2004 Golf PDF

Service
Workshop Manual
Golf 2004
Golf Plus 2005
. Volkswagen AG
Running gear, axles, steering
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Service Department. Technical Information
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Edition 08.2009
Service
AG. Volkswagen AG d
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List of Workshop Manual Repair
Manual
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Repair GroupsList of Workshop
Manual
Repair
Groups
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40 - Front suspension
42 - Rear suspension
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00 - Technical data
44 - Wheels, tyres, vehicle geometry
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Repair Group
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Technical information should always be available to the foremen and mechanics, because their
careful and constant adherence to the instructions is essential to ensure vehicle road-worthiness and
safety. In addition, the normal basic safety precautions for working on motor vehicles must, as a
matter of course, be observed.
All rights reserved.
No reproduction without prior agreement from publisher.
Copyright 2010 Volkswagen AG, Wolfsburg
K0058991120
Golf 2004 , Golf Plus 2005

Running gear, axles, steering - Edition 08.2009
Contents
00 - Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Checklist for evaluating running gear of accident vehicles . . . . . . . . . . . . . . . . . . . . . . . . . .
General information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1
3
40 - Front suspension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1
2
2.1
2.2
2.3
3
3.1
3.2
3.3
3.4
3.5
3.6
3.7
3.8
3.9
3.10
3.11
3.12
3.13
3.14
3.15
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3.16
3.17
3.18
4
4.1
4.2
4.3
5
5.1
5.2
5.3
6
6.1
6.2
6.3
6.4
6.5
6.6
6.7
6.8
7
7.1
8
8.1
Appraisal of accident vehicles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Repairing front suspension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Overview - front axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Raising wheel suspension to unladen position, Golf . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Raising wheel suspension to unladen position, Golf Plus, CrossGolf . . . . . . . . . . . . . . . .
Subframe, anti-roll bar, suspension link . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Assembly overview: subframe, anti-roll bar, suspension links . . . . . . . . . . . . . . . . . . . . . .
Assembly overview - front left vehicle level sender G78 . . . . . . . . . . . . . . . . . . . . . . . . . .
Removing and installing front left vehicle level sender G78 . . . . . . . . . . . . . . . . . . . . . . . .
Repairing thread in longitudinal member . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fixing position of subframe and brackets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Lowering subframe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removing and installing subframe without steering box . . . . . . . . . . . . . . . . . . . . . . . . . .
Removing and installing subframe with steering box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Repairing subframe (front-wheel drive) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Repairing subframe (four-wheel drive) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Checking swivel joint . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removing and installing swivel joint . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removing and installing suspension link with mounting bracket . . . . . . . . . . . . . . . . . . . .
Removing and installing suspension link with mounting bracket (left side for vehicles with
DSG or automatic gearboxes) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removing and installing suspension link with mounting bracket (right side for vehicles with
6-cylinder engines) . . . . .e.n .AG
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Renewing bonded rubber
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d b bracket with suspension link bush
Renewing mounting
nt.e . . . . . . . . . . . . . . . . . . . . . . . . . . .
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Removing aand
installing anti-roll bar . . . . . . . . . . . . . . . .e o.r a. . . . . . . . . . . . . . . . . . . . . . . . .
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Assemblys overview - wheel bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removing and installing wheel bearing housing (3-point mounting) . . . . . . . . . . . . . . . . . .
Removing and installing wheel bearing housing (4-point mounting) . . . . . . . . . . . . . . . . . .
Removing and installing wheel bearing housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Assembly overview: suspension strut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removing and installing suspension strut, Golf . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removing and installing suspension strut, Golf Plus, CrossGolf . . . . . . . . . . . . . . . . . . . .
Repairing suspension strut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removing and installing drive shafts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Loosening and tightening drive shaft hexagon bolt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Loosening and tightening 12-point flange bolt securing drive shaft . . . . . . . . . . . . . . . . . .
Removing and installing drive shaft with constant velocity joint . . . . . . . . . . . . . . . . . . . . . .
Removing and installing left drive shaft with (push-on) constant velocity slip joint . . . . . .
Removing and installing right drive shaft with (push-on) constant velocity slip joint . . . . . .
Removing and installing drive shafts with triple roller joint AAR2600i . . . . . . . . . . . . . . . .
Removing and installing drive shafts with triple roller joint AAR3300i . . . . . . . . . . . . . . . .
Removing and installing intermediate shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Repairing drive shaft - overview of drive shafts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Heat shields for drive shafts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Assembly overview - drive shaft with VL90 or VL100 constant velocity joint . . . . . . . . . . . .
Dismantling and assembling drive shaft with VL90 or VL100 constant velocity joint . . . . . .
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2
Contents
4
5
5
6
8
10
10
14
15
16
16
17
21
23
28
31
33
34
36
39
43
47
49
51
56
57
58
60
64
65
70
75
77
77
78
79
81
85
88
90
92
94
96
97
99

8.2
8.3
9
9.1
9.2
10
10.1
103
104
107
109
114
116
10.2
Checking outer constant velocity joint . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Checking inner constant velocity joint . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Assembly overview - drive shaft with VL107 constant velocity joint (bolt-on) . . . . . . . . . .
Dismantling and assembling drive shaft with VL107 constant velocity joint . . . . . . . . . . . .
Repairing intermediate shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Assembly overview - drive shaft with VL107 constant velocity slip joint (push-on) . . . . . .
Dismantling and assembling drive shaft with VL107 (push-on) constant velocity slip joint
........................................................................
11
11.1
12
12.1
Assembly overview - drive shaft with triple roller joint AAR2600i . . . . .

Dismantling and assembling drive shaft with triple roller joint AAR2600i
Assembly overview - drive shaft with triple roller joint AAR3300i . . . . .
121
122
127
129
..............
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..............
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117
119
42 - Rear suspension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134
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11.1
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8.1
8.2
8.3
9
9.1
9.2
10
10.1
10.2
11
Appraisal of accident vehicles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134

Repairing rear suspension (front-wheel drive) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135
Overview - rear axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135
Rear axle in unladen position, Golf . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 136
Rear axle in unladen position, Golf Plus, CrossGolf . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138
Assembly overview: subframe, transverse link, track rod (front-wheel drive) . . . . . . . . . . 140
Removing and installing rear axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143
Vehicle level sender for vehicles with automatic headlight range control . . . . . . . . . . . . . . 148
Renew vehicle level sender in vehicle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 148
Removing and installing upper transverse link . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149
Removing and installing lower transverse link . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 151
Removing and installing track rod . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 152
Assembly overview: wheel bearing housing, trailing arm (front-wheel drive) . . . . . . . . . . . . 156
Removing and installing wheel bearing housing . . . . . . . . . . n. A.G. . .Vo. l.ks.w.a.ge. n.A. . . . . . . . . . . 157
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olks . . . . . . . . . . . . . . . . . s. n.ot. g. . . . 161
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Removing and installing wheel bearing/wheel hubiseunit
. . . . . . . . . . . . . . . . . . . . . . . . . a.ra.n. 164
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Removing and installing trailing arm with mounting
bracket . . . . . . . . . . . . . . . . . . . . . . . . e166
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Repairing trailing arm . . . . . . . . . . . . . . . . s.s. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 170
Assembly overview: shock absorber, coil spring (front-wheel drive) . . . . . . . . . . . . . . . . . . 173
Removing and installing coil spring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 173
Removing and installing shock absorbers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 175
Repairing shock absorber . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 177
Assembly overview: anti-roll bar (front-wheel drive) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 179
Removing and installing anti-roll bar . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 179
Assembly overview - attachment parts for subframe Golf BlueMotion, Golf Plus BlueMotion
(front-wheel drive) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 182
Repairing rear suspension (four-wheel drive) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 183
Overview of rear axle (aluminium) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 183
Overview of rear axle (steel) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 185
Rear axle in unladen state (aluminium and steel) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 187
Assembly overview - subframe made from aluminium, final drive (four-wheel drive) . . . . 189
Repairing subframe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 195
Assembly overview - subframe made from steel, final drive (four-wheel drive) . . . . . . . . 199
Repairing subframe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 205
Assembly overview - control arm, track rod (four-wheel drive, subframe made from aluminium
and wheel bearing housing made from cast steel) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 212
Overview - rear left vehicle level sender G76 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 214
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1
2
2.1
2.2
2.3
3
3.1
3.2
3.3
3.4
3.5
3.6
4
4.1
4.2
4.3
4.4
4.5
5
5.1
5.2
5.3
6
6.1
7

16.1
16.2
16.3
17
17.1
18
18.1
19
19.1
19.2
19.3
19.4
19.5
19.6
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235
236
240
242
243
248
251
252
255
255
257
257
259
260
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15.1
15.2
15.3
16
AG.
14.1
14.2
14.3
15
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13.3
13.4
13.5
13.6
14
223
226
226
227
229
231
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13.1
Assembly overview - wheel bearing housing, trailing link (four-wheel drive, subframe made
from aluminium and wheel bearing housing made from cast steel) . . . . . . . . . . . . . . . . . .
Changing from wheel housing bearing made from cast steel to wheel bearing housing made
from aluminium . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Renewing bonded rubber bush for wheel bearing housing . . . . . . . . . . . . . . . . . . . . . . . .
Removing and installing wheel bearing/wheel hub unit . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removing and installing trailing arm with mounting bracket . . . . . . . . . . . . . . . . . . . . . . . .
Repairing trailing arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Assembly overview - wheel bearing housing, trailing link (four-wheel drive, subframe made
from steel and wheel bearing housing made from aluminium) . . . . . . . . . . . . . . . . . . . . . .
Renewing bonded rubber bush for wheel bearing housing . . . . . . . . . . . . . . . . . . . . . . . .
Removing and installing wheel bearing/wheel hub unit . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Assembly overview - shock absorber, coil spring (four-wheel drive, subframe made from
aluminium and wheel bearing housing made from cast steel) . . . . . . . . . . . . . . . . . . . . . .
Removing and installing coil spring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removing and installing shock absorbers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Repairing shock absorber . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Assembly overview - shock absorber, coil spring (four-wheel drive, subframe made from steel
and wheel bearing housing made from aluminium) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removing and installing coil spring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removing and installing shock absorbers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Repairing shock absorber . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Assembly overview - anti-roll bar (four-wheel drive, subframe made from aluminium and
wheel bearing housing made from cast steel) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removing and installing anti-roll bar . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Assembly overview - anti-roll bar (four-wheel drive, subframe made from steel and wheel
bearing housing made from aluminium) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removing and installing anti-roll bar . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Assembly overview - drive shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Loosening and tightening drive shaft hexagon bolt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Loosening and tightening 12-point bolt for drive shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removing and installing drive shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Dismantling and assembling drive shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Checking inner constant velocity joint . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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12.1
12.2
12.3
12.4
12.5
Renew vehicle level sender in vehicle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Removing and installing upper transverse link . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removing and installing lower transverse link . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removing and installing track rod . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Assembly overview - control arm, track rod (four-wheel drive, subframe made from steel and
wheel bearing housing made from aluminium) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
G. Volkswagen G d
Overview - rear left vehicle level sender G76 . . .lk.sw
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Renew vehicle level sender in vehicle . . . . e.d.by. . . . . . . . . . . . . . . . . . . . . . . . .t .gu.a.ra. . . . . .
n
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Removing and installing upper transversetholink . . . . . . . . . . . . . . . . . . . . . . . . . . . . . t.ee.o. . .
u
r
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Removing and installing lower transverse
link . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .a.c .
ss
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11.2
11.3
11.4
11.5
12
262
262
262
264
265
265
269
269
273
274
275
276
278
283
284
44 - Wheels, tyres, vehicle geometry . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 287

1
2

Torque settings for wheel bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 288
3
3.1
4
Fitting wheel and tyre . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 289

General information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 289
Removing and fitting tyres (wheels with tyre pressure monitoring) . . . . . . . . . . . . . . . . . . 290
Contents
iii

290
290
291
292
292
5
5.1
5.2
5.3
5.4
5.5
Removing and fitting tyres with run-flat capability to wheel rims . . . . . . . . . . . . . . . . . . . .

Notes on safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Pressing tyre off wheel rim . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removing tyre from wheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fitting tyre to wheel rim . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
294
294
294
296
296
298
6
7
7.1
7.2
7.3
8
8.1
8.2
8.3
8.4
8.5
8.6
8.7
8.8
8.9
8.10
8.11
8.12
9
9.1
9.2
9.3
9.4
9.5
9.6
10
10.1
11
Tyre monitor display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

n AG. Volkswagen A
Tyre pressure monitor (TPM) . o.lk.s.w.ag. e. . . . . . . . . . . . . G. d. o.e.s .no. . . . . . . . . . . . . . . . . . . . . . . .
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Button behaviour . . . . . . .ed. b.y . . . . . . . . . . . . . . . . . . . . . . . . . g.u.ar.a . . . . . . . . . . . . . . . . . . .
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Assembly overview - tyre
tho pressure sensor . . . . . . . . . . . . . . . . . . .e.or. . . . . . . . . . . . . . . .
u
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Removing and installing
tyre pressure sensor . . . . . . . . . . . . . . . . . . .ac. . . . . . . . . . . . . . .
ss
Wheel alignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Test prerequisites . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Test preparations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Wheel alignment specifications, Golf . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Wheel alignment specifications, Golf Plus, CrossGolf . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Overview - wheel alignment procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Correcting front axle camber . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Adjusting camber on rear axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Adjusting toe at rear axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Adjusting front axle toe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Basic setting for steering angle sender G85 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Vehicle data sticker . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Wheels, tyres . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Models with breakdown set . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Tyre sealant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removing a tyre . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fitting a new tyre . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Tyre sealant disposal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Alloy wheels with metal valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Instructions for changing or fitting wheels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fitting wheels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Protecting wheel centring seat against corrosion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
300
302
302
303
304
305
305
307
307
308
309
311
312
314
315
316
317
317
318
318
318
318
319
319
319
321
322
323
12
12.1
12.2
12.3
12.4
12.5
12.6
12.7
12.8
12.9
12.10
12.11
Rough running due to wheels/tyres - causes and rectification . . . . . . . . . . . . . . . . . . . . . .

Causes of rough running . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Balancing wheels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Conducting a road test before balancing wheels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Balancing wheels on stationary wheel balancing machine . . . . . . . . . . . . . . . . . . . . . . . .
Vibration control system VAS 6230 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Finish balancer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Radial and lateral runout of wheels and tyres . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Checking radial and lateral runout on wheels and tyres with tyre gauge V.A.G 1435 . . . .
Checking radial and lateral runout on wheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Matching . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Flat spots caused by storage or handling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
324
324
324
325
325
327
327
328
328
329
330
331
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4.2
4.3
4.4
4.5
Notes on safety and conditions for removing and fitting tyres (wheels with tyre pressure
monitoring) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Wheel change . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Pressing tyre off wheel rim . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removing tyre from wheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fitting tyre to wheel rim . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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4.1
48 - Steering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 333
1
iv
Contents

General repair instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Steering box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Gaskets and seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Nuts and bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Electrical components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Guided fault-finding, vehicle self-diagnosis and test instruments . . . . . . . . . . . . . . . . . . . .
3
3.1
Steering wheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 336

Removing and installing steering wheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 336
4
4.1
4.2
4.3
Steering column, Golf . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. Volkswag
Assembly overview: steering column . .k.sw. a. g.e.n .AG
. . . . . . . . e.n.A.G. d.o.es. . . . . . . . . . . . . . . . . . . .
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Removing and installing steering column
. . . . . . . . . . . . . . . . . . . . .t .gu.a.r . . . . . . . . . . . . . .
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Basic setting for steering anglethsensor
G85 steering angle sender must be nchecked
after the
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following repair work: . . . . .s a. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . r.a.c . . . . . . . . .
s
Handling and transporting steering column . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Checking steering column for damage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removing and installing mounting bracket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removing and installing strut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Steering column, Golf Plus, CrossGolf . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Assembly overview: steering column . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removing and installing steering column . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Basic setting for steering angle sensor G85 steering angle sender must be checked after the
following repair work: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Handling and transporting steering column . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Checking steering column for damage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removing and installing mounting bracket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removing and installing strut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Electromechanical steering box up to model year 2008 . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Assembly overview - electromechanical steering box, left-hand drive (1st and 2nd
generations) up to model year 2008 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Assembly overview - electromechanical steering box, right-hand drive (2nd generation) up
to model year 2008 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removing and installing steering box, left-hand drive (1st and 2nd generations) up to model
year 2008 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removing and installing steering box, right-hand drive (2nd generation) up to model year
2008 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Electromechanical steering box after model year 2009 . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Assembly overview - electromechanical steering box, left-hand drive (3rd generation) after
model year 2009 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Assembly overview - electromechanical steering box, right-hand drive (3rd generation) after
model year 2009 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removing and installing steering box, left-hand drive (3rd generation) after model year
2009 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removing and installing steering box, right-hand drive (3rd generation) after model year
2009 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Distinguishing between steering boxes (1st and 2nd generations), Golf . . . . . . . . . . . . . .
9
10
Differentiating between 2nd and 3rd generation steering boxes . . . . . . . . . . . . . . . . . . . . 399

Exchanging 1st generation steering box for 2nd generation steering box, Golf . . . . . . . . . . 400
11
11.1
11.2
12
12.1
12.2
Repairing electromechanical steering box (1st generation), Golf . . . . . . . . . . . . . . . . . . . .

Removing and installing boot . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Repairing electromechanical steering box (2nd and 3rd generations) . . . . . . . . . . . . . . . .
Removing and installing boot . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7.2
7.3
7.4
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5.5
5.6
5.7
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4.5
4.6
4.7
5
5.1
5.2
5.3
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2
2.1
2.2
2.3
2.4
2.5
Contents
334
334
334
334
335
335
339
339
339
345
345
346
346
348
351
351
351
357
357
358
358
360
363
363
365
366
374
383
383
384
385
391
398
401
401
403
406
406
408

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Technical data
Checklist for evaluating running gear

of accident vehicles
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Damage to running gear may go unnoticed during repairs to loadbearing and suspension parts of accident vehicles. Under certain
circumstances, this undiscovered damage could lead to serious
consequential damage during later vehicle operation. Therefore,
the following parts of accident vehicles must be examined in the
manner and order described independent of wheel alignment
which may have to be performed. If no deviations from specifica
tions are measured during wheel alignment, there are no defor
mations of the running gear.
Visual and functional examination of steering system
Visual examination for deformation and cracks
Examination for play in track rod joints and steering box
Visual examination for tears in boots
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by
Check for flawless function from lock to lock by moving the

steering from stop to stop. In the process, the steering wheel
must turn with a constant force without resistance.
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Check steering box and lines for secure seating.
ht
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Examine hydraulic lines, threaded connections and steering

gear for leaks.
do
c
um
en
Examine electrical and hydraulic lines and hoses for chafing,

cuts and kinks.
Visual inspection and functional check of running gear
Adhere to the sequence of the following inspection steps!
Exam all components shown in the assembly overviews for

deformation, cracks and other damage.
Renew damaged parts
Align wheels on a VOLKSWAGEN AG-approved wheel align
ment stand.
Visual and functional check of wheels and tyres
Check for true running and imbalance Wheels, tyres, wheel
alignment; Rep. Gr. 44
Check tyres for cuts and impact damage in the profile and on
the flanks Wheels, tyres, wheel alignment; Rep. Gr. 44 .
Check tyre inflation pressure; see tyre inflation pressure stick
er in fuel tank flap or Maintenance ; Booklet ; Check tyres:
condition, profile, inflation pressure, depth of tread
If rim of wheel and/or tyre is damaged, renew tyre. This also ap
plies if the circumstances of the accident and the damage to the
vehicle indicate possible damage which is not visible.
A further factor in the decision is the age of the tyre. Tyres should
not be older than 6 years.
Generally, in case of doubt:
Whenever a safety risk cannot be excluded, the tyre(s) must

be renewed.
1. Checklist for evaluating running gear of accident vehicles

Entire vehicle
Check other vehicle systems as well, for example:
Brake system including ABS
Visual and functional examination of exhaust system and pas
senger protection
Specifications for testing and adjusting can be found in the re
spective workshop manual in ELSA.
The examination for accident vehicles described here refers to
the running gear and does not purport to be a complete exami
nation of the entire vehicle.
Electronic vehicle systems
Safety-relevant systems like, for example, ABS/EDL; airbags;
electronically regulated suspension systems; electromechanical
or electrohydraulic steering and other driver assist systems, must
be read with the vehicle diagnosis, testing and information system
-VAS 5051- for possible stored fault messages. If faults are saved
in the fault memories of the systems mentioned above, repair
them according to instructions in workshop manuals in ELSA.
Following repairs, read fault memories of the affected systems
again to be sure that complete function has been restored.
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Prote
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Rep. Gr.00 - Technical data
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General information
Information concerning wheels, tyres and snow chains can be

found in Wheel and Tyre Guide Wheels, tyres, wheel align
ment; Rep. Gr. 44 .
rrectness of i
t to the co
nform
spec
a
t
i
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wit
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2. General information
un
le
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AG. Volkswagen AG d
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Golf 2004 , Golf ePlus
2005
d
nte
ir s
o
eo
Running gear, axles,
steering - Edition 08.2009
h
t
u
ra
a
c
ss
Appraisal of accident vehicles
es, in part or in w
l purpos
hole
ercia
, is n
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com
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Front suspension
rrectness of i
t to the co
n
f
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m
spec
atio
h re
n in
wit
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ng
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Rep. Gr.40 - Front suspension
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A checklist for evaluating running gear of accident vehicles can

be found under page 1 .
2.1
Overview - front axle

Note
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Repairing front suspension
rrectness of i
t to the co
nform
spec
atio
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n
wit
i
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n AG. Volkswagen AG do
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olks
Golfs 2004
V
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d
ran - Edition 08.2009
ir se
tee
o
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t
or
ac
au
s
s
It is not permitted to weld or straighten load-bearing or wheel-guiding components of the suspension.

