new tyre
  130
• 4.6 Disposal of tyre sealant
  130
• 5 Instructions for changing or fitting wheels
  131
• 5.1 Fitting wheels
  132
• 6 Protecting wheel centring seat against corrosion
  133
• 7 Rough running due to wheels/tyres - causes and rectification
  134
• 7.1 Causes of rough running
  134
• 7.2 Balancing wheels
  134
• 7.3 Conducting a road test before balancing wheels
  135
• 7.4 Balancing wheels on stationary wheel balancing machine
  135
• 7.5 Vibration control system VAS 6230
  137
• 7.6 Finish balancer
  137
• 7.7 Radial and lateral runout of wheels and tyres
  138
• 7.9 Checking radial and lateral runout on wheel
  139
• 7.10 Matching
  140
• 7.11 Flat spots caused by storage or handling
  141
• Steering
  143
• 1 Appraisal of accident vehicles
  143
• 2 Column tube with steering column to model year 2000
  144
• 2.1 Removing and installing column tube with steering column
  144
• 2.2 Assembly overview - steering column, column tube
  147
• 2.3 Dismantling and assembling column tube
  148
• 3 Airbag to model year 2000
  152
• 3.1 Location overview
  152
• 3.2 Safety precautions when working on the airbag
  152
• 3.3 Replacing airbag units following an accident
  153
• 3.4 Removing and installing driver's airbag unit
  153
• 3.5 Removing and installing steering wheel
  155
• 3.6 Removing and installing coil connector with slip ring
  155
• 4 Airbag, steering wheel, steering column from model year 2001
  157
• 4.1 Driver side airbag unit
  157
• 4.2 Removing and installing driver's airbag unit
  158
• 4.3 Repairing 4 spoke steering wheel
  161
• 4.4 Removing and installing column tube with steering column
  161
• 4.5 Checking ignition key lock
  165
• 4.6 Assembly overview - steering column, column tube
  167
• 4.7 Dismantling column tube and steering column
  168
• 4.8 Assembling column tube and steering column
  169
• 5 Repairing power assisted steering
  171
• 5.1 Removing and installing power assisted steering box to model year 2000
  171
• 5.2 Removing and installing power assisted steering box from model year 2001
  174
• 5.3 Assembly overview - power assisted steering box
  178
• 5.4 Assembly overview - power assisted steering box (RHD)
  180
• 5.5 Removing and installing track rod when steering box is installed
  182
• 5.6 Checking and adjusting track rod length
  184
• 6 Vane pump, reservoir, hydraulic pipes
  185
• 6.1 Checking vane pump delivery pressure
  185
• 6.2 Assembly overview - vane pump, hydraulic lines and reservoir to model year 2000
  186
• 6.4 Dismantling and assembling reservoir
  190
• 6.5 Checking hydraulic fluid level of power-assisted steering
  191
• 6.7 Installing vane pump
  194
• 6.8 Tensioning V-belt
  195
• 6.9 Assembly overview - power assisted steering vane pump, vehicles fitted with VR6 engine
  196
• 6.10 Removing and installing vane pump for vehicles with VR6 engines
  197