Contents: Removal ⬇ Installation ⬇
Removal
1. Where applicable, remove the hubcaps, then loosen the bolts on both rear wheels. Block the front wheels, then jack up and support the rear of the vehicle on axle stands. Remove the rear wheels.
2. On models with manual rear suspension damping control, relieve pressure in the system by releasing air through the valve in the luggage compartment.
3. On models with a catalytic converter, unscrew and remove the exhaust valve heat shield.
4. Measure the length of the threaded portion of the handbrake cable end protruding from the adjuster (on a torsion beam), then loosen the adjuster nut to loosen the cable.
5. Disconnect the rear section of the handbrake cable from the bracket on the underbody and release the cable from the brackets.
6. When working in the engine compartment, remove the filler cap of the overflow tank, then cover the filler neck with a piece of plastic and reinstall the cap. This will reduce fluid loss when the brake lines are disconnected.
7. Disconnect the flexible hoses from the rigid brake pipes at the front ends of the trailing arms. Be prepared for fluid to escape and plug the exposed ends of the pipes and hoses to prevent dirt from entering and further fluid loss.
8. Where applicable, unscrew the ABS sensor brackets and release their wiring from the brackets on the trailing arms. Support the sensor bracket by tying it to the underbody of the vehicle with wire or rope.
9. Loosen, but do not remove, the nuts and bolts securing the front ends of the trailing arms to the underbody of the vehicle (see illustration).
10. Support the torsion beam with a jack, placing a beam between them.
11. Loosen and remove the bolts securing the lower ends of the shock absorbers to the suspension trailing arms, then slowly lower the jack supporting the torsion beam.
12. Remove the suspension springs as described in Chapter 16.
13. Make sure the torsion beam is securely supported, then remove the nuts and bolts securing the front ends of the trailing arms to the underbody of the vehicle. Having an assistant will make this procedure much easier.
14. Remove the torsion beam/trailing arm assembly from underneath the rear of the vehicle.
15. If required, the brake components can be removed from the trailing arms. Remove the steering knuckles as described in Chapter 20, and the anti-roll bar, where used, as described in Chapter 18.
16. If necessary, replace the trailing arm bushings as described in Chapter 19.
Installation
17. Install the components that were removed from the torsion beam/trailing arm assembly.
18. Support the trailing arm torsion beam assembly with a jack under the rear of the vehicle.
19. Raise the jack and install the bolts and nuts securing the front ends of the trailing arms to the underbody.
Do not fully tighten the fasteners at this stage.
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20. Install the suspension springs as described in Chapter 16.
21. Raise the rear ends of the trailing arms and install the straps securing the lower ends of the shock absorbers. Tighten the bolts to the specified torque Specifications. Remove the jack from under the rear of the vehicle.
22. Where applicable, install the ABS sensor brackets and attach the wiring to the brackets on the trailing arms.
23. Remove the plugs from the brake pipes and hoses and connect them.
24. Insert the handbrake cable into the bracket on the bottom and secure the cable with the clamps.
25. Tighten the handbrake cable adjuster nut until the length of the threaded end protruding from the adjuster is equal to the measurement taken when removing it, then adjust the handbrake cable as described in Section 9.
26. On models with a catalytic converter, install the exhaust valve heat shield.
27. Install the rear wheels, then lower the vehicle to the ground and tighten the wheel bolts completely. Where applicable, install the hubcaps.
28. On models with manual rear suspension stiffness control, increase the pressure in the system to 0.8 bar.
29. Make sure that the vehicle is not parked downhill, then place a load of 70 kg on each front seat and rock the vehicle so that the suspension components are properly in place.
30. Without moving the vehicle, block the front wheels on both sides.
31. Working under the rear of the vehicle, tighten the bolts securing the front ends of the trailing arms to the underbody to the specified tightening torque Specifications.
32. Recheck the handbrake cable adjustment, then remove the plastic from under the reservoir cap and bleed the brake system as described in Section 9.
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