Always renew self-locking nuts.
Always renew corroded nuts and bolts.
Bonded rubber bushes can be twisted only to a limited extent. Therefore, you should only tighten the threa
ded connections of components with bonded rubber bushes when the wheel bearing housing is raised to
unladen position, Golf page 6 ; Golf Plus, CrossGolf page 8 .
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III - Assembly overview - sus

pension strut page 64
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II - Assembly overview - wheel

bearing page 56
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I - Assembly overview - sub

frame, anti-roll bar, suspen
sion links page 10
2. Repairing front suspension

The chapter Removing and installing drive shafts can be found
on page 77 .
The chapter Repairing drive shaft can be found on
page 94 .
2.2
Raising wheel suspension to unladen position, Golf
Special tools and workshop

equipment required
Engine and gearbox jack V.A.G 1383 A Tensioning strap -T10038-
AG. Volkswagen AG d
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Caution
All bolts on running gear components with bonded rubber

bushes may be tightened only when the component is in the
unladen position (normal position).
Bonded rubber bushes can be twisted only to a limited extent.
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Otherwise, the bonded rubber bush would be subject to torsion

loading, shortening its service life.
thi
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Axle components with bonded rubber bushes must therefore

be brought to a position equivalent to the unladen (normal) po
sition before being tightened.
rrectness of i
t to the co
n
f
o
r
mat
spec
ion
h re
wit
in
es, in part or in w
l purpos
hole
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un
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Support -T10149-
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axles, steering - Edition 08.2009
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Running gear,
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To simulate
ran the respec
ed this position on the lifting platform, raise
teejack -V.A.G
ris suspension with the engine and gearbox
o
tive wheel
h
t
or
u
ac
a
1383
A- and support -T10149- .
ss
Before the axle on one side is raised, both sides of the vehicle
must be strapped to the lifting platform arms with tensioning
straps -T10038- .
rrectness of i
t to the co
nform
spec
a
t
ion
h re
wit
in t
his
WARNING
If the vehicle is not strapped down, there is a danger that the

vehicle will slip off the lifting platform!
Turn wheel hub until one of the wheel bolt holes is at the top.
Attach support -T10149- to wheel hub using wheel bolt.
Respective nuts and bolts may be tightened only when dimension

-a- between the centre of wheel hub and edge of wheel housing
has been attained.
The dimension -a- depends on the ride height of the installed run
ning gear:
382 10 mm
402 10 mm
367 10 mm
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Standard running gear (2UA)

Heavy-duty running gear (2UB)
Sports running gear except 18"
wheels (2UC)
Sports running gear with 18"
wheels (G02/G05/G07/2UC)
Sports running gear GTI (G08)
Sports running gear R32 (G09)
Sports running gear GTI; US
version (G11)
BlueMotion (G04/2UC)
do
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um
en
Ride height -a- in mm
Running gear 1)
367 10 mm
360 10 mm
362 10 mm
382 10 mm
367 10 mm
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1)
The type of running gear fitted to the vehicle is recorded on the

vehicle data sticker. The running gear is identified by the PR
number. Which PR. No. refers to which running gear can be found
here page 317 .
Raise wheel bearing housing using engine and gearbox jack
-V.A.G 1383 A- until dimension -a- is attained.
WARNING
Never raise or lower the vehicle while the engine and

gearbox jack is positioned beneath the vehicle.
Do not leave the engine and gearbox jack -V.A.G 1383 Aunder the vehicle for longer than necessary.
Tighten affected nuts and bolts.
Lower wheel bearing housing.
Pull engine and gearbox jack -V.A.G 1383 A- out from under
vehicle.
Detach support -T10149- .

2.3
Raising wheel suspension to unladen position, Golf Plus, CrossGolf

equipment required
Engine and gearbox jack V.A.G 1383 A Tensioning strap -T10038 Support -T10149-
Axle components with bonded rubber bushes must therefore be

brought to a position equivalent to the unladen (normal) position
before being tightened.
To simulate this position on the lifting platform, raise the respec
tive wheel suspension with the engine and gearbox jack -V.A.G
1383 A- and support -T10149- .
AG.
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All bolts on running gear components with bonded rubber bushes

may be tightened only when the component is in the unladen po
sition (normal position).
ht
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Note
rrectness of i
t to the co
nform
spec
at
i
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o
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in t
his
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es, in part or in w
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erm
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straps -T10038- .
WARNING
. Volkswagen AG
AG
If the vehicle is not strapped down, there is a dangerksthat
agenthe
l w
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by
rrectness of i
t to the co
nform
spec
a
t
ion
h re
wit
in t
his
Respective nuts and bolts may be tightened only when dimension

-a- between the centre of wheel hub and edge of wheel housing
has been attained.
The dimension -a- depends on the ride height of the installed run
ning gear:
1)
383 10 mm
403 10 mm
368 10 mm
368 10 mm
400 10 mm
373 10 mm

here page 317 .
AG.
Prote
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-V.A.G 1383 A- until dimension -a- is attained.
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wheels (2UC)
wheels (G02/G07/2UC)
CrossGolf (2UB)
BlueMotion (G06)
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Running gear 1)
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is at the top.
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Turn wheel hub until one of the
ed
ris
ho
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u
s a holes
wheel sbolt
does
not
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WARNING

vehicle.
Detach support -T10149- .

Subframe, anti-roll bar, suspension

link
3.1
Assembly overview: subframe, anti-roll bar, suspension links
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It is not permitted to weld or straighten

wheel-guiding components of the suspension.
7 - Bolt
M12 x 1.5 x 90
70 Nm + 90 further
Always renew after removing
10
Prote
cted
by
6 - Bolt
M12 x 1.5 x 90
70 Nm + 90 further
Always renew after re
moving
AG.
5 - Bolt
50 Nm + 90 further
moving
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4 - Mounting bracket
Fixing position
page 17
With bonded rubber
bush
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3 - Bracket
Fixing position
page 17
If bracket is renewed,
the wheels must be
aligned page 305
do
c
um
en
2 - Coupling rod
Link between anti-roll
bar and suspension
strut
rrectness of i
t to the co
nform
spec
a
t
ion
h re
wit
in t
his
1 - Nut
65 Nm
When tightening, coun
ter hold on hexagon
socket of joint stub.
Self-locking
moving
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Caution
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load-bearing
or
a
c
ss

olkswag
en AG
Runningggear,
axles,
steering
- Edition 08.2009
en AG. V
d
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ed
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10 - Suspension link
Different versions of suspension links are possible (cast steel, aluminium).
Allocation Electronic parts catalogue ETKA
Note
If damaged, also renew swivel joint.

Removing and installing page 36
Renew bush page 47
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12 - Nut
M12 x 1.5
60 Nm
Self-locking
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If damaged, also renew swivel joint.

Renew bush page 47
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Note
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11 - Suspension link
Different versions of suspension links are possible (welded steel sheet, single-shell steel sheet).
rrectness of i
t to the co
n
f
o
r
m
spec
atio
h re
n in
wit
es, in part or in w
l purpos
hole
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, is n
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9 - Bolt
9 Nm
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8 - Front left vehicle level sender -G78 Removing and installing page 15
Can be tested in guided fault finding using Vehicle diagnosis, testing and information system VAS 5051
13 - Swivel joint
Checking page 33
Renew together with suspension link if suspension link is damaged
14 - Nut
For cast steel suspension link: 60 Nm
For sheet steel and forged aluminium suspension link: 100 Nm
Self-locking
15 - Nut
9 Nm
16 - Bolt
M12 x 1.5 x 100
70 Nm + 90 further
17 - Bolt
20 Nm + 90 further
18 - Bolt
M12 x 1.5 x 75
70 Nm + 90 further
3. Subframe, anti-roll bar, suspension link
11

19 - Bolt
M14 x 1.5 x 70
100 Nm + 90 further
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Do not tighten until pendulum
support is bolted to gearbox
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Always renew after
o
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or
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20 - Bracket for skid

ss plate
21 - Bolt
M10 x 75 strength class 8.8: 40 Nm and turn 90 further

Caution
From model year 08,

HeliCoil inserts are in
stalled in the pendulum
support connection in
the 02Q gearboxes.
Identification Rep. Gr.
34
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AG.
If there is no HeliCoil in
sert in the 02Q gearbox,
use bolts with the
strength class 8.8 and
the corresponding tor
que setting.
do
c
um
en
Use a bolt with hardness

class 10.9 for this and all
other gearboxes.
rrectness of i
t to the co
nform
spec
a
t
ion
h re
wit
in t
his
Always observe size and strength class of the bolt. Different torque specifications apply.
Prote
cted
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.
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22 - Bolt
Always observe strength class of the bolt. Different torque specifications apply.
12

Caution
From model year 08,

HeliCoil inserts are in
stalled in the pendulum
support connection in
the 02Q gearboxes.
Identification Rep. Gr.
34 .
AG. Volkswagen AG d
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rm
itte
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If there is no HeliCoil in
sert in the 02Q gearbox,
use bolts with the
strength class 8.8 and
the corresponding tor
que setting.
un
le

class 10.9 for this and all
other gearboxes.
rrectness of i
t to the co
n
f
o
r
m
spec
atio
h re
n in
wit
es, in part or in w
l purpos
hole
ercia
, is n
m
ot
com

23 - Bracket to pendulum support
Not an individual part
24 - Pendulum support
Bolt first to gearbox and then to subframe
Various versions
25 - Lower bonded rubber bush for pendulum support
Pressing out and in for vehicles with front-wheel drive page 28
Pressing out and in for vehicles with four-wheel drive page 31
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28 - Subframe
Various versions
Removing and installing without steering box page 21
Removing and installing with steering box page 23
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27 - Bolt
6 Nm
Self-locking
thi
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en
26 - Shield
For vehicles with front-wheel drive only
Prote
cted
by
29 - Upper bonder rubber bush for pendulum support

Pressing out and in for vehicles with front-wheel drive page 28
Pressing out and in for vehicles with four-wheel drive page 31
30 - Bolt
M12 x 1.5 x 110
70 Nm +180 further
Always tighten threaded connections in unladen position:
Golf page 6
Golf Plus, CrossGolf page 8
13

31 - Nut
65 Nm
When tightening, counter hold on hexagon socket of joint stub.
Self-locking
32 - Anti-roll bar
Various versions
3.2
Assembly overview - front left vehicle level sender -G78Note
The front left vehicle level sender -G78/- is only available as a replacement part complete with coupling rod
and upper and lower retaining plates.
Replace with subframe installed.

1 - Subframe
2 - Bolt
M6 x 16
9 Nm
rrectness of i
t to the co
nform
spec
a
t
ion
h re
wit
in t
his
ole,
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3 - Front left vehicle level send

er -G78- and front right vehicle
level sender -G289 Complete with attach
ments
Lever -arrow- must face
outwards
page 15
Following renewal, ba
sic settings for headlight
must be performed.
AG. Volkswagen AG d
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Basic setting of headlights

"Guided fault-finding" function
of vehicle diagnosis, testing
and information system
VAS 5051
AG.
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Prote
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by
c
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rig
ht.
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14
do
c
um
en
5 - Nut
9 Nm
Self-locking
moving
ht
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4 - Suspension link

3.3
Removing and installing front left vehicle

level sender -G78-
Special tools and workshop equipment required

Torque wrench -V.A.G 1410-
Removing
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b
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ran
ise
tee
r
o
h , steering must be
t
or
To remove front left vehicle level sender -G78u
ac
a
ss
turned to right lock to ensure clearance between
suspension link
Note
rrectness of i
t to the co
nform
spec
a
t
ion
h re
wit
in t
his
Remove bolt and nut.
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is n
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t
itte
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p
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nl
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ng
Separate connector.
ility
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and anti-roll bar.
Take out vehicle level sender.

Installing
Install in reverse order. Note the following points:

Note
Lever on vehicle level sender must face towards outside of
vehicle.
Thread of vehicle level sender must be screwed into front hole
AG.
Bolt on subframe
Nut
Use new nut
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Component
Prote
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.
Co
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Specified torques
ht
rig
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Co
t.
Perform basic setting of headlights "Guided fault-finding"

function of vehicle diagnostic, testing and information system
VAS 5051
do
c
um
en
in suspension link. Lug of bracket for vehicle level sender must

engage in rear hole in order to guarantee correct installation
position.
Specified torque
9 Nm
9 Nm
15

3.4
Repairing thread in longitudinal member

. Volkswagen AG
gen AG
d
oes
wa nuts in the longitudinal
nomember
Repairing the thread in Vcaptive
is
olks
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possible only underecertain
conditions
Body
Repairs;
Rep.
d
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ris
50 .
eo
tho
Fixing position of subframe and brack

ets
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f
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3.5
ra
c
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au
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rrectness of i
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spec
a
t
ion
h re
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his
Locating pins -T10096-
ht
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.
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Installing locating pins -T10096To fix position of subframe with brackets, locating pins -T10096must be screwed one after the other into positions -1-, -8-, -9- and
-18-.
Note
The locating pins -T10096- may be tightened only to a maximum

of 20 Nm; otherwise the threads of the locating pins may be dam
aged.
Replace mounting bracket securing bolts along both sides one
after the other with locating pins -T10096- and tighten them to
20 Nm.
16
do
c
um
en
Engine and gearbox jack -V.A.G 1383 A-

Fixing position of mounting bracket
Replace the bracket securing bolts along both sides one after
the other with locating pins -T10096- and tighten them to 20
Nm.
Fixing position of bracket

The position of the front axle is now fixed.
Continue with removal of anti-roll bar page 52 .
Continue with removing and installing steering box, left-hand
olksw2008
agen AG
drive (1st and 2nd generations) up toagmodel
n AG. Vyear
does
w e
not
page 369 .
olks
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ed
is
Continue with removing hand
or installing steering box, right-hand
ut to model year 2008 page 378 .
drive (2nd generation)s aup
ua
ran
tee
Continue with removing and installing steering box, right-hand

drive (3rd generation) after model year 2009 page 394 .
rrectness of i
t to the co
nform
spec
a
t
i
h re
o
n in
wit
thi
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a
itte
ir v
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p
or
nl
f
e
ng
Continue with removing and installing steering box, left-hand

drive (3rd generation) after model year 2009 page 387 .
or
ac
ility
ab
y li
an
pt
ce
Removing locating pins -T10096Remove in reverse order. Ensure that the locating pins -T10096are replaced one after the other with new bolts.
Specified torques
Component
Specified torque
70 Nm + 90
Bracket to body
Use new bolts
70 Nm + 90
Mounting bracket to body

Use new bolts
70 Nm + 90
AG.
agen
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Prote
cted
by
c
o
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rig
ht
.
C
op
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Lowering subframe
ht
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Co
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3.6
do
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Subframe to body
Use new bolts
17

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erm
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itte
ir va
du
p
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nl
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g
n
Turn steering wheel to straight-ahead position and remove ig

nition key so that the steering lock engages.
Remove footwell trim by removing nuts -arrows-.
AG.
18
agen
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Prote
cted
by
c
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py
rig
ht
.
C
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Install lower noise insulation General body repairs, exterior;

Rep. Gr. 50 ; Overview - noise insulation .
ht
rig
py
Co
t.
Remove bolt -1- and pull universal joint -2- off steering box.
rrectness of i
t to the co
nform
spec
atio
h re
n
wit
i
n
thi
sd
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en
Removing
ility
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Detach exhaust system bracket from subframe -arrows-.
Fixing subframe in position page 16
do
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a
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ir v
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f
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ng
Disconnect coupling rods from anti-roll bar.
rrectness of i
t to the co
nform
spec
a
t
i
h re
o
n in
wit
thi
s
Disconnect pendulum support from gearbox by removing bolts

-14-.
ility
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an
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ce
es n
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s
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ht
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cted
b
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c
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.
Co
py
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Position engine and gearbox jack -V.A.G 1383 A- under sub

frame.
AG.
Place, for example, a wooden block -1- between engine and

gearbox jack -V.A.G 1383 A- and subframe.
19

Remove bolts -4- and -5- and lower subframe a maximum of
10 cm.
Note
Be sure to observe electrical wires to avoid overstretching them.

Installing
Install in reverse order.
Install lower noise insulation General body repairs, exterior;
Rep. Gr. 50 ; Overview - noise insulation .
Note
Ensure boot is not damaged or twisted.
Specified torques
Component
Specified torque
Subframe to body
Use new bolts!
70 Nm + 90
Subframe to bracket
Use new bolts!
70 Nm + 90
Anti-roll bar to coupling rod

Use new nut.
65 Nm
Counterhold on multi-point socket of joint pin

Universal joint to steering box
Use new bolt
ility
ab
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an
pt
ce
AG. Volkswagen AG d
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subframe by
ara
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m
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erm
o
e
t
a
itte
riv
du
p
r
o
nl
f
e
ng
Exhaust system bracket to

Engine; Rep. Gr. 26
30 Nm
Specified torques for pendulum support to gearbox
rrectness of i
t to the co
nform
spec
a
t
ion
h re
wit
in t
his
Caution
From model year 08, HeliCoil inserts are installed in the pen
dulum support connection in the 02Q gearboxes. Identification
Rep. Gr. 34 .
Use a bolt with hardness class 10.9 for this and all other gear
boxes.
If there is no HeliCoil insert in the 02Q gearbox, use bolts with
the strength class 8.8 and the corresponding torque setting.
Bolt
Specified torque
40 Nm + 90 further
M10 x 35 strength class 10.9

Use new bolt
50 Nm + 90 further
AG.
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Prote
cted
by
c
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rig
ht
.
C
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ht
rig
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Co
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20
do
c
um
en

Use new bolt

Bolt
Specified torque

Use new bolt
ility
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3.7
AG. Volkswagen AG d
agen
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V
50
Nm
gu + 90 further
by
ara
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a
c
ss
Removing and installing subframe with

out steering box

ht
rig
py
Co
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by
AG.
Prote
cted
by
c
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p
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C
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rrectness of i
t to the co
nform
spec
a
t
i
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n in
wit
thi
sd
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en
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erm
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t
itte
ir va
du
p
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nl
f
e
g
n

Use new bolt
40 Nm + 90 further
Removing
Remove lower noise insulation General body repairs, ex
terior; Rep. Gr. 50 ; Overview - noise insulation .
Remove wheels.
Remove nuts -arrows-.
Detach exhaust system bracket from subframe.
Vehicles with front-wheel drive
21

Remove bolts -arrows- on heat shield.
Remove heat shield from subframe.
Continuation for all vehicles

-14-.
Fix position of subframe page 16 .
and subframe -4- and -5-.

