Suspension Control ( Automatic - Electronic ): Service and Repair
Self-leveling suspension, servicing
^ The system is bled automatically while driving.
^ The self-levelling suspension is adjusted by way of an adjustable length connecting link between the level control valve and a lever attached to the anti-roll bar of the rear axle.
Counterhold the corresponding components when tightening hydraulic connections
When fluid circuit has been opened always:
^ Check all unions for leaks, start engine and perform visual inspections.
^ Check hydraulic fluid level with unladen vehicle, top up fluid if necessary.
Components Numbered 1 through 37
Components Numbered 1 through 21 And 38 through 47
Components Numbered 48 through 78
Components Numbered 79 through 86
Note: Items -1- to -21- apply to 6-and 8cyl. engines.
1 - Cap with dipstick
2 - Strainer for reservoir
^ Use solvent to clean
3 - Reservoir
4 - Hose clip
^ Always replace
5 - Hose clamp
6 - Hose clamp
^ Can also be replaced by screw type hose clamp
7 - Return line
^ Screwed to item 13: 10 Nm (7 ft. lbs.)
8 - Return line Fluid cooler to connector
9 - Return line Steering box to fluid cooler
10 - Pressure line, 15 Nm (11 ft. lbs.)
11 - Return line, 15 Nm (11 ft. lbs.)
12 - Pressure line, 15 Nm (11 ft. lbs.)
13 - Return line, 15 Nm (11 ft. lbs.)
14 - Hex nut, 10 Nm (7 ft. lbs.)
15 - Bracket
16 - Clamp
17 - Bonded rubber bushing
18 - Nut with washer, 25 Nm (18 ft. lbs.)
19 - Bracket
20 - Combi bolt, 8 Nm (71 inch lbs.)
21 - Fluid cooler
^ Connected to radiator
^ Two versions with different pipe routing
Note: Items -22- to -37- apply only to 6-cyl engines.
22 - Combi bolt, 8 Nm (71 inch lbs.)
23 - Expansion hose
^ Piston pump to pressure pipe
24 - Suction hose Part section with pipe
25 - Combi bolt, 10 Nm (7 ft. lbs.)
26 - Retainer Bolted to cylinder head
27 - Threaded connection, 50 Nm (37 ft. lbs.)
28 - Seal
^ Always replace
29 - Tandem pump, 6cyl. engine
^ Tandem pump consists of piston pump and vane pump. Piston pump is responsible for self-levelling, vane pump for power-assisted steering
30 - Suction hose
^ Part section
31 - Banjo bolt, 25 Nm (18 ft. lbs.)
32 - Seal
^ Always replace
33 - Seal
^ Always replace
34 - Banjo bolt, 50 Nm (37 ft. lbs.)
35 - Line, 40 Nm (30 ft. lbs.)
^ Screw to expansion hose, counterhold at hexagon of expansion hose
^ Secured to intake manifold by way of bolt with washer item 36 -
36 - Bolt with washer, 8 Nm (71 inch lbs.)
37 - Expansion hose
^ Combined hose/pipe assembly, routed to steering box
Note: Items -38- to -47- apply only to 8-cyl. engines.
38 - Tandem pump, 8 cyl. engine
39 - Seal
^ Always renew
40 - Banjo bolt, 50 Nm (37 ft. lbs.)
41 - Suction hose
42 - Seal
^ Always renew
43 - Banjo bolt, 50 Nm (37 ft. lbs.)
44 - Expansion hose
^ Routed to steering box
45 - Seal
^ Always renew
46 - Banjo bolt, 25 Nm (18 ft. lbs.)
47 - Expansion hose
^ Piston pump to pressure pipe
^ Installation instructions, Refer to Fig. 2
48 - Hex bolt
49 - Bracket
^ Introduction of modified bracket as part of design enhancement
^ Bracket is additionally bolted to trapezium link mount
^ An M12 x 1.5 x 95 bolt with washer, shim and self locking nut are used for this purpose
^ Tightening torque: 70 Nm (52 ft. lbs.) plus additional 90 ° turn
50 - Level control valve
51 - Return line, 15 Nm
^ Connects level control valve to manifold item 67-
52 - Pressure line, 15 Nm (11 ft. lbs.)
