General Information
When installing waxed components, contact surfaces must be cleaned. Contact surfaces must be free of wax and grease.
Tightening specifications for non-lubricated bolts and nuts are given.
Always replace self-locking nuts and bolts.
Always replace the bolts and nuts, which are tightened with an additional tightening angle.
Welding or straightening operations are not permitted on load-bearing or wheel-controlling components.
Always avoid the following actions with coil springs: Hammer strokes, welding beads, applying color identification later.
Do not perform any welding or grinding (separating work) in coil spring or suspension strut area! Cover coil spring or suspension struts if necessary.
When loosening, removing or installing hydraulic, pneumatic or electrical line, always make a sketch or take a picture. This ensures installation is the same as the original.
If the cable ties, brackets or mounting elements were removed during the repair procedure, they must be installed at their original location.
Do not let the drive axle hang down. The inner joint could be damaged if it is bent too far.
Vehicles without a drive axle must not be moved, otherwise the wheel bearing will be damaged. If vehicle does have to be moved, always note the following points:
-- Install an outer joint in place of the drive axle.
-- Tighten the threaded connection between the drive axle and the wheel hub to 200 Nm.
Bonded rubber bushings have a limited range of motion. Only tighten threaded connections at control arms if vehicle is in curb weight position or control position.
- Wheel bearing, lifting to curb weight position on vehicles with coil springs, refer to WHEEL BEARING IN CURB WEIGHT, LIFTING VEHICLES WITH COIL SPRING .
As a running change in MY 2010, aluminum coupling rods were replaced by plastic coupling rods. Do not use different types of coupling rods on the same axle.
The suspension components could be damaged.
If the subframe mount, the steering gear or the subframe crossbrace are not installed correctly, do not rest the vehicle on its wheels.
The vehicle must not be supported on the subframe or the subframe crossbrace (e.g. using a floor jack).
If the vehicle must still have an axle alignment, every screw and nut that must be loosened for adjustment must be tightened to the tightening specification. Tighten the bolts and nuts to the specified additional tightening angle after the alignment/adjustment is complete.
If vehicle will be driving on the streets, all screws and nuts must be tightened properly!
There is a risk of injury if the engine starts automatically in vehicles with the Start/Stop System.
- For vehicles with an activated Start/Stop System (recognizable from a notification in the instrument cluster), the motor can be started automatically if needed.
- Make sure that the start/stop system is deactivated when working on the vehicle (turn off the ignition, turn on the ignition when necessary).
Handling the high voltage cables:
- Do not stand on or place tools on the high voltage cables or their components. This may damage the insulation.
- Do not bend or kink high voltage cables as this may damage the insulation.
- The round high voltage connectors are color coded with an exterior colored ring and mechanically coded with guide or code tabs. Observe the coding when connecting the round high voltage connector in order to avoid mechanical damage to the high voltage connector.
The engine could start unexpectedly.
For general work performed on the high voltage system the ignition must be switched off and the key must be kept outside of the vehicle interior.
High voltage components have hazardous voltage.
Note the following when working near high voltage components and high voltage cables:
- Cutting, deformed, and sharp edged tools or heat sources such as welding, solder, hot air and thermal glue are forbidden.
- Visually inspect the work area before working on high voltage components.
- Perform a visual inspection of the Electric Drive Power and Control Electronics -JX1-, the Electro-Drive Drive Motor -V141-, the Electrical A/C Compressor -V470- and the high voltage lines when working in the engine compartment.
- Visually inspect the high voltage cables and the covers when working on the underbody.
- Visually inspect the high voltage cables, the electronics and the High Voltage System Maintenance Connector -TW -, when working in the luggage compartment.
- Visually inspect all potential equalization cables.
Observe the following when performing the visual inspection:
- None of the components appear to have any external damage.
- The high voltage cable insulation and the potential equalization cable insulation are not damaged.
- The high voltage cables must not have any unusual deformations.
- Each high voltage component must be marked with a red warning label.
When working on vehicles with the ignition already switched on or that are ready to drive there is a danger of the engine starting unexpectedly and of being poisoned by gas in enclosed areas. Risk of body parts and/or clothing being clamped or pulled.
Perform the following before switching on the ignition:
- Move the selector lever into P.
- Activate the parking brake
- Turn off the ignition.
- Open the hood
- Connect the charger, such as the Battery Charger VAS5095A to the jump start of the 12V vehicle electrical system.
- Turn on the ignition.