Installing
Install noise insulation and tighten, specified torque General

body repairs, exterior; Rep. Gr. 50 ; Assembly overview noise insulation .
agen
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anti-roll bar -11- and -16-
Prote
cted
by
c
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rig
ht
.
C
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steering box -3- and -6-
ht
rig
py
Co
t.
Now unscrew bolts for:
AG.
Specified torques
Component
Specified torque
Subframe to body
Use new bolts
70 Nm + 90
Bracket to body
Use new bolts
70 Nm + 90
Anti-roll bar to subframe

Use new bolts
20 Nm + 90

Use new nut
65 Nm

Shield to subframe
Bolt M6 is self-locking
6 Nm
Swivel joint to cast steel suspension link

Use new nuts
60 Nm
Swivel joint to sheet steel or forged aluminium suspension

link
Use new nuts
100 Nm
22
rrectness of i
t to the co
nform
spec
atio
h re
n
wit
i
n
thi
sd
o
c
um
en
ole,
cial p
is n
mer
m
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r co
erm
o
e
t
itte
ir va
du
p
or
nl
f
e
g
n
ility
ab
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ce
Remove coupling rods from anti-roll bar.
es n
wage
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olks
V
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ran
ise
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t
or
u
ac
a
ss

Component
Specified torque
Steering box to subframe

Use new bolts
50 Nm + 90
Always renew clamp on 1st and 2nd generation steering

boxes
Exhaust system bracket to subframe
Engine; Rep. Gr. 26

Caution
AG. Volkswagen
AG o
n
From model year 08, HeliCoillksinserts
es npen
wage are installed indthe
ot g
o
V
yin the 02Q gearboxes. Identification
dulum support connection
ua
b
d
ran
ise
Rep. Gr. 34 .
tee
r
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iva
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p
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nl
f
e
ng

rrectness of i
t to the co
nform
spec
a
t
ion
h re
wit
in t
his
Bolt
or
ac
ility
ab
y li
an
pt
ce
a
class 10.9 for this and all other gear
ss
boxes.
Specified torque

Use new bolt
40 Nm + 90 further

Use new bolt
50 Nm + 90 further

Use new bolt
40 Nm + 90 further

Use new bolt
50 Nm + 90 further
Removing and installing subframe with

steering box
agen
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AG.
Prote
cted
by
c
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rig
ht
.
C
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Ball joint puller -3287 A-
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en
3.8
23

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ce
Remove battery and battery tray Electrical system; Rep.

Gr. 27 ; Battery; Removing and installing battery .
24
Prote
cted
by
Thread wiring harness out of all retainers along longitudinal

member so that it can be removed together with the steering
harness.
AG.
Separate connection -3-.
agen
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.
Co
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Disconnect earth cable -2-.
ht
rig
py
Co
t.
Disconnect cable -1- from electrics box.
rrectness of i
t to the co
nform
spec
at
i
h re
o
n
wit
in t
his
d
o
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en
Removing
es, in part or in w
l purpos
hole
ercia
, is n
m
m
ot p
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erm
o
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t
a
itte
v
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p
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n
AG. Volkswagen AG d
agen
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rrectness of i
t to the co
nform
spec
a
t
i
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o
n in
wit
thi
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ir v
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f
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ng
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s
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or
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ac
a
ss
Remove front wheels.

Separate connector for extended service intervals on oil sump.
Detach coupling rods from anti-roll bar.
agen
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Prote
cted
b
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c
op
yri
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.
Co
py
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Leave nut screwed on a few turns to protect thread on pin.
ht
rig
py
Co
t.
Loosen nut on track rod ball joint but do not remove complete
ly.
do
c
um
en
AG.
Press track rod ball joint off wheel bearing housing using ball
joint splitter -3287A- and remove nut now.
25
AG. Volkswagen
AG do
gen
Golf 2004 , Golf Pluslk2005
es n
swa
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Vo
y
ua
d b steering - Edition 08.2009
ra
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a
itte
iv
du
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r
o
nl
f
e
ng
Fix position of subframe with brackets. page 16
rrectness of i
t to the co
n
f
o
r
m
spec
atio
h re
n in
wit
cop
yri
gh
t
.
Co
py
i
Place a wooden block -1- or similar between V.A.G 1383 A

and subframe.
agen
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by
AG.
Prote
cted
by
Remove bolts -4 and 5- and lower subframe with brackets

slightly, observing electrical wires.
Lower engine and gearbox jack -V.A.G 1383 A- slowly while
guiding out wiring harness for steering box.
thi
sd
o
cu
m
en
Place engine and gearbox jack -V.A.G 1383 A- under sub

frame.
26
ility
ab
y li
an
pt
ce
-14-.
nte
eo
ra
c
ht
rig
py
Co
t.
e
ris
tho
u
a
Disconnect pendulum
support from gearbox by removing bolts
ss

Secure subframe to engine and gearbox jack -V.A.G 1383 Awith the appropriate strap.
Installing
Install noise insulation and tighten, specified torque General
body repairs, exterior; Rep. Gr. 50 ; Assembly overview noise insulation .
Specified torques
Component
Specified torque
Subframe to body
Use new bolts
70 Nm + 90

Use new nut
65 Nm

Track rod ball joint to wheel bearing housing
Use new nut
20 Nm + 90

Use new nuts
60 Nm

link
Use new nuts
100 Nm

Use new bolt
30 Nm
un
le
ility
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an
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ce
. Volkswagen AG
gen AG
does
swa
k
not
l
o
Exhaust system bracket to
gu
y Vsubframe
b
ara
d
Engine; Rep. Gr. r26
e
nte
is
o
eo
h
ut
ra
a
c
ss
Caution
Rep. Gr. 34 .
boxes.
Bolt
rrectness of i
t to the co
n
f
o
r
mat
spec
ion
h re
wit
in
es, in part or in w
l purpos
hole
ercia
, is n
m
ot
com
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rm
itte
d
Specified torque
r
te o
iva
r
rp
fo
40 Nm + 90 further
ng
50 Nm + 90 further
agen
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AG.
Prote
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by
cop
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.
Co
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ht
rig
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Co
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Use new bolt
thi
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en

Use new bolt
27

Bolt
Use new bolt
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erm
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a
itte
ir v
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p
or
nl
f
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ng
rrectness of i
t to the co
nform
spec
a
t
i
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n in
wit
thi
s
3.9
ility
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Use new bolt
Specified torque
AG. Volkswagen AG d
agen
oes
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not + 90 further
l
o
40
Nm
gu
yV
ara
db
nte
ir se
o
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t
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ra
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c
50 Nm + 90 further
ss
Repairing subframe (front-wheel drive)

equipment required
Removal tool -3372-
Assembly tool -T10214 Assembly tool -T10244-
Prote
cted
by
AG.
28
agen
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by
c
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p
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C
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Attach assembly tool -T10244- to subframe.
ht
rig
py
Co
t.
Remove subframe page 21 .
do
c
um
en
Pressing out bonded rubber bush

Press out both bonded rubber bushes at the same time as
illustrated.
Note
Flattened side of thrust piece -3372/1- must face towards in
sert -A- of traverse -T10244- because otherwise insert may be

damaged.
AG. Volkswagen AG d
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gu
of
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Tube -T10244/3- has a larger and a smaller internallkdiameter.
swa
The subframe must lie against the

tube -T10244/3-.
Bolt bonded rubber bushes together using original bolt, mak

ing sure that both notches -arrows- line up precisely.
Bonded rubber bush
3-
Tube -T10214/2-
4-
Tube -T10214/1-
5-
Thrust plate -VW 401-
6-
AG.
2-
agen
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Thrust piece -T10214/3-
Prote
cted
by
c
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rig
ht.
C
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1-
ht
rig
py
Co
t.
Insert assembled bonded rubber bushes with bolt head down

wards into tube -T10214/2- .
rrectness of i
t to the co
nform
spec
at
i
h re
o
n
wit
in t
his
d
o
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m
en
es, in part or in w
l purpos
hole
ercia
, is n
m
m
ot p
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erm
o
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t
a
itte
v
i
r
du
p
or
nl
f
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g
n
ility
ab
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ce
Pressing in bonded rubber bush
Vo
y diameter
large internal
db
ir se
tho
au
s
s
29

Press in bonded rubber bushes -1- until dimension -a- is ob
tained.
Dimension -a- = 2 - 3 mm.
Align tube -T10214/2- with pressed-in bonded rubber bushes

on subframe. Corners of inner core should be parallel to edge
of assembly tool -T10244- .
The distance -a- must be identical on the right and left to ensure
parallel installation.
Position subframe against smaller internal diameter of tube
-T10244/3-.
Press in bushes to stop and until a force of 20 kN is attained.

age
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Vol
y
b
ed
ris
ho
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ss
does
not
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The notches in the bonded rubber bushes must be centred in

the subframe opening.
A gap -arrow- between the bonded rubber bushes is accept

able.
Install subframe page 22 .
AG.
agen
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Prote
cted
by
c
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rig
ht.
C
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30
ht
rig
py
Co
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ng
r
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iva
r
rp
fo
It is permissible for the outer circumference -1- of the two bon

ded rubber bushes to project up to 2 mm over the edge in the
area of the opening for the pendulum support.
thi
sd
o
cu
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en
rrectness of i
t to the co
n
f
o
r
m
spec
atio
h re
n in
wit
es, in part or in w
l purpos
hole
ercia
, is n
m
ot
com
pe
rm
itte
d
ility
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un
le
Detach assembly tool -T10244- from subframe and check

pressed-in bonded rubber bushes forn Aproper
wagen AG
G. Volksseating.

3.10
Repairing subframe (four-wheel drive)

Assembly tool -T10214-
rrectness of i
t to the co
nform
spec
a
t
ion
h re
wit
in t
his
ole,
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is n
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f
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ility
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AG. Volkswagen AG d
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not
l
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by
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i
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AG.
cop
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.
Co
py
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Press out both bonded rubber bushes at the same time as

illustrated.
ht
rig
py
Co
t.
Remove subframe page 21 .
do
c
um
en
Prote
cted
by
Note
Chamfer of thrust piece -T10214/3- must point up.
Tube -T10244/3- has a larger and a smaller internal diameter.
The subframe must lie against the larger internal diameter of

the tube -T10244/3-.
31

Bolt bonded rubber bushes together using original bolt, mak
ing sure that both notches -arrows- line up precisely.
Insert assembled bonded rubber bushes with bolt head down

wards into tube -T10214/2- .
1-
2-
Bonded rubber bush
3-
Tube -T10214/2-
4-
Tube -T10214/1-
5-
6-
Align tube -T10214/2- with pressed-in bonded rubber bushes

on subframe. Corners of inner core should be parallel to edge
of assembly tool -T10244- .
The distance -a- must be identical on the right and left to ensure
parallel installation.
Position subframe against smaller internal diameter of tube
-T10244/3-.
AG.
Prote
cted
agen
lksw
Vo
by
b
y
c
op
yri
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.
Co
py
i
ht
rig
py
Co
t.
32
rrectness of i
t to the co
nform
spec
atio
h re
n
wit
i
n
thi
sd
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um
en
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Dimension -a- = 2 - 3 mm.
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Press in bonded rubber bushes -1- until dimension

tained.
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Press in bushes to stop and until a force of 20 kN is attained.
Detach assembly tool -T10244- from subframe and check
pressed-in bonded rubber bushes for proper seating.
The notches in the bonded rubber bushes must be centred in

the subframe opening.
A gap -arrow- between the bonded rubber bushes is accept

able.
rrectness of i
t to the co
nform
spec
a
t
i
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wit
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Install subframe page 22 .
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Prote
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Checking swivel joint
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Checking axial play

Firmly pull suspension link down in -direction of arrow- and
press up again.
Checking radial play
33

Press lower part of wheel forcefully inwards and outwards in
-direction of arrow-.
Note
There should be no palpable or visible play during both tests.
Observe swivel joint while performing tests.
Take into account possible existing play in wheel bearing or
in upper suspension strut mounting.
Check rubber boot for damage and renew swivel joint if nec
essary.
3.12
Removing and installing swivel joint

equipment required
Ball joint puller -3287A-
Engine and gearbox jack V.A.G 1383 A-
34
Prote
cted
Twelve-point bolt page 78
AG.
Hexagon bolt page 77
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Loosen drive shaft bolt at wheel hub:
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Removing
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Torque/angle wrench V.A.G 1756-
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Torque wrench -V.A.G

1332-

Caution
When bolt is loosened or tightened, vehicle must not be stand

ing on its wheels.
The wheel bearing can be damaged by the weight of the vehi
cle if the bolt is loosened.
If a vehicle must be moved with the drive shaft removed, an
outer joint must be fitted and tightened to 50 Nm.
Remove wheel.
Pull drive shaft slightly out of wheel hub.
Pull swivel bearing out of suspension link.
Bend suspension link downwards as far as necessary.
Install ball joint splitter -3287 A- as shown in illustration and

press out swivel joint.
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joint is pressed out).
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Place engine and gearbox jack -V.A.G 1383 A-s aor
c
s
derneath (danger of accident through falling parts when swivel
Leave nut screwed on a few turns to protect thread on swivel
joint.
rrectness of i
t to the co
nform
spec
a
t
ion
h re
wit
in t
his
Installing
Fit swivel joint in wheel bearing housing.

Fit drive shaft in wheel hub.
Screw on new self-locking nut and counterhold with -T40- Torx

key.
do
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Prote
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35

Tighten nuts -arrows-.
Note

Install wheel and tighten page 288 .
Tighten drive shaft bolt at wheel hub:
Note
During this step, vehicle must not be standing on its wheels or

wheel bearing will be damaged.
Specified torques
Component
Specified torque

Use new nuts
60 Nm

link
Use new nuts
100 Nm
. Volkswagen AG
gen AG
does
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60 Nm
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200c Nm +180
Swivel joint to wheel bearing housingby Volk

ed
Use new nut
ris
Drive shaft to wheel hub 12-point bolt

Use new bolt
3.13
70 Nm + 90
Removing and installing suspension link

with mounting bracket

AG.
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Prote
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by
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36
rrectness of i
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bolt
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Drive shaft to wheel hub

Use new bolt
tho
au
s
s
hexagon

Remove lower noise insulation Rep. Gr. 50 ; Assembly

overview - noise insulation .
Pull swivel joint out of suspension link.
AG.
Note
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Replace bolt for left side -1- and for right side -8- with locating
pins -T10096- and tighten locating pins to 20 Nm.
ht
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Fixing position of mounting bracket page 17 .
rrectness of i
t to the co
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spec
a
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Remove wheel.
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Removing
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The locating pins -T10096- may be tightened only to a maximum

of 20 Nm; otherwise the threads of the locating pins may be dam
aged.
Now remove bolt -10- for left side and bolt -17- for right side.
37
AG. Volkswagen AG d
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- Edition 08.2009
eo
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Remove suspension link with mounting bracket.
rrectness of i
t to the co
n
f
o
r
m
spec
atio
h re
n in
wit
Installing
Insert suspension link with mounting bracket into subframe.
Start bolts -10- and -17-, but do not yet tighten.
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Now replace locating pin -T10096- with a new bolt and tighten
to specified torque.
Bolt suspension link to swivel joint and tighten -arrows-.
38
ht
rig
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Co
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Start bolt -1- and tighten.
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Remove bolts -1-.

Bolt suspension link to bracket -10- and -17- in unladen state.
Continue installation in reverse order.
Note

Install lower noise insulation. Rep. Gr. 50 ; Assembly over
view - noise insulation .
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Component
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Specified torques
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db
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Specified torque
50 Nm + 90

Use new bolts
70 Nm + 90
rrectness of i
t to the co
nform
spec
a
t
ion
h re
wit
in t
his
Mounting bracket to bracket

Use new bolts

Use new nuts
60 Nm

link
Use new nuts
100 Nm
Suspension link to bracket

Use new bolt
70 Nm +180
Tighten bolt in unladen state
ht
rig
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Prote
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by
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with mounting bracket (left side for ve
hicles with DSG or automatic gearbox
es)
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3.14
39

un
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Removing
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db
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Remove left front wheel.
rrectness of i
t to the co
n
f
o
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m
spec
atio
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n in
wit
es, in part or in w
l purpos
hole
ercia
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ng
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-14-.
If present, detach coupling rod of front left vehicle level sender
-G78- from suspension link.
Fix position of bracket and mounting bracket of suspension
link on left side of vehicle with locating device -T10096 page 16 .
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db
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Loosen bolt -17-.
rrectness of i
t to the co
nform
spec
a
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i
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wit
thi
s
subframe on right side -5- and -12-.
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anti-roll bar -11- and -16-
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steering box -3- and -6-
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41

frame.
Remove bolts -2-, -4-, -5- and -12- and lower subframe with
brackets as far as necessary.
At the same time, lever dowel sleeves of steering box out of
left bracket.
Remove bolt -17- and remove suspension link from bracket.
Installing
Note
Ensure proper seating of dowel sleeves for steering box in
suspension bracket.
un
le
ility
ab
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an
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ce
Specified torque
rrectness of i
t to the co
n
f
o
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m
spec
atio
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wit
Component
es, in part or in w
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hole
ercia
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com
Specified torques
pe
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itte
d
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Install lower noise insulation General
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Rep. Gr. 50 ; Assembly overview
- noise insulation .
ho
t
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sa
s
Bracket to body
Use new bolts
70 Nm + 90

Use new bolts
70 Nm + 90
Mounting bracket to bracket

Use new bolts
50 Nm + 90
Subframe to bracket
Use new bolts
70 Nm + 90
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70 Nm + 90
ng
60 Nm
Prote
cted
by
42
AG.

Use new bolts
100 Nm
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link
Use new nuts
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Co
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Use new nuts
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sd
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Subframe to body
Use new bolts
20 Nm + 90

Component
Specified torque
Shield to subframe
6 Nm

Use new bolts
50 Nm + 90

boxes
Engine; Rep. Gr. 26

Caution
. Volkswagen AG
gen AG
d
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not in the pen
From model yearV08,
olks HeliCoil inserts are installed
gu
by
ara
dulum support
connection
in
the
02Q
gearboxes.
Identification
d
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Rep. Gr.
34
.
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rrectness of i
t to the co
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f
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spec
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l purpos
hole
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c
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Use a bolt
with hardness class 10.9 for this and all other gear
boxes.
Bolt
Use new bolt
Use new bolt
Use new bolt
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Prote
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ng
50 Nm + 90 further
40 Nm + 90 further
50 Nm + 90 further

with mounting bracket (right side for ve
hicles with 6-cylinder engines)
ht
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3.15
40 Nm + 90 further
thi
sd
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Use new bolt
Specified torque
43

Removing
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Pull swivel joint out of suspension link.
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by
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Prote
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by
c
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rig
ht
.
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rrectness of i
t to the co
nform
spec
a
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i
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wit
thi
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do
c
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44
ht
rig
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Co
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b
Remove wheel.
d
ran
ise
tee
r
o
h Rep. Gr. 50 ; Assembly
t
or
Remove lower noise insulation
u
ac
a
overview - noise insulationss.

Loosen bolt -10-.
Remove coupling rods from anti-roll bar.
steering box -3- and -6 and subframe -4- and -5-.
Lower subframe until bolt -10- can be unscrewed completely.
es n
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un
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Installing
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ab
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Unscrew bolts -1- and remove suspension link with bracket.
rrectness of i
t to the co
n
f
o
r
mat
spec
ion
h re
wit
in
es, in part or in w
l purpos
hole
ercia
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Insert suspension link with mounting bracket into subframe.
Start bolts -7- and -10-, but do not yet tighten.

Raise subframe back to its original position.
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ht
rig
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Co
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Tighten bolts -7-.
ng
Screw in bolts -4- and -5- and tighten.
thi
sd
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en
Now replace locating pins -T10096- at positions -1-, -8-, -9and -18- with new bolts and tighten them to specified torque.
Prote
cted
by
c
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py
rig
ht
.
C
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45

gen AG
AG. Volksw- aEdition
gensteering
do08.2009
es
swa
swivel joint and tighten
not
gu
ara
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-arrows-.
eo
ra
c
ility
ab
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an
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Bolt suspension link to bracket in unladen state -10-.

