Running gear

Chapter overview

• Technical data
  1
• 1 Technical data
  1
• 1.1 Running gear
  1
• 1.2 Steering
  1
• 1.3 Brakes
  1
• 1.4 Wheels, tyres
  3
• Front suspension
  5
• 1 Repairing front suspension (basic running gear)
  5
• 1.1 Removing and installing subframe, anti-roll bar and suspension link (basic running gear)
  6
• 1.2 Checking suspension link (basic and Plus running gear)
  9
• 1.3 Reworking cap nut in longitudinal member (basic and Plus running gear)
  9
• 1.4 Removing and installing wheel bearing, suspension strut, drive shaft (basic running gear)
  10
• 1.5 Repairing front suspension strut (basic and Plus running gear)
  14
• 2 Repairing front suspension (Plus running gear)
  17
• 2.2 Removing and installing suspension link (Plus running gear)
  20
• 2.3 Removing and installing wheel bearing, suspension strut (Plus running gear)
  22
• 2.4 Removing and installing drive shaft (Plus running gear)
  24
• 2.5 Removing and installing drive shaft with triple roller joint
  25
• 2.6 Wheel hubs with compressed splines, vehicles with Plus running gear
  27
• 3 Repairing drive shaft
  29
• 3.1 Repairing drive shaft with triple roller joint
  34
• 3.2 Dismantling and assembling triple roller joint
  36
• 3.3 Checking outer constant velocity joint
  39
• 3.4 Checking inner constant velocity joint
  40
• Rear suspension
  42
• 1 Repairing rear axle (front-wheel drive vehicles)
  42
• 1.1 Removing and installing bonded rubber bush
  44
• 1.2 Reworking cap nut in longitudinal member (vehicles with front-wheel drive)
  49
• 1.3 Revised weld studs for securing brake lines and hand brake cables
  50
• 2 Repairing rear axle (vehicles with four-wheel drive)
  55
• 2.1 Repairing rear drive shaft
  60
• 2.2 Reworking cap nut in longitudinal member (vehicles with four-wheel drive)
  62
• 2.3 Dismantling and assembling suspension strut (vehicles with four-wheel drive)
  63
• 3 Repairing wheel bearing
  66
• 3.1 Repairing wheel bearing, vehicles with front-wheel drive - drum brakes
  66
• 3.2 Repairing wheel bearing, vehicles with front-wheel drive - disc brakes
  70
• 3.3 Repairing wheel bearing, vehicles with four-wheel drive - disc brakes
  73
• Wheels, tyres, vehicle geometry
  77
• 1 Wheel alignment
  77
• 1.1 Test requirements:
  77
• 1.2 Vehicle alignment specifications (vehicles with front-wheel drive)
  77
• 1.3 Wheel alignment specifications (vehicles with four-wheel drive)
  78
• 1.4 Adjusting front wheel camber
  79
• 1.5 Calculating the direction of travel:
  79
• Anti-lock brake system
  80
• 1.1 Notes for repairs on ABS, ABS/EDL
  80
• 1.2 Removing and installing control unit
  81
• 1.3 Removing and installing speed sensor and speed sensor rotor
  81
• 2.1 Removing and installing hydraulic unit (LHD)
  83
• 2.2 Removing and installing brake pedal position sender, LHD
  84
• 3.1 Connecting brake lines from tandem brake master cylinder to hydraulic unit
  88
• 3.2 Adjusting brake light switch F
  89
• 3.3 Removing and installing brake pedal position sender, RHD
  89
• 3.4 Removing and installing hydraulic unit, RHD
  90
• 4.1 General information on this ABS
  93
• 4.2 Notes for repairs on ABS, ABS/EDL
  93
• 4.3 Removing and installing control unit and hydraulic unit
  94
• 5 Assembly overview - hydraulic unit, brake servo/brake master cylinder Teves 20 GI - LHD
  97
• 6 Assembly overview - hydraulic unit, RHD
  98
• 6.1 Connecting brake lines from tandem brake master cylinder to hydraulic unit
  99
• Brakes - mechanism
  100
• 1 Repairing front brakes
  100
• 1.1 Repairing front brakes, Girling brake caliper
  100
• 1.2 Removing and installing brake pads
  102
• 1.3 Repairing front brakes, Teves/ATE
  102
• 1.4 Removing and installing brake pads
  104
• 2 Repairing rear brakes, drum brakes
  107
• 2.1 Removing and installing rear brakes
  107
• 2.2 Releasing brake shoe adjustment
  108
• 2.3 Repairing rear brakes
  108
• 2.4 Removing and installing brake shoes
  110
• 2.5 Adjusting handbrake, drum brakes
  111
• 3 Repairing rear brakes, disc brakes
  112
• 3.1 Repairing Girling rear disc brakes, vehicles with front or four-wheel drive
  112
• 3.2 Removing and installing brake pads
  114
• 3.3 Adjusting handbrake, disc brakes
  115
• 4 Assembly overview - handbrake lever
  116
• 5 Removing and installing brake pedal/brake servo
  118
• 5.1 Removing and installing brake pedal
  119
• Brakes - hydraulics
  120
• 1 Assembly overview - brake master cylinder/brake servo
  120
• 2 Repairing Girling front brake calipers
  122
• 2.1 Removing and installing piston for front brake caliper
  123
• 3 Repairing Teves/ATE front brake caliper
  125
• 4 Repairing rear brake caliper
  128
• 4.1 Removing and installing piston for rear brake caliper
  129
• 5 Checking and adjusting brake pressure regulator
  131
• 5.1 Vehicles without ABS, vehicles with ABS, ABS/EDL, Teves 04
  131
• 5.2 Load dependent brake pressure regulator specifications
  131
• 6 Bleeding the brake system on vehicles with and without ABS or ABS/EDL
  133
• 6.1 Bleeding the brake system on vehicles with and without ABS or ABS/EDL
  133
• 6.3 Bleeding brake system without brake filling and bleeding unit
  134
• Steering
  136
• 1.1 Removing and installing airbag module
  138
• 1.2 Removing and installing steering wheel with airbag
  139
• 1.3 Removing and installing coil connector with slip ring
  140
• 1.4 Removing and installing column tube for height adjustable steering wheel
  141
• 2 Repairing power steering
  142
• 2.1 Checking pump delivery pressure
  142
• 2.2 Removing and installing power steering box
  142
• 2.3 Assembly overview - power steering box (TRW)
  144
• 2.4 Adjusting power steering box (TRW)
  146
• 2.5 Assembly overview - power steering box (ZF)
  147
• 2.6 Adjusting power steering box (ZF)
  149
• 2.7 Revised track rod ball joints
  149
• 2.9 Removing and installing track rod (TRW and ZF power steering box)
  152
• 2.10 Checking and adjusting length of left track rod
  154
• 3 Assembly overview - vane pump, hydraulic lines, reservoir (vehicles with 4-cyl. engines)
  155
• 3.1 Assembly overview - hydraulic lines, reservoir (vehicles with 4-cyl. engines)
  156
• 3.3 Removing and installing power steering vane pump (vehicles with 16V engine)
  158
• 3.4 Tensioning V-belt on vehicles with 4-cylinder engine
  159
• 4 Assembly overview - pressure line and cooling line (vehicles with VR6 engine)
  160
• 4.1 Removing and installing power steering vane pump (vehicles with VR6 engine)
  161