^ Connector item 55- / disconnection point on rear right longitudinal member
53 - Return line, 15 Nm (11 ft. lbs.)
^ Disconnection point at rear left wheel housing, Refer to Fig. 3 manifold
54 - Pressure line, 15 Nm (11 ft. lbs.)
^ Disconnection point at rear left wheel housing, Refer to Fig. 3 / level control valve
55 - Connector
^ Pressure pipes
56 - Pressure pipe, 15 Nm (11 ft. lbs.)
^ Connector item 55- / connector item 77-
57 - Pressure pipe, 15 Nm (11 ft. lbs.)
^ Level control valve / connector item 55-
58 - Hex bolt, 20 Nm (15 ft. lbs.)
61 - Washer
62 - Hex bolt, 10 Nm (7 ft. lbs.)
63 - Seal
^ Always replace
64 - Seal
^ Always replace
65 - Banjo bolt, 25 Nm (18 ft. lbs.)
66 - Return pipe, 15 Nm (11 ft. lbs.)
^ Manifold disconnection point at rear left longitudinal member
67 - Inlet union
68 - Return line, 15 Nm (11 ft. lbs.)
^ Manifold disconnection point at rear right longitudinal member
69 - Manifold
^ Return pipe / overflow pipes
70 - Washer
71 - Hex nut, 10 Nm (7 ft. lbs.)
Note:
^ Items -70- to -74- are in mirror-image arrangement on left and right of vehicle.
^ Spring cylinder is removed together with pressure pipe item 71-.
^ Unfasten pressure pipe on right side at -item 71- and item 52-.
^ Unfasten on left side at disconnection point on rear left longitudinal member item 78,
72 - Return line
^ Tighten to 15 Nm (11 ft. lbs.) at disconnection point -itern66-
CAUTION! Tighten to 10 Nm (7 ft. lbs.) at rear wheel housing spring cylinder disconnection point.
73 - Pressure line, 15 Nm (11 ft. lbs.)
^ Disconnection point at rear right longitudinal member spring cylinder
^ Pay attention to installation position at spring cylinder, Refer to Fig. 4
^ Pressure line must be handled carefully when removing spring cylinder. Do not bend
74 - Banjo bolt, 20 Nm (15 ft. lbs.)
75 - Seal
^ Always replace
76 - Spring cylinder with pressure accumulator
Note: Spring cylinder is removed together with pressure pipe item 71-.
77 - Bracket
78 - Bleed valve, 15 Nm (11 ft. lbs.)
79 - Connector
80 - Pressure line, 15 Nm (11 ft. lbs.)
^ Connector item 77- / disconnection point at rear left longitudinal member
81 - Hex bolt
82 - Lever
83 - Anti-roll bar
84 - Rubber mounting
85 - Clamp
86 - Self locking nut, 10 Nm (7 ft. lbs.)
^ Always replace
87 - Direction of travel
88 - Self locking nut, 5 Nm (44 inch lbs.)
^ Always replace
89 - Connecting link
^ Adjustable length for adjusting self-levelling suspension:
^ Unfasten hex nut arrow-, adjust length of connecting link and tighten nut to 2 Nm (18 inch lbs.)
90 - Securing plate
91 - Self locking nut, 5 Nm (44 inch lbs.)
^ Always replace
Fig. 1 Installation instructions: high pressure hose
Applies to items - 15 - and - 16 - , Refer to Suspension Control ( Automatic - Electronic Level ), Service and Repair,
^ Expansion hose should project 4 ± 2 mm out of clamp.
Fig. 2 Instructions for attaching high pressure hose to tandem pump
-A-: 25 Nm (18 ft. lbs.)
Fig. 3 Disconnection point at left rear wheel housing
1 - Pressure line
2 - Return line
3 - Brake line
4 - Brake line
Fig. 4 Installation position of pressure line at spring cylinder