Bolt coupling rods to anti-roll bar.
rrectness of i
t to the co
nform
spec
a
t
i
h re
o
n in
wit
thi
sd
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en
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ir va
du
p
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Bolt
olk
yV
db
e
suspension
ris link to
ho
ut
a
ss
Attach lower noise insulation Rep. Gr. 50 ; Assembly over

ht
rig
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Prote
cted
b
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c
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.
Co
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Specified torques
Component
Specified torque
Subframe to body
Use new bolts
70 Nm + 90
Bracket to body
Use new bolts
70 Nm + 90

Use new bolts
70 Nm + 90
Subframe to bracket
Use new bolts
70 Nm + 90

Use new nuts
60 Nm

link
Use new nuts
100 Nm

Use new nut
46
20 Nm + 90

Component
Specified torque

Use new bolt
70 Nm +180

Use new bolts
50 Nm + 90

boxes
Engine; Rep. Gr. 26
3.16
AG. Volkswagen AG d
agen
oe
w
s no
olks
Renewing bonded
bush for suspension
link
t gu
Vrubber
by
a
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or
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ss
equipment required
ed
ris
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Tube -T10219/1-
rrectness of i
t to the co
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f
o
r
m
spec
atio
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wit
es, in part or in w
l purpos
hole
ercia
, is n
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com
Drift -T10219/2-
ht
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Press tool -VW 411-
agen
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Prote
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by
c
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rig
ht
.
C
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47

Press out bonded rubber bush as illustrated.
1-
Press tool -VW 411-
2-
Tube -T10219/1-
3-

Apply the bonded rubber bush at an angle to prevent damage
when pressing in. The bonded rubber bush will then straighten up
as it is pressed in.
Moisten outer surface of bonded rubber bush with assembly
oil -G 294 421 A1- .
Apply bonded rubber bush at an angle (towards suspension
link). Lip -arrow- must slide into hole as shown.
1-
Drift -T10219/2-
2-
Tube -T10219/1-
3-
Press in bonded rubber bush until core of bush -1- and hole in
suspension link -2- are flush.
48
Prote
cted
2-
AG.
Tube -T10219/1-
agen
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1-
ht
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Co
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Press bush back slightly in the suspension link.
rrectness of i
t to the co
nform
spec
atio
h re
n
wit
i
n
thi
sd
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ole,
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is n
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t
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ir va
du
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AG. Volkswagen AG d
agen
oes
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not
l
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b
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a
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s

The dimensions -a- and -b- must be the same.
3.17
Renewing mounting bracket with suspension link bush

equipment required
Guide -VW 439 Thrust plate -VW 401-
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V
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Co
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fo
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f
o
r
mat
spec
ion
h re
wit
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es, in part or in w
l purpos
hole
ercia
, is n
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com
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un
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agen
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by
AG.
Prote
cted
by
c
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rig
ht.
C
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yi
49

Tube -VW 418 A-
lksw
agen AG
. Vooff
Pressing mounting bracket with
bush
suspension
link
gen AG
d
a
lksw
oes
no
t gu
Vo
The bonded rubber bush
by is available as a replacement part
ara only
ed mounting bracket.
nte
ir sthe
in conjunction with
o
e
h
ut
or
Note
Hold suspension link when pressing off.

1-
2-
Guide -VW 439-
3-
Pressing in mounting bracket with bush onto suspension link

Moisten hexagon flats of suspension link with assembly lubri
cant -G 294 421 A1- diluted 1:20.
Carefully press bush onto suspension link to stop.
Tube -VW 418 A-
2-
Bearing bracket with bonded rubber bush.
3-
Suspension link
4-
AG.
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Prote
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by
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50
ht
rig
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Co
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1-
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t to the co
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spec
atio
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wit
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n
ility
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ce
a
Press mounting
bracket with bonded rubber bush off suspenac
ss
sion link.

3.18
Removing and installing anti-roll bar

equipment required
Locating pins -T10096 Torque wrench -V.A.G
1332 Engine and gearbox jack V.A.G 1383 A-
ility
ab
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Co
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f
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spec
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Ball joint puller
es n
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-3287 A- ed by V
ran
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Prote
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.
Co
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Removing
51

Detach coupling rods from anti-roll bar.

Loosen nut on track rod ball joint on each side but do not re
move completely.
ility
ab
y li
an
pt
ce
rrectness of i
t to the co
nform
spec
a
t
ion
h re
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in t
his
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AG. Volkswagen AG d
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Press track rod ball joint off wheel bearingd bhousing
using ball
ara
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s
i
joint splitter -3287A-.
r
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Fixing position of subframe with bracket
page 16 .
ss
Unbolt anti-roll bar from subframe -11 and 16.

-14-.
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Prote
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by
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rig
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do
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52

Place engine and gearbox jack -V.A.G 1383 A- under sub
frame.

rrectness of i
t to the co
n
f
o
r
m
spec
atio
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n in
wit
ole,
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m
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AG. Volkswagen AG d
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ss
Now lift anti-roll bar -1- forwards over bracket -2- and down
from subframe.
Installing
Note
thi
sd
o
cu
m
en
ht
rig
py
Co
t.
Prote
cted
by
c
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rig
ht.
C
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Coat seal on steering box with suitable lubricant, e.g. soft

agen
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by
soap, before installing steering box.
After fitting the steering box to the jointed shaft, ensure that
the seal is not kinked when lying against the assembly plate
and that the opening to the footwell is correctly sealed. Oth
erwise, this can result in water leaks and/or noise.
AG.
Ensure sealing surfaces are clean.

Install lower noise insulation Rep. Gr. 50 ; Assembly over
Install front wheels and tighten page 288 .
Specified torques
Component
Subframe to body
Use new bolts
Specified torque
70 Nm + 90
53

Component
Specified torque
Bracket to body
Use new bolts
70 Nm + 90

Use new bolts
70 Nm + 90
Subframe to bracket
Use new bolts
70 Nm + 90

Use new nuts
60 Nm

link
Use new nuts
100 Nm

Use new nut

Use new bolts
70 Nm +180
rrectness of i
t to the co
nform
spec
a
t
ion
h re
wit
in t
his

Use new bolt
20 Nm + 90
ility
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an
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ce

Use new bolts
50 Nm + 90

boxes
Use new bolt
30 Nm
AG.
Prote
cted
by
boxes.
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.
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Rep. Gr. 34 .

Bolt
Specified torque

Use new bolt
40 Nm + 90 further

Use new bolt
50 Nm + 90 further

Use new bolt
40 Nm + 90 further
54
ht
rig
py
Co
t.
Caution
do
c
um
en
ole,
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m
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AG. Volkswagen AG d
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Bolt
Specified torque

Use new bolt
50 Nm + 90 further
After installing, perform basic settings for steering angle send

er -G85- Vehicle diagnosis, testing and information system
VAS 5051.
rrectness of i
t to the co
nform
spec
a
t
i
h re
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wit
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AG. Volkswagen AG d
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Prote
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.
Co
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55
es, in part or in w
l purpos
hole
ercia
, is n
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v
i
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agen
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by
AG.
Prote
cted
by
2 - Wheel hub with wheel bear

ing (3-point mounting) - FS III
brakes
page 57
The ABS sensor ring is
installed in the wheel
hub
Allocation Electronic
parts catalogue ETKA
rrectness of i
t to the co
nform
spec
at
i
h re
o
n
wit
in t
his
d
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en
1 - Wheel bearing housing (3point mounting) - FS III brakes

page 60
With integrated brake
carrier.
If wheel bearing housing
is renewed, wheels
must be aligned
page 305 .
ht
rig
py
Co
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Assembly overview - wheel bearing
ility
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AG. Volkswagen AG d
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Golf 2004 , Golf Plus
gu
y V 2005
b
ara
d
e
nte
steering
Edition
08.2009
is
r
o
eo
h
ut
ra
a
c
ss
cop
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.
Co
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i
3 - Suspension strut
4 - Multi-point socket head bolt
Tip of bolt must point in
direction of travel
5 - Front left speed sensor G47- / front right speed sensor
-G45 Before inserting speed
sensor, clean inner sur
face of fitting hole and
coat with lubricating
paste -G 000 650- .
6 - Hexagon socket bolt
8 Nm
7 - Track rod ball joint
8 - Splash plate
9 - Bolt
10 Nm
10 - Nut
M12 x 1.5
20 Nm + 90 further
Self-locking
11 - Wheel bearing housing (4-point mounting) - FS III brakes
With integrated brake carrier.
If wheel bearing housing is renewed, wheels must be aligned page 305 .
56

12 - Ventilated brake disc
13 - Bolt
M16 x 1.5 x 80
Hexagon bolt, 200 Nm and turn +180 further
12-point bolt, 70 Nm + 90 further
When bolt is loosened or tightened, vehicle mustn not
wagen A on its wheels
olksstanding
AG. Vbe
ole,
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mer
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The ABS sensor ring is installed in the wheel hub
Various versions
16 - Wheel bearing housing (4-point mounting) - FN3 brakes

With bolted-on brake carrier.
If wheel bearing housing is renewed, wheels must be aligned page 305 .
M12 x 1.5 x 45
70 Nm + 90 further
18 - Drive shaft
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19 - Nut
M12 x 1.5
70 Nm + 90 further
Self-locking
rrectness of i
t to the co
nform
spec
atio
h re
n
wit
i
n
thi
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G do
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Repairing front brake .tee o
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wage
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V
14 - Bolt
by
ed
ris
o
Torque setting Brake systems;
Rep. Gr. 46 ;
th
au
s
s
15 - Wheel hub with wheel bearing
(4-point mounting)
Removing and installing wheel bearing

housing (3-point mounting)

4. Assembly overview - wheel bearing
57

Removing
Note
Remove brake caliper and hang from body using wire Brake
system; Rep. Gr. 46 ; Repairing front brake .
rrectness of i
t to the co
nform
spec
a
t
i
h re
o
n in
wit
thi
s
Remove ABS speed sensor Brake systems; Rep. Gr. 46 ;

Repairing front brake.
Remove brake disc.
Press drive shaft as far as possible out of wheel hub (towards
gearbox).
Remove bolts -arrows-.
Take wheel bearing unit out of wheel bearing housing.
Installing

Install brake caliper Brake systems; Rep. Gr. 46 ; Repairing
front brake .
cop
yri
gh
t
.
Co
py
i
agen
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AG.
Prote
cted
by
Note
ht
rig
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Co
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do
c
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mer
m
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erm
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a
itte
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du
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f
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Remove wheel.
ility
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AG. Volkswagen AG d
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During this step, vehicle must dnot
by be standing on its wheels or
ara
e
nte
is
r
o
eo
h
t
u
ra
a
c
ss

Install ABS speed sensor Brake systems; Rep. Gr. 46 ;
Repairing front brake .
Specified torques
Component
Specified torque
Drive shaft to hub

Use new bolt
70 Nm + 90
Wheel hub with wheel bearing to wheel bearing housing

Use new bolts
70 Nm + 90
4.2

housing (4-point mounting)
58


Note

Prote
cted
by
c
o
py
rig
ht
.
C
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ht
rig
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Co
t.
Remove wheel.
do
c
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en
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mer
m
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c
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erm
o
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t
a
itte
riv
du
p
r
o
nl
f
e
ng
rrectness of i
t to the co
nform
spec
a
t
ion
h re
wit
in t
his
Removing
ility
ab
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an
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es n
wage
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V
ua
by
d
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o
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or
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s
s
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by
AG.

Remove brake disc.
gearbox).
Take wheel bearing unit out of wheel bearing housing.
Installing
Install brake caliper Brake systems; Rep. Gr. 46 ; Repairing
front brake .
Note

Install ABS speed sensor Brake systems; Rep. Gr. 46 ;
Repairing front brake .
59

Specified torques
Component
Specified torque
Drive shaft to wheel hub hexagon bolt

Use new bolt
ole,
cial p
is n
mer
m
ot p
o
c
r
erm
o
e
t
a
itte
iv
du
pr
r
o
nl
f
e
ng
ility
ab
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an
pt
ce
Drive shaft to wheel hub 12-point

Use new bolt
AG. Volkswagen AG d 200 Nm +180

agen
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b
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bolt ut
70 Nm + e90
or
ac
a
ss

Use new bolts
rrectness of i
t to the co
nform
spec
a
t
ion
h re
wit
in t
his
4.3
70 Nm + 90
Removing and installing wheel bearing housing

equipment required
Ball joint puller -3287A Torque wrench -V.A.G
1332-
AG.
Prote
cted
by
agen
lksw
Vo
by
cop
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gh
t
.
Co
py
i
ht
rig
py
Co
t.
60
do
c
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gu
ara
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ra
c
rrectness of i
t to the co
n
f
o
r
m
spec
atio
h re
n in
wit
Removing
es, in part or in w
l purpos
hole
ercia
, is n
m
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com
pe
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un
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Spreader -3424-
by
ed
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th
au
ss
swage2004
n AG d , Golf Plus 2005
AG. VolkGolf
agen
oes
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no-t Edition 08.2009
Running
gear,
axles,
steering
l
o
V
ng
AG.
Prote
cted
by
Remove wheel.
agen
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Vo
by
c
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p
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C
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thi
sd
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cu
m
en
Note
ht
rig
py
Co
t.
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te o
iva
r
rp
fo
Remove brake disc.
Now remove backplate from wheel bearing housing.
ly.
joint splitter -3287A- and remove nut now.
gearbox).
61
Insert spreader -3424- into slot of wheel bearing housing.

Turn ratchet handle through 90 and detach from spreader
-3424- .
agen
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by
AG.
Prote
cted
by
c
o
py
rig
ht.
C
op
yi
Now position engine and gearbox jack -V.A.G 1383 A- under

wheel bearing housing.
First press swivel joint off suspension link in order to press
wheel bearing housing off suspension strut.
Note
If wheel bearing housing is renewed, swivel joint must be trans

ferred. Always use new nuts.
Installing
Carry out installation in the reverse sequence, noting the follow
ing:
Note

If wheel bearing housing is renewed, wheels must be aligned
page 305 .
62
ht
rig
py
Co
t.
Loosen nuts -arrows-.
rrectness of i
t to the co
nform
spec
atio
h re
n
wit
i
n
thi
sd
o
c
um
en
ole,
cial p
is n
mer
m
ot p
r co
erm
o
e
t
itte
ir va
du
p
or
nl
f
e
g
n
Remove threaded connection between wheel bearing housing

and suspension strut -arrow-.
ility
ab
y li
an
pt
ce
AG. Volkswagen AG d
agen
oes
ksw
not
l
o
V
gu
y
b
ara
d 2005
nte
ir se
o
eo
h steering - Edition 08.2009
t
u
ra
a
c
ss

Specified torques
Component
Specified torque
Suspension strut to wheel bearing housing

Use new nut
70 Nm + 90

Use new nuts
60 Nm

link
Use new nuts
100 Nm

Use new nut
20 Nm + 90

Use new bolt
200 Nm +180

Use new bolt
70 Nm + 90
rrectness of i
t to the co
nform
spec
a
t
ion
h re
wit
in t
his
ole,
cial p
is n
mer
m
ot p
o
c
r
erm
o
e
t
a
itte
riv
du
p
r
o
nl
f
e
ng
ility
ab
y li
an
pt
ce
AG. Volkswagen AG d
agen
oes
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not
l
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by
ara
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s
ri
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h
t
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a
c
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do
c
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en
ht
rig
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Co
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agen
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AG.
Prote
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by
c
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p
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C
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63

Assembly overview: suspension strut
rrectness of i
t to the co
nform
spec
a
t
ion
h re
wit
in t
his
3 - Protective sleeve
ole,
cial p
is n
mer
m
ot p
o
c
r
erm
o
e
t
a
itte
riv
du
p
r
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nl
f
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ng
2 - Bump stop
AG. Volkswagen AG d
agen
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by
ara
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s
i
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t
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c
ss
ility
ab
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an
pt
ce
1 - Shock absorber
Can be renewed sepa
rately
4 - Coil spring
page 76
Observe colour coding
Spring allocation via PR No.
These numbers are located on

the vehicle data sticker.
Surface of coil must not
be damaged.
10 - Protective cap
64
Prote
cted
by
9 - Bolt
15 Nm + 90 further
AG.
8 - Suspension strut turret
agen
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C
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7 - Nut
M14 x 1.5
60 Nm
Self-locking
moving
ht
rig
py
Co
t.
6 - Suspension strut mounting

Note correct installation
position page 67
do
c
um
en
5 - Deep groove ball thrust

bearing

5.1
Removing and installing suspension strut, Golf

equipment required
ility
ab
y li
an
pt
ce
rrectness of i
t to the co
nform
spec
a
t
i
h re
o
n in
wit
thi
sd
o
cu
m
en
es, in part or in w
l purpos
hole
ercia
, is n
m
m
ot p
r co
erm
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t
a
itte
v
i
r
du
p
or
nl
f
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g
n
Support -T10149-
AG. Volkswagen AG d
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Spreader -3424-
agen
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AG.
Prote
cted
by
cop
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t
.
Co
py
i
Removing
Note

Remove wheel.
5. Assembly overview: suspension strut
65

Unscrew hexagon nut for coupling rod -arrow- from suspen
sion strut.
Unhook speed sensor wiring from suspension strut.
es, in part or in w
l purpos
hole
ercia
, is n
m
m
ot p
r co
erm
o
e
t
a
itte
v
i
r
du
p
or
nl
f
e
ng
Pull wheel bearing housing with swivel joint out of suspension

link.
Pull outer joint of drive shaft out of wheel hub.
Secure drive shaft to body with wire.
Caution
Do not allow the drive shaft to hang down under its own weight,
for this would allow the inner joint to bend too far and be dam
aged.
Bolt swivel joint to suspension link again.
Separate threaded connection between wheel bearing hous

ing and suspension strut -arrow-.
66
AG.
Do not lift or lower the vehicle while the engine and gear
box jack -V.A.G 1383 A- is under the vehicle. The vehicle
could slip off the lifting platform.
agen
lksw
Vo
by
Prote
cted
by
c
o
py
rig
ht.
C
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yi
WARNING
ht
rig
py
Co
t.
Bolt engine and gearbox jack -V.A.G 1383 A- with support

-T10149- to wheel hub using a wheel bolt.
rrectness of i
t to the co
nform
spec
at
i
h re
o
n
wit
in t
his
d
o
cu
m
en
ility
ab
y li
an
pt
ce
AG. Volkswagen AG d
agen
oes
ksw
not
l
o
V
gu
by
ara
d
nte
ir se
o
eo
h
t
u
ra
a
c
ss

-3424- .
Press brake disc towards suspension strut by hand.
Otherwise the shock absorber tube can cant in the bore of the
Pull wheel bearing housing downwards off shock absorber
tube and lower with engine and gearbox jack -V.A.G 1383 Auntil shock absorber tube is free.
Tie wheel bearing housing up to subframe bracket using a
piece of wire.
WARNING
Remove wiper arms Rep. Gr. 92 ; Wiper system; Removing
and installing wiper arms .
Remove plenum chamber cover.
AG. Volkswagen A
G do
agen
es n absorber
Remove hexagonobolts
lksw -arrows- for upper shock
ot g
V
mounting anddremove
suspension strut.
ua
by
r
Installing
Insert suspension strut with one of the two markings

-arrows- pointing forwards.
rrectness of i
t to the co
nform
spec
a
t
i
h re
o
n in
wit
thi
s
Installation position of spring plate
do
c
um
en
ole,
cial p
is n
mer
m
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c
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erm
te o
a
itte
ir v
du
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or
nl
f
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ng
ility
ab
y li
an
pt
ce
ss
an
tee
or
ac
e
ris
ho
t
au
ht
rig
py
Co
t.
agen
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by
AG.
Prote
cted
by
c
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py
rig
ht
.
C
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yi
67

Edition
agen A 08.2009
AG. Volk-sw
Install wiper arms Rep. Gr. 92 ; Wiper system; Removing

and installing wiper arms .
WARNING
cop
yri
gh
t
.
Co
py
i
agen
lksw
Vo
by
Prote
cted
by
Remove wire from wheel bearing housing.
ht
rig
py
Co
t.
Position suspension strut on wheel bearing housing.

