Level Control

Level control




- Fold the backrests forwards in the second row of seats.




- Remove the two floor hatches. First lift up slightly and then pull them loose from the mountings at the front edge.
If the rear floor hatch is equipped with a carrier bag holder on the lower side, the floor hatch is secured by a strap with knobs on each of the shorter sides of the storage box.
- Turn the knobs 90°. Remove the straps.




- Remove the two storage boxes.




- Remove the two side floor hatches on the left and right-hand sides of the cargo compartment.




- Release the tensioning strap for the jack and lift it out.




- Remove the four screws holding the support for the floor in the cargo compartment at the rear edge.




- Remove the screw at the front edge of the support for the floor in the cargo compartment.




- Carefully pull off the support for the floor at the front edge in the cargo compartment by lifting it slightly so that it releases from the insulation panel. Then pull it slightly inwards towards the centre of the car. Pull carefully, the support for the floor in the cargo compartment is brittle.




- Carefully pull off the floor support at the rear edge by first pressing in the side panel slightly at the bottom edge, opposite the two seats on the floor support so that it comes away. Then lift it out.

Note! Do not damage the floor support, it is brittle.




- Push the insulation panel away from the shock absorber mounting in the cargo compartment.




- Carefully fold the foam rubber seal away from the upper shock absorber mounting
- Remove the cover over the shock absorber mounting.




- Remove the nut for the upper bearing for the shock absorber. Use socket P/N 9995500 and a Torx 40 socket as a counterhold
- Discard the nut. There is a new nut in the kit
- Repeat applicable points on the other side.




- Raise the car
- Remove the wheels
- Remove the lower screw in the shock absorber mounting in the lower control arm. Discard the screw. There is a new screw in the kit
- Remove the shock absorber.




- Secure a tensioning strap between the mounting for the jack and the outer hole on the bottom of the lower control arm to relieve the load on the screw in the front mounting for the lateral link.




- Using a workshop hoist, position it under the rear mounting for the lower lateral link in the stub axle to relieve the load on the screw in the front mounting for the lateral link
- Remove the screw from the front mounting for the lateral strut whilst removing the load from the tensioning strap and the workshop hoist
- Discard the screw. There is a new screw in the kit.




- Remove the screw and the nut for the track rod mounting in the stub axle and position the end over the mounting
- Discard the screw and nut. There is a new screw and nut in the kit.




- Position the workshop hoist under the rear mounting lug for the lower mounting for the shock absorber to relieve the load on the screw for the lower control arm mounting in the stub axle
- Relieve the load, remove the screw and carefully lower the workshop hoist
- Discard the screw. There is a new screw in the kit.




- Lower the outer end of the lower control arm far enough that the old spring can be removed.




- Take a new spring from the kit, insert it from above with the wide section of the spring downwards. The control arm may need to be pressed downwards slightly to get the spring into position
- Position the ends of the spring against the stops in the upper mounting and control arm
- Position the workshop hoist under the rear eyelet for the shock absorber mounting in the control arm
- Carefully press the control arm up into position. Take a new M12x100 screw from the kit and tighten the control arm to the stub axle. Do not tighten fully yet.




- Take a new M12x60 screw and nut from the kit for the track rod
- Position the loose end of the track rod
- Position the workshop hoist under the rear mounting for the lateral link in the stub axle
- Press the stub axle up and align the screw in the track rod and stub axle. Install the nut. Do not fully tighten yet.




- Take a new M12x100 screw from the kit for the front mounting for the lateral link
- Position the front end of the lateral link by pressing up the stub axle using the workshop hoist. Use the mounting for the lateral link in the stub axle as a lifting point. Adjust to the correct position using the tensioning strap. Install a new screw. Do not tighten fully yet.




- Take the upper bearing for the shock absorber. Lubricate it using soapy water or similar so that it will easily slide into place in the upper mounting.




- Take the new shock absorber from the kit. Install the bearing. Ensure that the bearing is positioned on the shock absorber with the bearing slightly turned in relation to the length of the car, so that it aligns in the corresponding hole in the upper mounting in the body.

- Raise the new shock absorber through the lower control arm, the spring and up into the mounting in the body. Ensure that the loose bearing does not spin on the shock absorber and end up in the wrong position
- Take a new M12x110 screw from the kit. Tighten the shock absorber. Tighten to 80 Nm ( 59 lbf. ft.)
- Remove the tensioning strap and the workshop hoist
- Repeat applicable points on the other side.




- Lower the car to the next suspension setting
- Position a jack under the lower mounting for the shock absorber. Raise the car slightly
- Check that the upper shock absorber bearing is correctly seated in its upper mounting in the body by sliding in the loose washer (1) for the bearing that is there. The bearing must be seated in the upper mounting as illustrated.




- When the bearing is correctly positioned, raise the car further using the jack until the bearing is fully up in the bearing
- Pull the washer forward and install it on the shock absorber
- Take a new nut from the kit. Install it on the shock absorber. Tighten. Tighten the nut. Tighten to 80 Nm (59 lbf. ft.). Use socket P/N 999 5500 and a Torx 40 socket as a counterhold
- Remove the jack
- Repeat applicable points on the other side.




- Raise the car
- Detach the mountings for the parking brake cables from the sub-frame.

Relieve the load on the rear suspension using tensioner 999 5659

Illustration A




Tensioner, P/N 999 5659, is used when working on the suspension where the screwed joints for the rubber bushings need to be tightened to the normal position (i.e. in the same position as the car would be in on the ground with three occupants and a full tank). The tensioner takes the loads off the suspension components when removing/installing them.

Illustration B




The tool is attached to the sub-frame using mounting 999 7061. This means that the stability of the hoist is not affected during work.

Illustration C




- Install the threaded rod on the tensioner (P/N 999 5659)
- Raise the tensioner using the threaded rod (P/N 999 5659)
- Insert the threaded rod in the mounting (P/N 999 7061) from underneath
- Insert the locking washer and handle into the mounting (P/N 999 7061) from the side under the threaded screw
- Lock the screw in the locking washer and align the locking washer in the mounting.

Note! The locking washer has a locating pin which must be aligned on the screw.




- Install two screws, P/N 5470-36, from the kit, P/N 998 9761, in the holes for the control arms.




- Install the rails, P/N 5740-1, converted according to WG-276, on the control arms. Ensure that the rollers lie against the rails on both sides of the control arms.

Note! The tensioner must be applied as far out as possible on the tensioner plate to ensure the correct lift force.




- Raise the control arms to their normal position using the tensioner.




- Raise the control arms so that the distance between the centre of the wheel and the edge of the wing is 453 mm (17 13/16")
- Tighten the screws in the joints as follows:
- The track rod mountings in the stub axles. Tighten to 80 Nm (59 lbf. ft.)
- The lower mountings for the control arms in the stub axles. Tighten to 80 Nm (59 lbf. ft.)
- The front mountings for the support arms in the body. Tighten to 80 Nm (59 lbf. ft.).
- Remove the tensioner and associated components
- Reinstall the mountings for the parking brake cables in the sub-frame.

- Lower the car
- Reinstall the wheels. Tighten the wheel studs crosswise. Tighten to 140 Nm (103 lbf. ft.)
- Reinstall the covers and the foam rubber seals over the upper shock absorber mountings
- Fold the insulation panels and floor carpets back into position
- Reposition the seats.

Reinstall:
- the support for the floor in the cargo compartment
- the jack
- the side floor hatches
- the storage boxes
- the floor hatches.