FRONT GAS-FILLED STRUT, VENTING AND EMPTYING
A - Venting through Drill Holes
Secure gas-filled shock absorber vertically in vise, with piston rod facing down.
Scheme 278
| WARNING | Wear protective goggles while drilling. |
Drill a 3 mm hole -arrow A- through the shock absorber outer tube.
Note. Gas escapes when drilling.
Continue drilling until the tube inside is drilled through (approximately 25 mm deep).
Drill a second 6 mm hole -arrow B- through the outer and inner shock absorber tubes.
Hold shock absorber over appropriate container for catching oil and move piston rod repeatedly through the entire stroke until no more oil flows out.
B - Open with Pipe Cutter
Special tools and workshop equipment required
- Pipe cutter, commercially available
| WARNING | Wear protective goggles when drilling or sawing. |
Drill a 3 mm hole -arrow- through the shock absorber outer tube or saw through the tube wall.
Scheme 279
Note. Gas escapes when drilling or sawing.
Attach a pipe cutter (commercially available), as shown in the illustration, and cut through the outer shock absorber tube.
Pull the piston rod upward, hold the inner shock absorber tube in place with pliers and push it downward so that it remains in the outer shock absorber tube when the piston rod is slowly raised.
Remove the piston rod from the shock absorber inner tube.
Empty the shock absorber tube.
REAR GAS-FILLED STRUT, VENTING
A - Venting through Drill Holes
Secure gas-filled shock absorber vertically in vise, with piston rod facing down.
Scheme 280
| WARNING | Wear protective goggles while drilling. |
Drill a 3 mm hole -arrow A- through the shock absorber outer tube.
Note. Gas escapes when drilling.
Continue drilling until the tube inside is drilled through (approximately 25 mm deep).
Drill a second 6 mm hole -arrow B- through the outer and inner shock absorber tubes.
Hold shock absorber over appropriate container for catching oil and move piston rod repeatedly through entire stroke until no more oil flows out.
B - Open with Pipe Cutter
Special tools and workshop equipment required
- Pipe cutter, commercially available
| WARNING | Wear protective goggles when drilling or sawing. |
Drill a 3 mm hole -arrow- through the shock absorber outer tube or saw through the tube wall.
Scheme 281
Note. Gas escapes when drilling or sawing.
Attach a pipe cutter (commercially available), as shown in the illustration, and cut through the outer shock absorber tube.
Pull the piston rod upward, hold the inner shock absorber tube in place with pliers and push it downward so that it remains in the outer shock absorber tube when the piston rod is slowly raised.
Remove the piston rod from the shock absorber inner tube.
Empty the shock absorber tube.
POWER STEERING GEAR, EMPTYING
Note. The room temperature must be at least 20 °C (68 °F) when emptying the power steering gear.
Hold the power steering gear that will be opened over the oil collecting container and let the hydraulic oil drain.
Clamp the power steering gear horizontally in the vise with the connections facing down.
Place the oil collecting container under the power steering gear.
Move the steering rack over the tie rod approximately 6 times over the from one end to the other.
Dispose of the power steering gear.
CHASSIS
| Front axle | Five-link - front axle, upper and lower transverse link, transverse stabilizer, twin gas-filled strut | |
|---|---|---|
| Rear Axle | Track controlled axle, upper and lower transverse links, transverse stabilizer, individual wheel suspension, twin gas-filled struts with coil spring | |
| FWD/AWD | |||||
|---|---|---|---|---|---|
| Standard Suspension 1BA (1) | China City Suspension 1BB (1) | Sport Suspension 1BD (1) | Allroad Steel Spring Suspension 1BP (2) | ||
| Wheelbase | Mm | Approximately 2812 | Approximately 2873 | Approximately 2815 | Approximately 2809 |
| Front track | Mm | Approximately 1567 | Approximately 1567 | Approximately 1569 | Approximately 1588 |
| Rear track | Mm | Approximately 1557 | Approximately 1557 | Approximately 1558 | Approximately 1581 |
| Maximum steering angle at curved inner wheel | Degree | 39° 57' | 39° 57' | 39° 57' | 39° 57' |
| (1) Front/rear track width, applies only to 205/60/R16 tires on ET39 rims. (2) Front/rear track width, applies only to 225/55/R17 tires on ET26 rims. | |||||
| (1) | Front/rear track width, applies only to 205/60/R16 tires on ET39 rims. |
| (2) | Front/rear track width, applies only to 225/55/R17 tires on ET26 rims. |
Note. The specified values apply to all engine versions. Tracks change with use of wheels with different offset.
| FWD/AWD | |||||
|---|---|---|---|---|---|
| Sport Suspension 1BE (1) | Chassis with Electronic Damping 1BL (1) | Heavy Duty Suspension 1BR (1) | Sport Chassis (S-Line) 1BV (1) | ||
| Wheelbase | Mm | Approximately 2815 | Approximately 2815 | Approximately 2811 | Approximately 2815 |
| Front track | Mm | Approximately 1569 | Approximately 1569 | Approximately 1565 | Approximately 1569 |
| Rear track | Mm | Approximately 1558 | Approximately 1558 | Approximately 1556 | Approximately 1558 |
| Maximum steering angle at curved inner wheel | Degree | 39° 57' | 39° 57' | 39° 57' | 39° 57' |
| (1) Front/rear track width, applies only to 205/60/R16 tires on ET39 rims. | |||||
| (1) | Front/rear track width, applies only to 205/60/R16 tires on ET39 rims. |
Note. The specified values apply to all engine versions. Tracks change with use of wheels with different offset.
| Steering Gear | Maintenance-free rack-and-pinion steering with servo assist | |
|---|---|---|
| Turning diameter | Approximately 11.50 meters | |
SHOCK ABSORBERS, LEAKING
Shock absorbers are frequently rejected and exchanged because of leaks. Examinations on the test stand and on the vehicle have shown that the replacement of a large number of rejected shock absorbers was not justified.
Slight leaking of oil ("sweating") at piston rod seal is no reason to replace a shock absorber. A shock absorber damp with oil is OK under the following circumstances
Scheme 282
- Oil leakage (shaded in illustration) is visible, but dull, matte and possibly dry due to dust.
Note. Minor oil excretion is advantageous since piston rod oil seal gets lubricated, which increases service life. This is true for front and rear shock absorbers.
SHOCK ABSORBER NOISES
Shock absorbers are frequently rejected and exchanged because of rumbling noises. Examinations on the test stand and vehicle have shown that there was not complaint with approximately 70% of the rejected shock absorbers and the replacement was not justified.
With complaints that are interpreted as rumbling or knocking sounds, proceed as follows.
Determine on a road test with the customer - if possible on a dry stretch of road with irregularities - where, when and how these sounds change.
Note. Only in the rarest of cases shock absorbers are the fault for noises.
SHOCK ABSORBERS, CHECKING WHEN REMOVED
Defective shock absorbers are noticeable when driving due to loud rumbling noises - a result of wheel hopping - especially on poor stretches of road. Moreover, they can be recognized by a large loss of oil.
Note. Shock absorbers are maintenance-free, shock absorber oil cannot be topped off.
A removed shock absorber can be checked by hand as follows
Press shock absorber together by hand.
- Piston rod must move with even resistance throughout entire stroke and without jerking.
Release piston rods.
- For shock absorbers with sufficient gas pressure, piston rod returns to initial position automatically.
Note. If this is not the case, shock absorber must be replaced. As long as oil loss is not large, the effectiveness represents that of a conventional shock absorber. The damping function is also completely available without gas pressure, as long as there is no large loss of oil. However, noise may increase.