AG.
Using gearbox jack, carefully raise wheel bearing housing until

bolt securing suspension strut to wheel bearing housing can
be inserted.
Press brake disc towards suspension strut by hand while lift
ing.
Remove spreader -3424- .
Tighten threaded connection between wheel bearing housing
and suspension strut -arrowWARNING
68
rrectness of i
t to the co
nform
spec
a
t
ion
h re
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his

do
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upper
G do
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shock absorber
ran
tee
or
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Tighten hexagon bolts
ed -arrows- for
ris
ing.
ho
t
au
ss
Install plenum
chamber cover.
Remove nuts
pe
rm
itte
d
un
le
Fit drive shaft in wheel hub.
Fit wheel bearing housing with swivel joint in suspension link.
rrectness of i
t to the co
n
f
o
r
m
spec
atio
h re
n in
wit
Note
es, in part or in w
l purpos
hole
ercia
, is n
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com
Bolt swivel joint to suspension link.
ility
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wage
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Running
gear,
axles,
ua
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or
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.
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AG.
Specified torques
Component
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thi
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Note
Specified torque

Use new nut
70 Nm + 90
Suspension strut to body (suspension turret)

Use new bolts
15 Nm + 90

Use new nuts
60 Nm

link
Use new nuts
100 Nm
Coupling rod to suspension strut

Use new nut
65 Nm

Use new bolt
200 Nm +180

Use new bolt
70 Nm + 90
69

5.2
Removing and installing suspension strut, Golf Plus, CrossGolf

equipment required
1332 Spreader -3424 Engine and gearbox jack V.A.G 1383 A Support -T10149-
Prote
cted
by

Note

Remove wheel.
70
AG.
agen
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C
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ht
rig
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Co
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Removing
rrectness of i
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nform
spec
at
i
h re
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in t
his
d
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hole
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AG. Volkswagen AG d
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not
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ss

Unscrew hexagon nut for coupling rod -arrow- from suspen
sion strut.
Unhook speed sensor wiring at suspension strut.

link.
Pull outer joint of drive shaft out of wheel hub.
Secure drive shaft to body with wire.
es n
wage
ot g
olks
V
ua
by
d
ran
ir se
tee
o
h
Do not allow the drive shaft to hang
down
under
its
own
weight,
t
or
u
ac
for this would allow the innerss ajoint to bend too far and be dam
Caution
Bolt swivel joint to suspension link again.

WARNING
Separate threaded connection between wheel bearing hous

ing and suspension strut -arrow-.
rrectness of i
t to the co
nform
spec
atio
h re
n
wit
i
n
thi
sd
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n
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ab
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aged.
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agen
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Prote
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by
c
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py
rig
ht
.
C
op
yi
71

-3424- .
Press brake disc towards suspension strut by hand.
Note
Pull wheel bearing housing downwards off shock absorber
tube and lower with engine and gearbox jack -V.A.G 1383 Auntil shock absorber tube is free.
Tie wheel bearing housing up to subframe bracket using a
piece of wire.
WARNING
Remove centre section of bulkhead Rep. Gr. 50 ; Assembly
overview - plenum chamber bulkhead .
Remove bolts -arrows- Rep. Gr. 92 ; Windscreen wash/
wipe system; Removing and installing windscreen wiper sys
tem and then remove windscreen wiper motor.
AG.
agen
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72
Prote
cted
by
c
o
py
rig
ht
.
C
op
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Installing
ht
rig
py
Co
t.
Remove hexagon bolts -arrows- for upper shock absorber

mounting and remove suspension strut.
rrectness of i
t to the co
nform
spec
at
i
h re
o
n
wit
in t
his
d
o
cu
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en
es, in part or in w
l purpos
hole
ercia
, is n
m
m
ot p
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erm
o
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t
a
itte
v
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du
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f
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ng
ility
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db
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s
s

Installation position of spring plate
Insert suspension strut with one of the two
markings
es n
wage
-arrows- pointing forwards.
o
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t gu
ara
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c
rrectness of i
t to the co
nform
spec
a
t
ion
h re
wit
in t
his
Tighten hexagon bolts -arrows- for upper shock absorber mount

ing.
Install windscreen wiper motor Rep. Gr. 92 ; Windscreen
wash/wipe system; Removing and installing windscreen wiper
system .
Install centre section of bulkhead Rep. Gr. 50 ; Assembly
overview - plenum chamber bulkhead .
agen
lksw
Vo
by
AG.
Prote
cted
by
cop
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gh
t
.
Co
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WARNING
ht
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do
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iva
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f
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ng
ility
ab
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an
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ce
yV
db
ise
r
tho
au
ss
Position suspension strut on wheel bearing housing.
Remove wire from wheel bearing housing.
Using gearbox jack, carefully raise wheel bearing housing until

bolt securing suspension strut to wheel bearing housing can
be inserted.
Press brake disc towards suspension strut by hand while lift
ing.
Remove spreader -3424- .
73
AG. Volkswagen AG d
agen
oes
ksw
Vol
by
d
Running gear, axles, steering -risEdition
08.2009
e
WARNING
Fit drive shaft into wheel bearing.

Fit wheel bearing housing with swivel joint in suspension link.
Bolt swivel joint to suspension link.
c
o
p
yri
gh
t.
C
op
yi
AG.
Prote
cted
by
agen
lksw
Vo
by
ht
rig
py
Co
t.
Note
rrectness of i
t to the co
nform
spec
a
t
i
h re
o
n in
wit
thi
sd
o
cu
m
en
ole,
cial p
is n
mer
m
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erm
o
e
t
itte
ir va
du
p
or
nl
f
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g
n
wheel bearing housing
ility
ab
y li
an
pt
ce
Tighten threaded connection

and suspension strut -arrow-
ho
ut
a
between
ss
not
gu
ara
nte
eo
ra
c

Note

Specified torques
Component
Specified torque

Use new nut
70 Nm + 90
Suspension strut to body (suspension turret)

Use new bolts
15 Nm + 90

Use new nuts
60 Nm

link
Use new nuts
100 Nm
Coupling rod to suspension strut

Use new nut
65 Nm

Use new bolt
74
200 Nm + 180

Component
Specified torque

Use new bolt
5.3
70 Nm + 90
Repairing suspension strut

equipment required
1332 Spring compressor -V.A.Gwagen AG. Volkswagen AG doe
s no
olks
1752/1t gu
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Spring retainertho-V.A.G
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1752/4sa
or
ac
Commercially available
ratchet handle
ht
rig
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Co
t.
Shock absorber set T10001-
rrectness of i
t to the co
nform
spec
at
i
h re
o
n
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in t
his
d
o
cu
m
en
es, in part or in w
l purpos
hole
ercia
, is n
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erm
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t
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v
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agen
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AG.
Prote
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by
cop
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i
Remove suspension strut page 70 or page 65 .
75

AG. Volkswagen AG d
agen08.2009
oes
Running gear, axles, steering - oEdition
no
lksw
yV
db
ir se
tho
au
Removing coil spring

es, in part or in w
l purpos
hole
ercia
, is n
m
m
ot p
r co
erm
o
e
t
a
itte
v
i
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du
p
or
nl
f
e
g
n
Spring compressor -V.A.G 1752/1-
2-
3-
Tool insert -T10001/8-
4-
Ratchet handle -T10001/11-
5-
Tool insert -T10001/5-
6-
Spring retainer -V.A.G 1752/4WARNING
First compress spring far enough to ensure that upper spring

plate is free.
agen
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Vo
by
Prote
cted
by
c
o
py
rig
ht
.
C
op
yi
Unscrew hexagon nut from piston rod.
Remove individual components of suspension strut and coil

spring with spring compressor -V.A.G 1752/1- .
ht
rig
py
Co
t.
Ensure that coil spring is seated correctly in spring retainer V.A.G 1752/4- -arrow-.
rrectness of i
t to the co
nform
spec
at
i
h re
o
n
wit
in t
his
d
o
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en
1-
ility
ab
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ce
Compress coil spring withssspring compressor -V.A.G 1752/1until deep groove ball thrust bearing is free at top.
t gu
ara
nte
eo
ra
c
AG.
Installing coil spring

Fit coil spring with spring compressor -V.A.G 1752/1- onto
lower spring plate.
The end of the coil spring must lie against the stop -arrow-.
Tighten new hexagon nut on piston rod.
Relieve tension on spring compressor -V.A.G 1752/1- and re
move from coil spring.
Install suspension strut page 72 or page 67 .
Specified torques
Component
Suspension strut mounting to shock absorber
Use new nut
76
Specified torque
60 Nm

Removing and installing drive shafts
Removing and installing drive shaft with constant velocity joint

page 79 .
Removing and installing left drive shaft with (push-on) constant
velocity slip joint page 81 .
Removing and installing right drive shaft with (push-on) constant
velocity slip joint page 85 .
Removing and installing drive shafts with triple roller joint
AAR2600i page 88 .
Removing and installing drive shafts with triple roller joint
AAR3300i page 90 .
Volkswagen AG
.
gen AG
Removing and installing intermediate shaft
page
92
.
swa
WARNING
by
ed
ris
o
th
au
ss
k
Vol
un
le
pe
rm
itte
d
ility
ab
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pt
ce
When removing and installing drive shafts, do not allow them

to hang free and stop against joints due to over bending.
does
not
gu
ara
nte
eo
ra
c
es, in part or in w
l purpos
hole
ercia
, is n
m
ot
com
Loosening and tightening drive shaft

hexagon bolt
rrectness of i
t to the co
n
f
o
r
m
spec
atio
h re
n in
wit
6.1
ng
Prote
cted
b
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c
op
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.
Co
py
i
agen
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by
If wheel bearings are loaded with weight of vehicle, bearing will

be damaged. This reduces the service life of the wheel bearing.
It is therefore important to note the following:
ht
rig
py
Co
t.
Wheel bearings must not be subjected to load after bolt securing

drive shaft to wheel hub has been loosened.
thi
sd
o
cu
m
en
r
te o
iva
r
rp
fo
Torque/angle wrench -V.A.G 1756-
AG.
Procedure for loosening hexagon bolt.

Do not attempt to move the vehicle without the drive shafts fitted
as this would result in wheel bearing damage. If the vehicle does
have to be moved, always note the following points:
Fit an outer joint in place of drive shaft.
Tighten outer joint to 120 Nm.
Loosening hexagon bolt
For vehicles which are still standing on their wheels, loosen
the hexagon bolt a maximum of 90, as the wheel bearing will
otherwise be damaged.
Raise vehicle so that wheels are off the ground.
Have second mechanic apply brakes.
6. Removing and installing drive shafts
77

Remove hexagon bolt -arrow-.
Note
ility
ab
y li
an
pt
ce
Renew hexagon bolt.
rrectness of i
t to the co
nform
spec
a
t
i
h re
o
n in
wit
thi
s
ole,
cial p
is n
mer
m
ot p
o
c
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erm
te o
a
itte
ir v
du
p
or
nl
f
e
ng
Tightening hexagon bolt
AG. Volkswagen AG d
agen
oes
ksw
not
l
o
gu
yV
b
ara
d
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nte
is
r
o
eo
h
ut
ra
a
c
ss
The wheels must not be in contact with the ground when the drive
shaft bolt is tightened; otherwise, the wheel bearing will be dam
aged.
Tighten hexagon bolt to 200 Nm.
Lower vehicle onto its wheels.
Turn hexagon bolt 180 further.
6.2
Loosening and tightening 12-point

flange bolt securing drive shaft
Procedure for loosening 12-point flange bolt.

78
Prote
cted
by

AG.

agen
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.
Co
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Socket, 24 mm -T10361-
do
c
um
en

Loosening 12-point bolt
e
wage
s no
olksdo not loosen 12-point bolt
To avoid damage to wheel bearing,
t gu
yV
bfurther
ara
d
using 24 mm socket -T10361than
90
with
vehicle
still
nte
ir se
eo
standing on its wheels. utho
ra
c
sa
un
le
ility
ab
y li
an
pt
ce
Raise vehicle so that swheels are off the ground.

pe
rm
itte
d
rrectness of i
t to the co
n
f
o
r
mat
spec
ion
h re
wit
in
es, in part or in w
l purpos
hole
ercia
, is n
m
ot
com
Remove 12-point bolt -arrow-.

Fitting 12-point bolt
Renew 12-point bolt.
Note
aged.
Prote
cted
by
c
o
py
rig
ht
.
C
op
yi
Removing and installing drive shaft with

constant velocity joint
AG.
agen
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6.3
ht
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Co
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ng
Turn 12-point bolt 90 further.
thi
sd
o
cu
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en
r
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iva
r
rp
fo
Tighten 12-point bolt to 70 Nm.
79

Removing
Caution
During this step, vehicle must not be standing on its wheels.

Unbolt drive shaft from gearbox flange shaft.
Remove wheel.
Push drive shaft outer joint out of wheel hub by hand.
link.
Pull drive shaft out of wheel hub.
AG. Volkswagen AG d
agen
oes
ksw
not
l
o
gu
yV
b
ar
d
e
Remove any paint
nte
is residue and/or corrosion on thread and asplines
r
o
eo
h
of outer joint.aut
ra
c
s
s
Installing
ole,
cial p
is n
mer
m
ot p
o
c
r
erm
o
e
t
a
itte
iv
du
pr
r
o
nl
f
e
ng
Guide outer joint into wheel hub splines as far as possible.
rrectness of i
t to the co
nform
spec
a
t
ion
h re
wit
in t
his
agen
lksw
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by
AG.
Prote
cted
b
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c
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yri
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.
Co
py
i
ht
rig
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do
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um
en
80
ility
ab
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an
pt
ce
Insert drive shaft.

Bolt swivel joint to suspension link -arrows-.
Note

Place inner joint of drive shaft in position and tighten bolts di
agonally to 10 Nm.
Tighten multi-point socket-head bolts diagonally to the speci
fied torque.
Note
. Volkswagen AG
gen AG
d
a
oes
ksw
not on its wheels or
During this step,
must not be standing
olvehicle
gu
yV
b
ara
wheel bearing
will
be
damaged.
d
e
n
s
Specified torques
Component
Use new nuts

link
Use new nuts
Use new bolt
Use new bolt
rrectness of i
t to the co
nform
spec
a
t
ion
h re
wit
in t
his
ole,
cial p
is n
mer
m
ot p
o
c
r
erm
o
e
t
a
itte
riv
du
p
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o
nl
f
e
ng
and tighten page 288 .
tee
or
ac
ility
ab
y li
an
pt
ce
ri
ho
ut
a
Install
wheel
ss
Specified torque
60 Nm
100 Nm
200 Nm +180
70 Nm + 90
ht
rig
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Co
t.
Use new backing plates

cop
yri
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t
.
Co
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i
Drive shaft to flange shaft on gearbox M10 multi-point

socket
Use new bolts
AG.
Prote
cted
by
6.4
agen
lksw
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do
c
um
en
Drive shaft to flange shaft on gearbox M8 multi-point sock

40 Nm
et
Initially tighten diagonally to 10 Nm.
Use new bolts
70 Nm
Removing and installing left drive shaft

with (push-on) constant velocity slip joint
81

Multi-purpose tool -VW 771-
Drive shaft puller -T10382-
Loosen drive shaft bolt at wheel hub page 78 .
Prote
cted
by
c
o
py
rig
ht
.
C
op
yi

Remove wheel.
82
AG.

agen
lksw
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by

ht
rig
py
Co
t.
Caution
rrectness of i
t to the co
nform
spec
atio
h re
n
wit
i
n
thi
sd
o
c
um
en
Removing
ole,
cial p
is n
mer
m
ot p
r co
erm
o
e
t
itte
ir va
du
p
or
nl
f
e
g
n
ility
ab
y li
an
pt
ce
es n
wage
ot g
olks
V
y
ua
db
ran
e
is
tee
r
o
h
t
or
u
ac
a
ss

link.
es
wage
ks
Vol
by
Push drive shaft outer joint out ofedwheel
hub by hand.
falling.
not
gu
ara
nte
eo
ra
c
ility
ab
y li
an
pt
ce
Position puller -T10382/1- behind constant velocity slip joint

-1-.
Cut-out -arrow- of puller -T10382/1- must face constant velocity
slip joint -1-.
rrectness of i
t to the co
nform
spec
atio
h re
n
wit
i
n
thi
sd
o
c
um
en
ole,
cial p
is n
mer
m
ot p
r co
erm
o
e
t
itte
ir va
du
p
or
nl
f
e
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n
Secure drive shaft to
is
or
thit
u
prevent
from
a
ss
ht
rig
py
Co
t.
agen
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by
AG.
Prote
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by
cop
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.
Co
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i
83

Install spindles -T10382/2- and traverse -T10382/3- on puller
plate -T10382/1- .
Install multi-purpose tool -VW 771- on traverse -T10382/3- .
Pull out drive shaft with a couple of strikes of multi-purpose
tool -VW 771- .
Remove drive shaft from vehicle.
Installing
Remove any paint residue and/or corrosion on thread and splines
of outer joint.
Insert new retaining ring in groove in stub shaft on gearbox.
Lightly grease splines of stub shaft with
universal
-G
. Volkswaggrease
en AG
AG
does
agen
060 735 A2ksw
not
Vol
y
db
e of gearbox and constant velocity

Mesh outer and inner splines
ris
tho
slip joint.
u
a
rrectness of i
t to the co
nform
spec
a
t
ion
h re
wit
in t
his
Note
Never use a hammer or other striking tool!

Check that constant velocity slip joint is seated securely by
pulling on constant velocity joint against resistance of retaining
ring.
Caution
For this check, pull only on constant velocity slip joint, not on
drive shaft.
Detach tensioning strap -T10038- .
agen
lksw
Vo
by
Prote
cted
by
c
o
py
rig
ht.
C
op
yi

AG.
Note

Tighten drive shaft bolt at wheel hub page 78 .
Note

84
ht
rig
py
Co
t.
do
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um
en
ole,
cial p
is n
mer
m
ot p
o
c
r
erm
o
e
t
a
itte
riv
du
p
r
o
nl
f
e
ng
Now push constant velocity joint onto stub shaft of gearbox

with a sudden, hard push.
ility
ab
y li
an
pt
ce
ss
Slide drive shaft into constant velocity joint to stop by hand.
gu
ara
nte
eo
ra
c
Specified torques
ility
ab
y li
an
pt
ce
un
le
Component
. Volkswaggear,
en AG axles, steering - Edition 08.2009
Running
n AG
does
wage
s
k
not
l
o
V
gu
y
b
ara
d
e
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Specified
c torque
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Use new nuts
100 Nm
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60 Nm

Use new bolt
6.5
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Use new nuts
70 Nm + 90 further
Removing and installing right drive shaft with (push-on) constant velocity
slip joint
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Drive shaft puller -T10382-
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Tensioning strap -T10038-
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Multi-purpose tool -VW

771-
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equipment required
Removing
Loosen drive shaft bolt at wheel hub page 78 .
85

Caution

Remove wheel.
link.
Unbolt coupling rods from anti-roll bars on both sides.
Push drive shaft outer joint out of wheel hub by hand.
Secure drive shaft to prevent it from falling.
Set up drive shaft puller -T10382- .
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For the constant velocity slip joint -1-, notch -arrow- in the puller
plate -T10382/1- must face the spindles -T10382/2- .
rrectness of i
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Note
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Assemble drive shaft puller -T10382- complete with multi-pur

pose tool -VW 771- .
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shaft puller -T10382- can be applied parallel to drive shaft.
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In order to pull the drive shaft out of the gearbox using the drive
shaft puller -T10382- , the suspension strut with all attachments
must be pulled to the rear.

Set up drive shaft puller -T10382- and pull out drive shaft.
Remove drive shaft from vehicle.
Installing
of outer joint.
Insert new retaining ring in groove in stub shaft on gearbox.
Grease splines of stub shaft lightly with universal grease -G
060 735 A2 Mesh outer and inner splines of gearbox and constant velocity
slip joint.
Slide drive shaft into constant velocity joint to stop by hand.
Now push constant velocity joint onto stub shaft of gearbox
with a sudden, hard push.
Note

Check that constant velocity slip joint is seated securely by
pulling on constant velocity joint against resistance of retaining
ring.
Caution
For this check, pull only on constant velocity slip joint, not on
drive shaft.
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Guide outer joint into wheel ahub
splines as far as possible.
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Note

Tighten drive shaft bolt at wheel hub page 78 .
Note

AG.

Use new nuts
Specified torque
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Component
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Specified torques
do
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60 Nm
87

Component
Specified torque

link
Use new nuts
100 Nm

Use new bolt
6.6
70 Nm + 90 further

with triple roller joint AAR2600i

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Note

Remove wheel.
88
AG.
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Wedge -T10161-
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link.
Pull drive shaft out of wheel hub and tie up to body.
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Insert wedge -T10161between
gearbox
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and
tripleuaran
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Press inner joints out of gearbox by striking wedge -T10161-
Remove drive shaft.

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Fit new retaining ring into groove of joint pin.

