Suspension Control ( Automatic - Electronic ): Service and Repair

Automatic level control

Note! The following special tools are used for this installation: 999 5500, 999 5409

Note! Carry out all the points in this instruction on the right and the left-hand sides, unless otherwise specified.

Preparations, rear suspension




- Fold both the rear backrests forward.




- Remove the clip (1) at the left-hand side cushion.




- Detach the cargo compartment carpet at the rear edge (turn the two knobs (1) a quarter turn).




- Pull up the front of the cargo compartment carpet. Fold the front half back over the rear half of the cargo compartment carpet.




- Slide the entire cargo compartment carpet forward slightly. Twist slightly to remove the cargo compartment carpet through the tailgate opening
- Remove the cargo compartment carpet.




- Press the centres of the clips until a click is heard. Remove the clips
- Remove the plastic nut.




- Turn the knob (1) a quarter turn
- Fold the side panels down. Lift the panels out.




- Remove the clips (1) in the front side panel in the cargo compartment. Remove the panel.




- Remove the foam rubber seal (1) above the rear shock absorber mountings.

Removing the shock absorbers etc.




- Remove the screw (1) and the washer (1) holding the upper shock absorber bearing at the car body.




- Raise the car.

Remove:
- the rear wheels
- the nut (1) for the anti-roll bar. Use a Torx socket as a counterhold to protect the rubber boot
- the outer end of the anti-roll bar from the lower ball joint bolt (2) of the anti-roll bar link.




- Remove the protective cover for the lower shock absorber mounting. First remove the screw (1). Then pull off the protective cover downwards.




- Remove the screw (1) for the lower shock absorber bearing
- Pull off the shock absorber from the lower bearing.

Note! The spring may be slightly compressed, therefore press the lower control arm downwards using a jimmy bar as illustrated.





Remove:
- the two screws (1) which hold the shock absorber in place including the spring and the upper bearing on the underside of the frame member
- the entire shock absorber assembly.




- Remove the rubber mounting (1) for the rear silencer. This is to facilitate removing the anti-roll bar.





Remove:
- the mountings (1) for the front rubber mounting of the rear silencer with exhaust pipe
- the brackets (2) for mounting the handbrake cables.




- Remove the nuts (1) in the flange between the catalytic converter and the front silencer in order to further lower the end of the exhaust system.




- Slacken off the two screws (1) on the bracket for the rubber mounting of the front shock absorbers.

Note! Slacken off the screws, but leave the bracket and the exhaust system hanging securely.





Remove:
- the screw (1) and the nut (1) for the anti roll bar mounting in the sub frame
- the anti-roll bar (2). Pull it out from the side while twisting it.

Install:
- the new anti roll bar in the mountings on the underside of the sub frame
- newscrews and nuts from the kit. Tighten to 80 Nm (59 lbf.ft.).




- Mark the position of the rubber liner (1) in the upper bearing (2) with a chalk mark (3).




- Secure the spring in a vice, as illustrated
- Relieve the load on the spring using spring clamps (P/N 999 5409). Position the spring clamps opposite each other and tighten alternately.

Remove:
- the nut (1) for the upper bearing (2). Use a socket, (P/N 999 5500) and a 3/8" Torx-socket as a counterhold
- the upper bearing (2)
- the spring (3).

- Remove the old shock absorber.

Installing the shock absorber etc.




- Compress the new spring to a length of approximately 260 mm (10 1/4"). Use spring clamps (P/N 999 5409).




- Remove the rubber liner (1) for the spring. Position the rubber liner on the new spring.

Note! The groove (2) in the rubber liner.





Install:
- the new spring (1) on the new shock absorber. Ensure that the end of the spring is correctly seated (2) on the shock absorber.




- Reinstall the upper bearing (1) on the rubber lining (2) of the spring
- Check that the mark (3) on the upper bearing is in line with the mark (3) on the rubber lining.




- Install the new nut (1) from the kit at the upper bearing (2)
- Tighten the nut. Tighten to 60 Nm (45 lbf.ft). Use a socket, (P/N 9995500) and a 3/8" Torx-socket as a counterhold
- Remove the spring clamps.

- Reinstall the shock absorber and spring and the upper bearing with a new nut from the kit.
- Press down the lower trailing arm using a jimmy bar to position the entire unit
- Lower the car slightly. Install the screw and the washer holding the upper shock absorber bearing at the car body. Do not tighten fully yet
- Screw the assembly into place on the under side of the frame member. Tighten to 50 Nm (37 lbf.ft.)
- Reinstall the lower shock absorber bearing in the mounting on the trailing arm. Use a vice to facilitate installation
- Tighten the shock absorber. Use a new screw from the kit. Tighten to 80 Nm (59 lbf.ft.).
- Reinstall the splash guard.

- Tighten the bracket for the rubber mountings for the front shock absorbers.
- Tighten the nuts in the flange between the catalytic converter and the front shock absorber.
- Tighten the mounting brackets for the handbrake cables.
- Tighten the brackets for the front rubber mountings for the rear shock absorbers.
- Install the rubber mounting for the rear silencer.

- Reinstall the lower ball joint bolt for the anti-roll bar link in the end of the anti-roll bar.
- Tighten using a new nut from the kit. Tighten to 80 Nm (59 lbf.ft). Use a Torx socket as a counterhold to protect the rubber boot
- Reinstall the wheels. Tighten crosswise. Tighten to 140 Nm (104 lbf.ft.)
- Lower the car
- Tighten the screw in the upper shock absorber bearing.

Reinstall:
- the foam rubber seals over the rear shock absorber mountings
- the panels in the cargo compartment
- the cargo compartment carpet
- Fold the rear backrests into position.