Mesh outer and inner splines of joint body and gearbox.
Slide drive shaft into joint body to stop by hand.
Now suddenly push joint body into gearbox.
The joint travel can be used for the sudden push. Do not, how
ever, pull the drive shaft too far out of the joint body.
Note
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Prote
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For this check, pull only on joint body and not on drive shaft.
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Check that drive shaft is seated securely in gearbox by pulling

on joint body against resistance of retaining ring.
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Installing
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AG.
89

Note

Note
olkswagen AG
does
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During this step, vehicle must not be standing on its wheels or kswagen AG. V
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Specified torque
60 Nm

link
Use new nuts
100 Nm

Use new bolt
200 Nm +180

Use new bolt
70 Nm + 90

with triple roller joint AAR3300i
Removing
90
AG.
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6.7
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Component
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Specified torques
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Remove wheel.
Unbolt drive shaft from gearbox flange shaft.
link.
Pull drive shaft out of wheel hub.
Installing
of outer joint.
Insert drive shaft.
Note

Place inner joint of drive shaft in position and tighten bolts di
agonally to 10 Nm.
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Note
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his

Component
Specified torque

Use new nuts
60 Nm

link
Use new nuts
100 Nm
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200 Nm +180
AG.

Use new bolt
Prote
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Use new bolt
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Specified torques
70 Nm + 90
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Tighten multi-point socket-head bolts diagonally to the speci
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Install lower noise insulation. Rep. Gr. 50 ; Assembly
over
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91
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Specified torque
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Component
Drive shaft to flange shaft on gearbox M10 multi-point

socket
Use new bolts
6.8
rrectness of i
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spec
a
t
i
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Drive shaft to flange shaft on gearbox M8 multi-point sock

40 Nm
et
Use new bolts
70 Nm
Removing and installing intermediate

shaft

Prote
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by
Repairing intermediate shaft page 114 .

Installing
First renew seal -1- on gearbox.
92
AG.
Pull intermediate shaft off gearbox.
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Loosen all bolts on bearing bracket -arrows-.
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Remove drive shaft on right side page 80 .
do
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Removing

Now push intermediate shaft onto stub
shaft of gearbox until
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Tighten bolts -arrows- to prescribed torque.

Install drive shaft page 80 .
Prote
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Intermediate shaft bearing to bearing bracket
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Component
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Specified torques
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at
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Specified torque
20 Nm
93

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94
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III - Assembly overview - drive

shaft with VL107 constant ve
locity slip joint (push-on)
page 116
rrectness of i
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n
f
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m
spec
atio
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wit
II - Assembly overview - drive

shaft with VL107 constant ve
locity joint (bolt-on)
page 107
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I - Assembly overview - drive

shaft with VL90 or VL100 con
stant velocity joint
page 97
un
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Repairing drive shaft - overview of drive shafts
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IV - Assembly overview - drive
shaft with triple roller joint
AAR2600i page 121
V - Assembly overview - drive
shaft with triple roller joint
AAR3300i page 127
Distinguishing between drive shafts when installed

VL90
VL100
VL107 (bolton)
VL 107 (pushon)
AAR2600i
AAR3300i
90
100
107
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Diameter of
inner joint in
mm
Cover be
tween inner
joint and drive
flange
With bearing
bracket on
right side
Inner joint fit
ted in gearbox
Inner joint
pushed onto
stub shaft
rrectness of i
t to the co
nform
spec
a
t
i
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7. Repairing drive shaft - overview of drive shafts
95

7.1
Heat shields for drive shafts
Front-wheel drive
Component
Specified torque
Hexagon bolt -1-
25 Nm
Four-wheel drive:
Component
Specified torque
Specified torque
20 Nm
Initially tighten all nuts to
10 Nm
r
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Nuts -1-
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Component
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Four-wheel drive:
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20 Nm
Initially tighten all nuts to n AG. Volkswagen AG
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10 Nm olkswage
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Nuts -1-

Assembly overview - drive shaft with VL90 or VL100 constant velocity

joint
1 - Outer constant velocity joint

Renew only as com
plete unit
Removing page 101
Installing: drive onto
shaft to stop using a
plastic mallet
Checking page 103
2
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M16 x 1.5 x 80
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Hexagonssbolt,
200 Nm
When bolt is loosened or tight

ened, vehicle must not be
standing on its wheels
3 - Right drive shaft
4 - Hose clip
moving
Tightening page 103
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6 - Hose clip
moving
Tightening page 103
ht
rig
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5 - Boot
Check for splits and
chafing
Material: Hytrel (poly
ester elastomer)
rrectness of i
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spec
a
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and turn +180 further

12-point bolt, 70 Nm +
90 further
moving
Prote
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7 - Dished spring
Installation position page 101
8 - Thrust washer
9 - Retaining ring
Insert in groove in shaft
10 - Boot for constant velocity joint
Material: Hytrel (polyester elastomer)
Without breather hole
Check for splits and chafing
Drive off constant velocity joint with a drift
Coat sealing surface with D 454 300 A2 before installing constant velocity joint
8. Assembly overview - drive shaft with VL90 or VL100 constant velocity joint
97

11 - Hose clip
Tightening page 103
12 - Left drive shaft
13 - Locking plate
Renew each time after removing
Initially tighten diagonally to 10 Nm
un
le
Always renew bolts after removing
15 - Retaining ring
Remove and install with -VW 161- A.
16 - Seal
Adhesive surface on constant velocity joint must be free of oil and grease!
17 - Inner constant velocity joint
Renew only as complete unit
Pressing off page 102
Pressing on page 102
Checking page 104
AG.
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98
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18 - Dished spring
rrectness of i
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spec
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M10 bolt: 70 Nm
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M8 bolt: 40 Nm
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and then
t
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8.1
Dismantling and assembling drive shaft with VL90 or VL100 constant ve

locity joint

equipment required
Thrust plate -VW 401 Thrust plate -VW 402 Press tool -VW 408 A Press tool -VW 411 Tube -VW 416 B Thrust plate -VW 447 H-
rrectness of i
t to the co
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spec
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99

Circlip pliers -VW 161 A Torque wrench -V.A.G
1331 Torque wrench -V.A.G
1332 Special pliers -V.A.G 1682-
AG.
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100
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Assembly
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tool -T10065by
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Puller -T10382-
Removing outer constant velocity joint

Clamp drive shaft in vice using protective jaw covers.
Fold back boot.
Set puller -T10382- up so that smooth side of puller plate T10382/1- points to spindles -T10382/2- .
Assemble puller -T10382- complete with multi-purpose tool VW 771- .
Pull constant velocity joint from drive shaft with puller -T10382and multi-purpose tool -VW 771- .
1-
Puller plate -T10382/1-
2-
Spindles -T10382/2AG. Volkswagen AG d

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Driving on outer constant velocity joint
rrectness of i
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spec
a
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Installation position of dished spring 1 and thrust washer 2 on

outer joint
1-
Dished spring
2-
Thrust washer
Install new retaining ring.
If necessary, push new joint boot onto drive shaft.
do
c
um
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rig
py
Co
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Drive onto shaft with plastic head hammer until retaining ring
engages.
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101

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Assembling
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Pressing off inner constant velocity joint
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Chamfer on internal circumference of ball hub (splines) must face

contact shoulder on drive shaft.
102
Prote
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Note
AG.
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Pressing on inner constant velocity joint
agen
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Dished spring
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1-
do
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Installation position of dished spring at inner joint

Tighten hose clip on outer joint
Apply special pliers -V.A.G 1682- as shown in diagram. En
sure that the jaws of the pliers seat in the ends of the hose clip
-arrows B-.
Tighten hose clip by turning spindle with a torque wrench (do
not cant pliers).
Note
pe
rm
itte
d
un
le
Specified torque: 25 Nm.
Use torque wrench -C- with adjustment range 5 ... 50 Nm, (e.g.
Make sure thread of spindle -A- on pliers moves freely. Lubri
rrectness of i
t to the co
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spec
atio
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torque wrench -V.A.G 1331- ).
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AG. Volkswagen AG d
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Because a stainless steel ehose
d b clip is required due to the hard uara
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material of the joint boothor(compared
to rubber), it is possible to
eo
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tighten the hose clips aonly
with special pliers -V.A.G 1682- .
c
s
cate with MoS2 grease if necessary.
If the thread is tight (e.g. due to dirt), the required clamping
force for the clip will not be attained although the correct torque
is applied.
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Checking outer constant velocity joint

AG.
8.2
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Tightening hose clip on small diameter
The joint is to be dismantled to renew the grease if it is heavily

soiled, or to check the running surfaces of the balls for wear and
damage.
Removing
Before dismantling, mark position of ball hub in relation to ball
cage and joint body with an electric scriber or oil stone.
Swing ball hub and ball cage.
Remove balls one at a time.
103

Turn cage until the two rectangular windows -arrow- align with
joint body.
Take out cage with hub.
Swing segment of hub into square cage window.

Tip hub out of cage.
The six balls for each joint belong to a tolerance group. Check
stub axle, hub, cage and balls for small indentations (pitting) and
traces of seizing. Too much circumferential backlash in the joint
becomes noticeable during load change jolts; in such cases, the
joint must be renewed. Smoothing and traces of wear of the balls
are no reason to change the joint.
Installing
Pack half of total grease quantity (40 g) into joint body.
Fit cage with hub into joint body.
ility
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Press in opposing balls one after the other; ethe
d b original position
ran
s
i
tee
r
of the hub relative to the cage and joint tbody
must
be
restored.
o
h
or
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ac
a
ss
Fit new retaining ring into hub.
pe
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Distribute remaining grease in boot.
Removing
es, in part or in w
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Checking inner constant velocity joint
rrectness of i
t to the co
n
f
o
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mat
spec
ion
h re
wit
in
8.3

soiled, and to check the running surfaces and the balls for wear
and damage.
Press out joint body in direction of arrow.
Press balls out of cage.
AG.
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104
ht
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The ball hub and joint body are paired. Do not interchange them.
thi
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Note

Tip ball hub out of ball cage via ball track -arrows-.
Check joint body, ball hub, ball cage and balls for pitting and
traces of seizing.
Excessive circumferential backlash in the joint is noticeable dur
ing load change jolts. In this case the joint must be replaced.
Smoothing and traces of wear of the balls are no reason to renew
the joint.
Installing
Insert hub into cage via the two chamfers. The hub can be
installed in any position. Press balls into cage.
The ball hub has two different distances between the ball tracks:
a smaller one and a larger one.
Insert hub complete with cage and balls into joint body, making
sure that a smaller gap -b- faces open side of joint body.
. Volkswagen AG
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Also make sure that chamfer onVinner
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hub is visible after swinging eitd binto
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rrectness of i
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wit
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s
Swing ball hub into place by swinging hub out of cage as

shown in figure -arrows-.
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105

Swivel in hub with balls by applying firm pressure to cage
-arrow-.
Checking function of constant velocity joint
. Volkswagen AG
n AGhub
The constant velocity joint is correctly assembled if the
ball
ge
does
swa
k
not
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can be moved by hand backwards and forwardsy Vover its entire
gu
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range of axial movement.
nt
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Prote
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Co
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Co
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do
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106
rrectness of i
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nform
spec
a
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ion
h re
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ss

Assembly overview - drive shaft with VL107 constant velocity joint

(bolt-on)

Renew only as com
plete unit
Removing page 110 .
Installing: drive onto agen AG. Volkswagen AG do
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shaft to stop using
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plastic mallet
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t page 103
or
Checking
u
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ss
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f
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m
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2 - Bolt
M16 x 1.5 x 80
Hexagon bolt, 200 Nm
90 further
moving

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cop
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5 - Hose clip
moving
Tightening page 113
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4 - Boot
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ester elastomer)
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3 - Hose clip
moving
Tightening page 113
Prote
cted
by
6 - Dished spring
7 - Thrust washer
8 - Retaining ring
10 - Dished spring
9. Assembly overview - drive shaft with VL107 constant velocity joint (bolt-on)
107

11 - Hose clip
Tightening page 113
12 - Drive shaft
13 - Intermediate shaft
For Golf only
Right side of vehicle:
Repairing page 114
14 - Cover
Always renew
15 - Retaining ring
Remove and install with circlip pliers -VW 161 A16 - Seal
Checking page 104
es n
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db
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18 - Cap
Drive off carefully
Adhesive surface must be free of oil and grease!
rrectness of i
t to the co
n
f
o
r
m
spec
atio
h re
n in
wit
19 - Locking plate

Initially tighten diagonally to 10 Nm and then tighten diagonally to specified torque.
M8 bolt: 40 Nm
M10 bolt: 70 Nm

21 - Hose clip
Tightening page 113
AG.
108
agen
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24 - Bearing bracket
For Golf only
ht
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23 - Countersunk head bolt

Initially tighten to 5 Nm and then to 35 Nm
For Golf only
Qty. 3
thi
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en
22 - Bolt
20 Nm
For Golf only

25 - Bearing
For Golf only
Pressing off on page 114
9.1
Dismantling and assembling drive shaft with VL107 constant velocity joint

equipment required
Thrust plate -VW 401 Thrust plate -VW 402 Press tool -VW 408 A Support sleeve -VW 522 Tensioner -40 - 204 A-
AG. Volkswagen AG d
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ercia
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Special pliers -V.A.G 1682-
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C
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109

rrectness of i
t to the co
n
f
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m
spec
atio
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n in
wit
es, in part or in w
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hole
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Puller -T10382-
AG. Volkswagen AG d
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1-
2-
Spindles -T10382/2-
110
AG.
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Fold back boot.
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Installation position of dished spring and thrust washer on outer
joint
1-
Dished spring
2-
Thrust washer
Knock onto shaft with plastic hammer until circlip engages.
Driving off cover for inner joint

Remove retaining ring.
Remove both hose clips and slide
Dished spring
AG.
1-
agen
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.
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Assembling
rrectness of i
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nform
spec
at
i
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Use drift to drive off boot.
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bootatowards outer joint.
ac
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111

Press joint on to stop.
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by
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tee
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or
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s
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Install retaining ring.
Apply continuous bead of sealant (2...3 mm ) past inner edge

of holes -arrow- to clean surface of cover.
Using bolts -arrows-, align new cover in relation to bolt holes.

The alignment must be very accurate, because no further align
ment is possible once the part has been hammered on.
AG.
agen
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C
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112
ht
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Wipe off surplus sealant.
r
fo
ng
Drive on cover using a plastic hammer.
rrectness of i
t to the co
nform
spec
a
t
i
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o
n in
wit
thi
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Coat sealing surface of cover with -D 454 300 A2- .

-arrows B-.
olkswagen AG
en AG. V
g
does
Tighten hose clip by turning spindle
swa a torque wrench (do
not
olkwith
gu
yV
not cant pliers).
b
ara
ed
material of the joint boot (compared to rubber), it is possible to

tighten the hose clip only with special pliers -V.A.G 1682- .

Use torque wrench -C- with adjustment range 5 50 Nm, (e.g.
is applied.

Checking outer constant velocity joint page 103
Checking inner constant velocity joint page 104
ht
rig
py
Co
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Checking function of constant velocity joint page 106
rrectness of i
t to the co
nform
spec
atio
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n
wit
i
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n
Because a stainless steel hose clip is required due to the hard
ility
ab
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Note
nte
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ra
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ut
a
ss
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Prote
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c
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.
Co
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113

9.2
Repairing intermediate shaft

es n
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ran
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or
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db
e
equipment required
ris
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Thrust plate
s a -VW 401-
Thrust piece -T10032 Thrust piece -3118 Separating device Kukko

-15-2-
ht
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Prote
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rig
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.
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Pressing off bearing

Press bearing off intermediate shaft as shown in figure.
The jaws of the Kukko splitter -15-2- must be facing shaft.
1-
Intermediate shaft with bearing
2-
3-
4-
Separating device Kukko -15-2Note
Hold shaft when pressing out.
114
rrectness of i
t to the co
nform
spec
atio
h re
n
wit
i
n
thi
sd
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erm
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ir va
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p
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n
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Pressing on bearing
Press bearing to stop on intermediate shaft as shown in figure.
1-
Thrust piece -T10032-
2-
Intermediate shaft
3-
Bearing
4-
Thrust piece -3118-
5-
6-
Separating device Kukko -15-2-
7-
Thrust plate -VW
es
wage402ks
Vol
not
g
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by of press tool -3118- must be facing
Shoulder -arrowran bearing.
ed
ris
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a
ss
tee
or
ac
rrectness of i
t to the co
nform
spec
a
t
i
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wit
thi
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rig
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ir va
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n
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agen
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Vo
by
AG.
Prote
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by
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rig
ht.
C
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yi
115

10
Assembly overview - drive shaft with VL107 constant velocity slip joint
(push-on)

Renew only complete
Removing page 117 .
plastic mallet
Checking page 119
2 - Bolt
70 Nm + 90 further
moving
n
wage
olks
V
y
db
ise
or
th
au
4 - Thrust washer
Installation position
page 118
5 - Dished spring
Installation position
page 118
6 - Clamp
moving
Tightening page 119
10 - Clamp
Tightening page 119
11 - Boot for constant velocity slip joint
12 - Circlip
116
AG.
9 - Drive shaft
agen
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Prote
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by
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ht
.
C
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8 - Clamp
Tightening page 119
ht
rig
py
Co
t.
7 - Boot
chafing
rrectness of i
t to the co
nform
spec
a
t
i
h re
o
n in
wit
thi
sd
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3 - Circlip
moving
AG. Volkswagen AG d
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13 - Clamp
Tightening page 119
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Golf
2004
, Golf
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ise Running gear, axles, steering - Edition
r
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rrectness of i
t to the co
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f
o
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mat
spec
ion
h re
wit
in
10.1
es, in part or in w
l purpos
hole
ercia
, is n
m
ot
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14 - Constant velocity slip joint

Renew only complete
Removing page 118
Installing: drive onto shaft to stop using a plastic mallet
Dismantling and assembling drive shaft

with VL107 (push-on) constant velocity
slip joint
ht
rig
py
Co
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ng
thi
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agen
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by
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Prote
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by
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rig
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.
C
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Puller -T10382-

Fold back boot.
10. Assembly overview - drive shaft with VL107 constant velocity slip joint (push-on)
117

1-
2-
Spindles -T10382/2-

outer joint
2-

Fold back boot.
12-
Puller plate -T10382/1Spindles -T10382/2-
Prote
cted
by
c
o
py
rig
ht.
C
op
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ht
rig
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Co
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agen
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118
do
c
um
en
Driving on inner constant velocity slip joint
rrectness of i
t to the co
nform
spec
a
t
ion
h re
wit
in t
his
Removing inner constant velocity slip joint
ility
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AG. Volkswagen AG d
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not
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Thrust washeror
eo
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t
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ra
a
c
Install new retaining
ring.
ss
Dished spring
ole,
cial p
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mer
m
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erm
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t
a
itte
iv
du
pr
r
o
nl
f
e
ng
1-

sure jaws of tool contact corners -arrows B- of hose clamp.
not cant pliers).
Note
Because a stainless steel clip is required due to the hard ma
terial of the joint boot (compared to rubber), it is possible to

tighten the clip only with special pliers -V.A.G 1682- .

. Volkswagen AG
gen AG
does
is applied.
swa
not
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ara
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c
ility
ab
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ce
rrectness of i
t to the co
n
f
o
r
mat
spec
ion
h re
wit
in
10.2
es, in part or in w
l purpos
hole
ercia
, is n
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com
pe
rm
itte
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un
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Tightening hose clip on small
olk
yV
db
e
s
ri
ho
diameter
ut
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Prote
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by
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thi
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Removing
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fo

damage.
10. Assembly overview - drive shaft with VL107 constant velocity slip joint (push-on)
119

joint body.
Swing segment of hub into square cage window.

The six balls for each joint belong to a tolerance group. Check
traces of seizing. Too much circumferential
backlash in the joint
AG. Volkswagen AG d
agen
o s
becomes noticeable during
ksw load change jolts; in esuch
not cases, the
l
o
V
joint must be renewed.
ua the balls
by Smoothing and traces of weargof
d
ran
ise
are no reason to
tee
or change the joint.
h
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ility
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Installing ss a
es, in part or in w
l purpos
hole
ercia
, is n
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ng
AG.
Prote
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by
agen
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p
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C
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Co
t.
120
thi
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rrectness of i
t to the co
n
f
o
r
m
spec
atio
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n in
wit
Press in opposing balls one after the other; the original position
of the hub relative to the cage and joint body must be restored.

11
Assembly overview - drive shaft with triple roller joint AAR2600i
pe
rm
itte
d
un
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Renew only as com
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Removing page 124 .
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Installing: drive onto y Volks
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Checking page 103
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2 - Bolt
M16 x 1.5 x 80
90 further
moving
3 - Right drive shaft
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5 - Hose clip
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Tightening page 103
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4 - Left drive shaft
7 - Hose clip
Tightening page 103
8 - Dished spring
Installation position page 124 .
9 - Thrust washer
10 - Retaining ring
11 - Hose clip
Tighten hose clip with hose clip pliers -V.A.G 127512 - Boot for triple roller joint
11. Assembly overview - drive shaft with triple roller joint AAR2600i
121

13 - Hose clip
Tighten hose clip with hose clip pliers -V.A.G 127514 - Retaining ring
15 - Joint body
16 - Retaining ring
Insert in groove in shaft using circlip pliers -VW 161 A- .
17 - Triple roller spider with rollers
The chamfer -arrow- points towards drive shaft splines.
11.1

equipment required
Thrust plate -VW 401n AG. Volkswagen AG do
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Press tool -VW
Tube -VW 416 B-
Thrust washer -VW 447 H-
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Press tool -VW


1331-
Special pliers -V.A.G 1682 Assembly tool -T10065-
rrectness of i
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a
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Torque wrench V.A.G 1332-
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Hose clip pliers -V.A.G

1275-
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123
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Edition
08.2009
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Puller -T10382-

Fold back boot.
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2-
Spindles -T10382/2-
AG.
1-

joint
1-
Dished spring
2-
Thrust washer

Dismantling
Unfasten both hose clips on inner joint and push back boot.
Pull joint body off drive shaft.
124
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- or -VW 161 A Set drive shaft into press.
rrectness of i
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a
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1 - Pliers (commercially available)
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Golf
2004
,
Golf
Plus
2005
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Press triple roller spider off drive shaft.

Pull boot off shaft.
Prote
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Fitting triple roller spider
AG.
Push joint body onto shaft.
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Push joint boot onto shaft.
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Push small hose clip for boot onto shaft.
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Assembling
do
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Clean shaft, joint body and groove for seal.
Drive shaft (tapered version)

Chamfer on spider faces towards shaft and is used as an assem
bly aid.
Fit triple roller spider onto shaft and press on to stop.

Ensure that pressure does not exceed 3.0 t.
If necessary, coat splines of drive shaft and triple roller spider
with lubricant paste G 052 142 A2.
Insert retaining ring, ensuring that it is seated correctly.
As of 08.2004, a different grease is used in the triple roller joints.
This grease cannot be mixed with the previous one. The triple
roller joint must therefore be cleaned before greasing during re
pair work.
Press 70 grammes of drive shaft grease from repair set into
triple roller joint.
Slide joint body over rollers and hold.
Press 60 g of drive shaft grease from repair kit into rear of triple
roller joint.
Install joint boot.
Drive shaft (cylindrical version)
125

roller joint.
Install joint boot.
Tighten both hose clips with hose clip pliers -V.A.G 1275- .
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Running gear, oaxles,
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Assembly overview - drive shaft with triple roller joint AAR3300i

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3 - Hose clip
moving
Tightening page 103
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rrectness of i
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spec
a
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2 - Bolt
M16 x 1.5 x 80
90 further
moving
ility
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Renew only as com
plete unit
Removing page 131 .
shaft with plastic mallet
until compressed retain
ing ring seats.
Checking page 103
ht
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t.
12
n AG. V
wage
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by
ed
ris
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au
ss
4 - Boot for constant velocity

joint
chafing
ester elastomer)
5 - Hose clip
moving
Tightening page 103
6 - Dished spring
7 - Thrust washer
8 - Retaining ring
9 - Retaining ring
10 - Triple roller spider with rollers
The chamfer -arrow- points towards drive shaft splines.
11 - Hose clip
127

Tighten hose clip with hose clip pliers -V.A.G 127512 - Boot for triple roller joint
13 - Hose clip
Tighten hose clip with hose clip pliers -V.A.G 127514 - Drive shaft
15 - Bolt
20 Nm
For Golf only
16 - Bearing bracket
For Golf only
17 - Bearing
For Golf only
18 - Joint body with intermediate shaft
For Golf only
For right side of vehicle
19 - Countersunk head bolt
Initially tighten to 5 Nm and then to 35 Nm
For Golf only
20 - Joint body
For left side of vehicle
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M10 bolt: 70 Nm
o
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Always renew
bolts after removing
M8 bolt: 40 Nm
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128
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12.1

equipment required
Thrust plate -VW 401 Thrust plate -VW 402 Press tool -VW 411 Tube -VW 416 B-
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Thrust washer -VW 447 H-
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Press tool -VW 408 A-
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129

1331 Torque wrench V.A.G 1332 Special pliers -V.A.G 1682 Assembly tool -T10065-
rrectness of i
t to the co
nform
spec
a
t
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h re
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AG. Volkswagen AG d
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130

Puller -T10382-

Fold back boot.
Spindles -T10382/2-
AG.
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1-
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AG. Volkswagen AG d
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Prote
cted
by

joint
1-
Dished spring
2-
Thrust washer

Dismantling
Unfasten both hose clips on inner joint and push back boot.
Pull joint body off drive shaft.
131

1 - Pliers (commercially available)
- or -VW 161 A Set drive shaft into press.
Press triple roller spider off drive shaft.

Pull boot off shaft.
Clean shaft, joint body and groove for seal.
Assembling
Push small hose clip for boot onto shaft.
Push joint boot onto shaft.
Push joint body onto shaft.
Drive shaft (tapered version)
Chamfer on spider faces towards shaft and is used as an assem
bly aid.
ole,
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is n
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Fit triple roller spider onto shaft and
AG. Volkswagen AG d
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press on to stop.
rrectness of i
t to the co
nform
spec
a
t
ion
h re
wit
in t
his

As of 08.2004, a different grease is used in the triple roller joints.
This grease cannot be mixed with the previous one. The triple
roller joint must therefore be cleaned before greasing during re
pair work.
roller joint.
Prote
cted
by
AG.
agen
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132
c
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p
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C
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Drive shaft (cylindrical version)
do
c
um
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ht
rig
py
Co
t.
Install joint boot.

If necessary, coat splines of drive shafts and triple roller star
with lubricating paste -G 052 142 A2- .
roller joint.
Install joint boot.
Install hose clip.

Note
rrectness of i
t to the co
nform
spec
a
t
ion
h re
wit
in t
his
Tighten hose clip using hose clip pliers -V.A.G 1275-.
do
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To make it easier to insert the multi-point socket-head bolts when

installing the drive shaft, position ear -arrow A- of hose clip be
tween mounting flanges -arrows B- of joint body.
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Tighten small hose clip using hose clip pliers -V.A.G 1275-.
agen
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133

42
Rear suspension

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Rep. Gr.42 - Rear suspension
do
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134
rrectness of i
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Repairing rear suspension (frontwheel drive)
2.1
Overview - rear axle
I - Assembly overview: sub

frame, transverse link, track
rod (front-wheel drive)
page 140
II - Assembly overview: wheel
bearing housing, trailing arm
(front-wheel drive)
page 156
III - Assembly overview: shock
absorber, coil spring (frontwheel drive) page 173
IV - Assembly overview: antiroll bar (front-wheel drive)
page 179
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It is not permitted to weld or straighten load-bearing or wheel-
guiding components of the suspension.

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Therefore, you should only tighten the threaded connections

of components with bonded rubber bushes when the wheel
bearing housing is raised to unladen position, Golf
page 136 ; Golf Plus, CrossGolf page 138 .
rrectness of i
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2. Repairing rear suspension (front-wheel drive)
135

Rear axle in unladen position, Golf
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To simulate this position on the lifting platform, raise the axle on
one side using the engine and gearbox jack -V.A.G 1383 A- and
support -T10149- .
136
Prote
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Note
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Support -T10149-
AG.
Tensioning strap -T10038-
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2.2

straps -T10038- .
WARNING

Attach support -T10149- with a wheel bolt.
Threaded connections may be tightened only when dimension
-a- between the centre of wheel hub and lower edge of wheel
housing, measured before starting work, has been attained.
Measuring dimension -aThe dimension -a- depends on the ride height of the installed run
ning gear:
Running gear 1)
un
le
a
ss
pe
rm
itte
d
365 10 mm
es, in part or in w
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365 10 mm
360 10 mm
380 10 mm
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olkswagen AG
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380 10 mm swagen AG. V

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400 10
d mm
e
ris
ho 10 mm
365ut
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wheels (2UC)
version (G11)
BlueMotion (G04/2UC)
365 10 mm

here page 317 .
ng
AG.
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Do not leave the engine and gearbox jack under the ve

hicle for longer than necessary.
ht
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thi
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WARNING
r
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until dimension -a- is attained.

Pull engine and gearbox jack out from underneath vehicle.
Remove support -T10149- .
137

2.3
Rear axle in unladen position, Golf Plus, CrossGolf

equipment required
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a
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support -T10149- .
138
Prote
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straps -T10038- .
WARNING

ning gear:
Running gear 1)
wheels (2UC)
wheels (G02/G07/2UC)
CrossGolf (2UB)
BlueMotion (G06)

378 10 mm
398 10 mm
363 10 mm
363 10 mm
395 10 mm
370 10 mm
1)

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here page 317 .
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WARNING
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th
Raise wheel bearing housing using engine and gearbox
jack
au
ss
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t to the co
nform
spec
a
t
ion
h re
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his

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139
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Prote
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3 - Eccentric washer
Inner hole with lug
4 - Eccentric bolt
For track adjustment
Check wheel alignment
whenever this compo
nent is loosened
page 305 .
Inner hole with lug
6 - Nut
95 Nm
Note
M12 x 1.5
Self-locking
Golf page 136
7 - Subframe
8 - Bolt
M12 x 1.5 x 90
90 Nm + 90 further
9 - Lower transverse link
140
AG.
Golf Plus, CrossGolf

page 138
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Golf page 136
do
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2 - Nut
M12 x 1.5
95 Nm
Self-locking
moving
Always tighten threaded
connections in unladen
position:
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1 - Eccentric bolt
For camber adjustment
whenever this compo
nent is loosened
page 305 .
rrectness of i
t to the co
nform
spec
a
t
ion
h re
wit
in t
his
Assembly overview: subframe, transverse link, track rod (front-wheel

drive)
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Running gear, axles, steering - Edition
AG. Volkswagen AG d
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08.2009
c
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10 - Nut
M12 x 1.5 x 75
90 Nm + 90 further
Self-locking
Golf page 136
11 - Bolt
12 - Threaded rivet
M6
13 - Spreader rivet
14 - Stone deflector
15 - Bolt
8 Nm
16 - Nut
M14 x 1.5
130 Nm + 90 further
Self-locking
Golf page 136
olkswagen AG
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17 - Bolt
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Always tighten threaded connections in
position:
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Golf page 136
19 - Washer
rrectness of i
t to the co
nform
spec
a
t
ion
h re
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his
18 - Upper transverse link

20 - Nut
M14 x 1.5
130 Nm + 90 further
Self-locking
Golf page 136
do
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21 - Wheel bearing housing

3. Assembly overview: subframe, transverse link, track rod (front-wheel drive)
141

22 - Washer
23 - Bolt
Golf page 136
Forwards closed (left and right track rods differ)
rrectness of i
t to the co
nform
spec
a
t
i
h re
o
n in
wit
thi
s
Downwards open (left and right track rods identical)

It is permitted to install mixed types.
25 - Bolt
26 - Nut
M12 x 1.5
90 Nm + 90 further
Self-locking
Golf page 136
AG.
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142
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24 - Track rod
Various versions
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3.1
Removing and installing rear axle

equipment required
1332 Engine/gearbox jack V.A.G 1383/A Tensioning strap -T10038-
AG. Volkswagen AG d
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spec
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wit
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hole
ercia
, is n
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un
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Removing subframe with attachments

Remove wheels.
Removing coil springs page 174

Remove front and rear silencers of exhaust system Engine
Rep. Gr. 26
On vehicles with automatic headlight range control, separate
wiring connection -1-.
ht
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Remove ABS speed sensor out of wheel bearing housing.
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143

Remove screw -arrow-.
Lever off spring clip -1- for handbrake cable.

Push lever -2- in -direction of arrow- and unhook brake cable
-3-.
Unscrew hexagon bolt -1- and detach handbrake cable -2from brake cable bracket.
rrectness of i
t to the co
nform
spec
a
t
i
h re
o
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wit
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Vehicles with retainer for handbrake cable
Remove retainer -1- by pushing out inner pin of rivet -arrow-.
AG.
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do
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144
ht
rig
py
Co
t.

Unclip speed sensor wire from retainer -1- -arrows-.
Pull out hose retainer -1- on both sides of vehicle.
Mark installation position of bearing bracket on body.

WARNING

vehicle will slip off the lifting platform/hoist.
rrectness of i
t to the co
nform
spec
at
i
h re
o
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in t
his
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Now secure vehicle to hoist using tensioning straps -T10038

-.
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.
C
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145
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f
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frame using universal gearbox mounting -V.A.G 1359/2- and
secure with tensioning strap.
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AG. Volkswagen AG d
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Golf 2004 , hGolf
Plus 2005
o
eo
t
u
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a axles, steering - Edition 08.2009
Running gear,
c
ss
rrectness of i
t to the co
nform
spec
a
t
i
h re
o
n in
wit
thi
s
Unscrew bolt -1- or -2- on both sides.

Note
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Prote
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Note
The locating devices -T10096- must only be tightened to a max

imum of 20 Nm; otherwise the threads of the locating pins may
be damaged.
Unscrew remaining 2 bolts from subframe.
Carefully lower subframe with attachments a maximum of 30
mm.
Note
When lowering, ensure there is sufficient clearance to the brake

lines and electrical cables.
Unclip brake line -1- from clips -arrows-.
Note
The clips will be destroyed and must be renewed.
For reasons of clarity, the illustration shows the subframe from
above in removed state.
Lower subframe with attachments.

Installing subframe with attachments
146
ht
rig
py
Co
t.
Secure position of subframe using 2 locking devices -T10096and tighten to 20 Nm.
do
c
um
en
Only the left vehicle side is shown to improve clarity.

n AG. Volkswagen AG o
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wage axles, steering - dEdition
Running
gear,
08.2009
s
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180 Nm
50 Nm + 45
AG.
Handbrake cable to trailing arm

Brake systems; Rep. Gr. 46
90 Nm + 90
rrectness of i
t to the co
nform
spec
at
i
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his
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Shock absorber to wheel bearing housing

Use new bolts
Specified torque
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Subframe to body
Use new bolts
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Component
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Specified torques
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147

3.2
Vehicle level sender for vehicles with automatic headlight range control
Note
The vehicle level sender is available as a replacement part only complete with coupling rod and upper and
lower retaining plates.
Renewing without removing subframe page 148 .

Control unit for headlight range control -J431- .
1 - Subframe
un
le
pe
rm
itte
d
es, in part or in w
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hole
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com
3 - Bolt
5 Nm
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148
AG.
Renew vehicle level sender in vehicle
agen
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3.3
ht
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Perform basic settings of

headlights using Vehicle di
agnosis, testing and informa
tion system VAS 5051.
thi
sd
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r
te o
iva
r
rp
fo
rrectness of i
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f
o
r
mat
spec
ion
h re
wit
in
4 - Rear left vehicle level send

er -G76 Complete with attach
ments
outwards
Renewing in vehicle
page 148
must be performed.

Removing
Remove bolts -2- from lower transverse link.
Remove bolts -arrows- from subframe.
Remove rear left vehicle level sender -G76- .
Installing
AG. Volkswagen AG d
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After completing installation, carry out basic
setting
of
head
t
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a
c
lights "Guided fault-finding" function
ss of vehicle diagnosis,
agen
The lever of rear left vehicle level sender -G76- must face
ksw outside
Vol
y
of vehicle.
db
Specified torque
Rear left vehicle level sender -G76- to lower transverse link

and subframe
3.4
5 Nm
Removing and installing upper trans

verse link

rrectness of i
t to the co
nform
spec
a
t
ion
h re
wit
in t
his
Component
do
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Specified torques
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testing and information system VAS 5051 .
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i
Removing
Remove wheel.
Remove coil spring page 173 .
149

Unhook speed sensor line -arrow A- from upper transverse
link.
Remove bolt -1-.
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f
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ng
Remove bolt -arrow-.
ility
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an
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Mark position of eccentric bolt -arrow- relative to subframe us

ing e.g. a felt tip pen.
Installing
rrectness of i
t to the co
nform
spec
a
t
ion
h re
wit
in t
his
Remove upper transverse link.
Install upper transverse link on vehicle and tighten bolts hand

tight.
The transverse link may be bolted only when dimension a has
been attained.
Golf page 137
Bolt upper transverse link to subframe and tighten new nut to

specified torque.
Attach speed sensor line -arrow A- from upper transverse link.

Install coil spring page 173 .
Perform wheel alignment page 305 .
150
AG.
The washer -2- must be installed so that there is a gap

-arrow B- between the washer and the backplate -3-.
agen
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ht
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Note
ht
rig
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Tighten bolt -1- for upper transverse link.
do
c
um
en
Observe mark made for position of eccentric bolt -arrow- rel

ative to subframe.

Specified torques
Component
Specified torque
Upper transverse link to wheel bearing housing

Use new nuts and bolts
130 Nm + 90
Tighten threaded connections only when vehicle is in

the normal running position.
Upper transverse link to subframe
Use new nut

95 Nm
To tighten nuts, set torque wrench -V.A.G
1332- to 80 Nm.
Applies only in conjunction with insert tool,

18 mm -T10179-
3.5
Removing and installing lower trans

verse link

Removing
ility
ab
y li
an
pt
ce
Remove coil spring. page 173 .
un
le
Remove wheel.
AG. Volkswagen AG d
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Remove bolt -arrow- for lower transverse link -1-.
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fo
rrectness of i
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n
f
o
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m
spec
atio
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n in
wit
es, in part or in w
l purpos
hole
ercia
, is n
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com
Vehicles with dynamic headlight range control
agen
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by
AG.
Prote
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by
cop
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.
Co
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151

AG. Volkswagen AG d
n
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wage
Running gear, axles, Vsteering
- Edition 08.2009 es not g
olks
Remove bolts
ua
ran
tee
transverse link.

rrectness of i
t to the co
nform
spec
a
t
i
h re
o
n in
wit
thi
s
Disconnect and lower rear part of exhaust system.

Remove lower transverse link.
Installing
Install lower transverse link on vehicle and tighten bolts hand

tight.
The transverse link may be bolted only when dimension a has
been attained page 137 .
Bolt upper transverse link to subframe and tighten new nut
-arrow- only to specified torque.
ative to subframe.
Prote
cted
by
c
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py
rig
ht
.
C
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AG.
agen
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Install bolts -1- in lower transverse link.
ht
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Reinstall rear section of exhaust system.
do
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or
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by
ed
ris
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-1- from
th lower
au
ss
Tighten bolt -arrow- for lower transverse link -1-.

Specified torques
Component
Specified torque
Lower transverse link to wheel bearing housing

90 Nm + 90

Lower transverse link to subframe
Use new nut
the normal running position
3.6
Removing and installing track rod
152
95 Nm

Removing

Remove nut -1- and pull coupling rod -2- out of anti-roll bar.
rrectness of i
t to the co
nform
spec
a
t
ion
h re
wit
in t
his
Remove bolt -arrow- for track rod -3-.
ility
ab
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an
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ce
Remove bolts -arrows- for anti-roll bar clamp.
do
c
um
en
ole,
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is n
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te
itte
iva
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du
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f
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Remove
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wheel.
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Prote
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by
cop
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.
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153

Remove nut -arrow- and remove bolt towards rear.
Remove track rod.
Installing
Install track rod on vehicle and tighten bolts hand tight.
Note
Note different versions of track rods: downwards open or forwards

closed.
The track rod may be bolted only when dimension a has been
attained page 137 .
kswagnut
Bolt track rod to subframe andgetighten
en Ato
AG. Volnew
G dspecified
a n
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torque.
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Tighten bolts -arrows- for anti-roll bar clamp.
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.
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Tighten bolt -arrow- for track rod -3-.

agen
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Connect coupling rod -2- to anti-roll bar and tighten nut -1-.
154
AG.
rrectness of i
t to the co
nform
spec
at
i
h re
o
n
wit
in t
his
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es, in part or in w
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hole
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erm
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t
a
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v
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f
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ng
ility
ab
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an
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ss
gu
ara
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ra
c
by
ed
ris
o
th
au
Specified torques
ole,
cial p
is n
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m
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o
c
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erm
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t
a
itte
riv
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f
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Specified torque
Track rod to wheel bearing housing

ility
ab
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ce
Component

AG. Volkswagen AG d
agen
oes
Running
ksw
not gear, axles, steering - Edition 08.2009
l
o
gu
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ara
db
nte
ise
r
o
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h
ut
ra
a
c
ss
130 Nm + 90
rrectness of i
t to the co
nform
spec
a
t
ion
h re
wit
in t
his

Track rod to subframe
90 Nm + 90

Use new bolts
25 Nm +45

Use new nut
45 Nm
do
c
um
en
ht
rig
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Co
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AG.
Prote
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.
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155

Assembly overview: wheel bearing housing, trailing arm (front-wheel

drive)
1 - Bolt
50 Nm +45 further
moving
3 - Bolt
M12 x 1.5 x 80
90 Nm + 90 further
moving
4 - Coupling rod
Modified coupling rod
for model year 2004
During production start up, a
change was made from cou
pling rods with two ball joints to
coupling rods with one ball joint
and one bonded rubber bush.
The end with the bonded rub
ber bush is bolted to the antiroll bar.
A mixed installation is not per
missible.
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wage
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V
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db
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tee
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itte
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ility
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5 - Bolt
90 Nm +45 further
Observe tightening se
quence page 168
moving
un
le
Connects anti-roll bar to

trailing arm and wheel
bearing housing
rrectness of i
t to the co
n
f
o
r
mat
spec
ion
h re
wit
in
7 - Bolt
8 Nm
es, in part or in w
l purpos
hole
ercia
, is n
m
ot
com
6 - Trailing arm
Repairing page 170
8 - Rear right speed sensor -G44- / rear left speed sensor -G46 Can be tested in guided fault finding using Vehicle diagnosis, testing and information system VAS 5051
Before inserting sensor, clean inner surface of bore and coat with lubricating paste -G 000 650-
ng
AG.
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Prote
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by
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156
ht
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11 - Nut
45 Nm
thi
sd
o
cu
m
en
10 - Bonded rubber bush

Renewing page 161
r
te o
iva
r
rp
fo


12 - Bolt
4 Nm
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13 - Brake disc
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14 - Grease cap
Pressing off and driving in page 164
rrectness of i
t to the co
nform
spec
a
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i
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A proper seal can be achieved only by installing a new grease cap.

15 - Bolt
M16 x 1.5 x 70
180 Nm +180 further
Loosen and tighten with bit XZN 18 -T10162 Always renew after removing
ABS sensor ring is installed in wheel bearing.
The wheel bearing and wheel hub are assembled one housing.
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4.1
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18 - Backplate
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17 - Bolt
12 Nm
do
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This wheel bearing/wheel hub unit is maintenance-free and has zero play. Adjustments and repairs are not
possible!

housing

Removing
Remove wheel.
Remove wheel bearing/wheel hub unit page 164 .
Remove backplate.
Remove ABS speed sensor out of wheel bearing housing.
4. Assembly overview: wheel bearing housing, trailing arm (front-wheel drive)
157

Remove bolt for track rod -1-, upper transverse link -2- and
lower transverse link -3- from wheel housing -4-.
Remove coupling rod -arrow- from wheel bearing housing.
Hold wheel bearing housing and remove bolts -arrows-.

Remove coupling rod -1- from trailing arm.
Installing
Attach coupling rod -arrow- to wheel bearing housing hand

tight.
AG.
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by
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158
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a
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wit
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Install bolts for track rod -1-, upper transverse link -2- and low
er transverse link -3-.
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Threaded connection for trailing arm and wheel bearing housing
may be tightened only after all other components (particularly the
spring and shock absorber) of respective wheel suspension have
been installed. To tighten, wheel suspension must be in extended
position. Only then do trailing arm and wheel bearing housing
move to the necessary position -arrows-.
It is important to keep to the specified sequence for the following
operations.
Position trailing arm and mounting bracket on wheel bearing

housing using bolts -2- but do not tighten yet.
Install bolts -arrows- and tighten to prescribed torque.

Install backplate.
Install wheel bearing/wheel hub unit.
Bolt connections on wheel bearing
housing may be tightened only
AG. Volkswagen AG
when dimension aswhas
dopage
137 .
agenbeen obtained
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Tighten bolt for lower transverse link -3-.
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Tighten bolt for track rod -1-.
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159

Note

Tighten bolt -arrow-.

Install ABS speed sensor in wheel bearing housing.
Install brake disc.
Attach brake carrier with brake caliper Brake systems; Rep.
Gr. 46 .
Specified torques
Component
Specified torque

130 Nm + 90
AG. Volkswagen AG d
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Wheel bearing housing to lower
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130 Nm + 90

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spec
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wit
Wheel bearing housing to track rod

Coupling rod to wheel bearing housing

Use new nut
45 Nm
Splash plate to wheel bearing housing

ABS speed sensor to wheel bearing housing
Brake disc to wheel bearing housing.
12 Nm
8 Nm
180 Nm
4 Nm
ng
AG.
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160
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90 Nm +45
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Trailing arm to wheel bearing housing

Use new bolts

4.2

equipment required
Press tool -30 - 506 B Drift sleeve -41-501 Sleeve -3160 Assembly tool -3301 Assembly tool -3346 Assembly tool -3350-
rrectness of i
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Remove wheel bearing/wheel hub unit page 164 .
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Remove wheel.
do
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Removing
AG.
Prote
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by
161

Remove backplate.
Attach tools as shown in figure.

1-
Nut -3346/3-
2-
Thrust piece -3301-
3-
Tube -3301/3-
4-
Drift sleeve -41 - 501-
5-
Thrust piece -3350/1-
6-
Spindle -3346/2-
Pull out bonded rubber bush by tightening spindle.

Pulling in bonded rubber bush
Attach tools as
2-
Thrust piece -3301-
3-
Press tool -30 - 506 B-
4-
Bonded rubber bush
5-
Sleeve -3160-
6-
Thrust piece -3350/2-
7-
Spindle -3346/2-
Pull in bonded rubber bush by turning spindle.

Note
Do not use lubricant.
Install bonded rubber bush carefully so that it does not cant.

Installing
Install backplate.
Prote
cted
b
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Bolt connections on wheel bearing housing may be tightened only

when dimension a has been obtained page 137 .
AG.
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162
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Install wheel bearing/wheel hub unit.
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Nut -3346/3-
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Install brake disc.
Specified torques
Component
Specified torque
Wheel bearing housing to lower suspension link

90 Nm + 90

12 Nm
4 Nm
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Gr. 46 .
163

4.3
Removing and installing wheel bearing/wheel hub unit

equipment required
Hub grease cap puller -VW
637/2 Fitting sleeve -3241 Torque wrench -V.A.G
1410 Tool insert -T10162-
rrectness of i
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Removing
Raise vehicle.
Remove wheel.
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164

Loosen grease cap from seat by tapping lightly on the claw of hub
grease cap puller -VW 637/2-.
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Lever off grease cap.
Remove brake carrier with brake caliper and hang from body
with wire Brake systems; Rep. Gr. 46 .
Hang brake caliper from body.
rrectness of i
t to the co
nform
spec
a
t
ion
h re
wit
in t
his
Note
Remove cross-head screw for brake disc and remove brake

disc.
Remove multi-point socket head bolt using socket insert T10162- .
Pull wheel hub/wheel bearing unit off stub axle.
Installing
Carefully push wheel bearing/wheel hub unit onto stub axle.

Use a new multi-point socket head bolt and tighten it.
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Note
do
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Ensure that the wheel bearing/wheel hub unit does not cant!
First tighten the bolt to the prescribed torque using a torque

AG.
wrench.
Use a rigid spanner to turn bolt further for specified additional
turn.
165

Drive on grease cap with fitting sleeve -3241/4-.
Note
Always renew removed grease caps.
Damaged grease caps may allow moisture to enter the bear
ing. Therefore, always use the tool shown in the illustration.

Install wheel and tighten bolts or nuts page 288 .
Specified torques
Component
Specified torque

Use new bolt
180 Nm + 180
4.4
4 Nm
Removing and installing trailing arm with

mounting bracket

Support -T10149-
Removing
Prote
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AG.
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166
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Remove wheel.
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Remove bolt -arrow- securing handbrake cable -1- to trailing
arm -2-.

Unbolt coupling rod -1- from trailing arm.

ht
rig
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Co
t.
Mark installation position of mounting bracket on body.
rrectness of i
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spec
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Remove trailing arm with mounting bracket.
If the trailing arm is to be renewed, the mounting bracket must be
removed from the longitudinal member.
The position of the mounting bracket relative to the trailing arm
must then be adjusted page 167 .
Determining position of mounting bracket in relation to trailing arm
167

Dimension -a- is 34 1 mm.
1-
Mounting bracket
2-
Trailing arm
pe
rm
itte
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Installing
un
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Tighten bolt when dimension -a- is set.
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Position: threaded connection between trailing arm and wheel
bearing housing
ng
Tighten bolts -arrows- on position of old imprint.

Lower wheel suspension again using engine and gearbox jack
-V.A.G 1383 A- and remove support -T10149- from wheel hub.
168
AG.
Raise wheel suspension using engine and gearbox jack V.A.G 1383 A- and support -T10149- until mounting bracket
contacts body.
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Attach coupling rod -3- to trailing arm but do not tighten nut
yet.
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operations.

Tighten bolts -2- for trailing arm to specified torque, observing
the required component position page 168 .
Bolt coupling rod -1- to wheel bearing housing and anti-roll bar.
Bolt handbrake cable -1- to trailing arm -2- -arrow-.
Attach retainer -1- by pushing in inner pin of rivet -arrow-.

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AG.
Prote
cted
by
Specified torques
Component
Specified torque

Use new bolts
90 Nm +45
Trailing arm to mounting bracket

Use new bolt
90 Nm + 90
169

Component
Specified torque

Use new bolts
50 Nm +45
Coupling rod to trailing arm.

Use new nut
45 Nm

Repairing trailing arm

es, in part or in w
l purpos
hole
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Remove trailing arm page 166 .
170
Prote
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at
i
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Removal tool -3372-
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equipment required
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Set up tools as shown in figure.
1-
Tube -T10230/3-
2-
3-
Removal tool -3372-
4-
5-
Press out bonded rubber bush.

Place trailing arm on a flat surface.
olkswagen AG
en AG. V
does
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Mark a vertical
no
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Dimension -A- = 114 mm
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a
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do
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There are two different types of bonded rubber bushes. On both

types, the marked line must be between the projections -1- after
being pressed in.
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171

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Set up tools as shown in figure.y Volks

b
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2-
ss
Thrust plate -T10230/12(chamfer must face bonded rubber
bush)
3-
Bonded rubber bush
4-
Removal tool -3372-
5-
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Tube -T10230/5-
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1-
Press bonded rubber bush in flush.

Attach mounting bracket to trailing arm page 167 .
ng
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172
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Install trailing arm page 168 .

Assembly overview: shock absorber, coil spring (front-wheel drive)
1 - Upper spring seat

2 - Coil spring
Note various versions of
running gear
page 317
page 173
3 - Lower spring seat
End of coil spring turned
to stop
4 - Bolt
M14 x 1.5 x 70
180 Nm
5 - Bolt
50 Nm +45 further
moving
6 - Shock absorber
page 175
Note different versions
of running gear
page 317 , vehicle
data plate
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page 151
AG. Volkswagen AG d
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5.1
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page 157
Removing and installing coil spring

Suspension strut clamp -V.A.G 1752-
do
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5. Assembly overview: shock absorber, coil spring (front-wheel drive)
173

Spring retainer -V.A.G 1752/4-
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Removing
Remove wheel.
Insert spring compressor -3-.
WARNING
rrectness of i
t to the co
nform
spec
a
t
ion
h re
wit
in t
his
Adapter -V.A.G 1752/9- , not illustrated
Ensure that coil spring is correctly seated in spring retainers V.A.G 1752/4- -2- (accident risk).
Use a spanner or a reversible ratchet handle to compress
spring compressor.
3-
Prote
cted
by
Adapter -V.A.G 1752/9-
Installing
Note correct installation position.
End of spring -arrow- must lie against stop on lower spring seat.
Install spring together with spring seat.
The bottom spring seat has a pin.
174
AG.
2-
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Remove spring.
do
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Compress coil spring until it can be removed.

Insert this pin in holes in lower transverse link -arrow-.
Then insert top spring seat into upper end of spring.
Release tension on spring while locating upper spring seat on
lug on body.
Remove spring compressor.
n AG. Volkswagen A
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Voand
Install wheel
by
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Removing and installing shock absorb

ers

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Remove wheel.
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Removing
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Remove wheel housing liner General body repairs, exterior;

Rep. Gr. 66 .
AG.

175

Remove shock absorber.
Installing
The shock absorber may be bolted to the wheel bearing housing
only when dimension a has been attained page 137 .
Install shock absorber and tighten bolts -arrows-.
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Install wheel housing liner General body repairs, exterior;

Rep. Gr. 66 .
176
Specified torque
50 Nm +45
AG.
Shock absorber to body

Use new bolts
180 Nm
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Specified torques
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Repairing shock absorber
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1 - Shock absorber
page 175
of running gear
page 317 , vehicle
data plate
4 - Support ring
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6 - Shock absorber mounting

For shock absorbers
with support ring
Item 4 (page 177)
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5 - Bump stop
For shock absorbers
with support ring
Item 4 (page 177)
7 - Nut
M10 x 1.0
25 Nm
moving
Loosening and tighten
ing page 178
8 - Cover
For shock absorbers without support ring Item 4 (page 177)
10 - Bump stop
177

Shock absorber set -T10001-
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Loosening and tightening threaded connection for shock absorb

er mounting
3-
Ratchet handle -T10001/11-
4-
Socket -T10001/1-
Component
Shock absorber mounting to shock absorber
Use new nut
178
Specified torque
25 Nm
do
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Specified torque
AG.
Socket -T10001/9-
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Commercially available ratchet handle
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1-

Assembly overview: anti-roll bar (front-wheel drive)
1 - Anti-roll bar
of running gear
page 317 , vehicle
data plate
page 179
2 - Bush
Always renew bushes
on both sides of the ve
hicle.
3 - Clamp
4 - Bolt
25 Nm +45 further
Tighten evenly.
moving
position:
Golf page 136
7 - Coupling rod
Modified coupling rod
for model year 2004
rrectness of i
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6 - Nut
45 Nm
Self-locking
moving
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page 138
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During production start up, a change was made from coupling rods with two ball joints to coupling rods with
one ball joint and one bonded rubber bush. The end with the bonded rubber bush is bolted to the anti-roll bar.
A mixed installation is not permissible.
Connects anti-roll bar to trailing arm and wheel bearing housing
AG.
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9 - Subframe
do
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8 - Shield
Only in vehicles having two ball joints in coupling rod. For vehicles with new coupling rod (one ball joint
and one bonded rubber bush), no shield is installed. See also Item 7 (page 179) .
6. Assembly overview: anti-roll bar (front-wheel drive)
179

Removing
Note
The following procedure is for the left side of the vehicle. The
procedure for the right side of the vehicle is identical.
Note
Do not loosen bolt -arrow- for track rod -3-.
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Remove anti-roll bar.

Installing
Install anti-roll bar in vehicle.
Evenly tighten bolts -arrows- for anti-roll bar clamp.
AG.
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Removes abolts -arrows- for anti-roll bar clamp.
c
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Running
gear,
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.
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G
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Use new bolts
Specified torque
25 Nm + 45

45 Nm
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Component
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Specified torques
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Connect coupling rod -2- to
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6. Assembly overview: anti-roll bar (front-wheel drive)
181

Assembly overview - attachment parts for subframe Golf BlueMotion,

Golf Plus BlueMotion (front-wheel drive)
1 - Subframe
2 - Bolt
3 - Angle piece
4 - Nut
20 Nm
5 - Bolt
6 - Nut
2 Nm
7 - Left shield
8 - Right shield
Installing
Hook in shield on sub

frame
Item 1 (page 182)
-arrow-
Pivot shield in
-direction of arrow- onto
rivet screws and tighten
nuts
9 - Angle piece
With rivet screw
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182
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Repairing rear suspension (fourwheel drive)
8.1
Overview of rear axle (aluminium)

Note

Bonded rubber bushes can be twisted only to a limited extent. Therefore, tighten the bolted connections of
components with bonded rubber bushes only when the wheel bearing housing is raised to unladen position
page 187 .
Always renew bonded rubber bush on both sides of the vehicle.

AG. Volkswagen AG d
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I - Assembly overview
- sub
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(four-wheel
is
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drive, aluminium)
page
189
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II - Assembly overview - control

arm, track rod (four-wheel
drive, subframe made from
aluminium and wheel bearing
housing made from cast steel)
page 212
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8. Repairing rear suspension (four-wheel drive)
183

III - Wheel bearing housing,
trailing link (four-wheel drive,
subframe made from alumini
um and wheel bearing housing
made from cast steel)
page 234
IV - Shock absorber, coil spring
(four-wheel drive, subframe
made from aluminium and
wheel bearing housing made
from cast steel) page 257
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184
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V - Anti-roll bar (four-wheel Volkswa

by
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aluminium and wheel tbearing
ho
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housing made from scast
steel)
s
page 265

8.2
Overview of rear axle (steel)

Note

Bonded rubber bushes can be twisted only to a limited extent. Therefore, tighten the bolted connections of
components with bonded rubber bushes only when the wheel bearing housing is raised to unladen position
page 187 .
Always renew bonded rubber bush on both sides of the vehicle.

I - Assembly overview - sub
frame, final drive (four-wheel wagen AG. Volkswagen AG doe
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drive, steel) page 199 y Volks
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II - Assembly overview
ho - control
ut
arm, track rod (four-wheel
a
s
drive, subframes made from
steel and wheel bearing hous
ing made from aluminium)
page 223
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185

III - Wheel bearing housing,
trailing link (four-wheel drive,
subframe made from steel and
wheel bearing housing made
from aluminium) page 251
IV - Shock absorber, coil spring
(four-wheel drive, subframe
made from steel and wheel
bearing housing made from
aluminium) page 262
V - Anti-roll bar (four-wheel
steel and wheel bearing hous
ing made from aluminium)
page 269
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186
rrectness of i
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8.3
Rear axle in unladen state (aluminium and steel)

equipment required
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support -T10149- .
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187

straps -T10038- .
WARNING

ning gear:
Running gear 1)
un
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365
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365 10 mm
360 10 mm
380 10 mm
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380 10 mm
400 10 mm
365 10 mm
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wheels (2UC)
version (G11)

here page 317 .
WARNING
Prote
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188
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Assembly overview - subframe made from aluminium, final drive (fourwheel drive)
-Arrow- indicates direction of travel.

1 - Subframe
Note
2 - Nut
50 Nm +180 further
moving
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3 - Rear bonded rubber bush
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Renewing page
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5 - Cross member
6 - Bolt
7 - Final drive
Rep. Gr. 39 ; Remov
ing and installing rear fi
nal drive
8 - Bolt
M12 x 1.5 x 85
60 Nm + 90 further
9 - Washer
10 - Bracket
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11 - Bolt
M12 x 1.5 x 85
60 Nm + 90 further
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at
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4 - Front bonded rubber
bush
ss
Renewing page 195
not
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9. Assembly overview - subframe made from aluminium, final drive (four-wheel drive)
189
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Please note that subsequent assembly work for which the hexa
gon or twelve-point bolt of the drive shaft has to be loosened
requires that the vehicle is stood on its wheels. Loosen hexagon
bolt page 274 or loosen twelve-point bolt of drive shaft
page 275 .
Remove front and rear exhaust system silencer Rep. Gr.

26 ; Exhaust system; Removing and installing parts of the ex
haust system .
Disconnect electrical connections between rear axle and
body.
Lever off retainer -1- for handbrake cable.

Press lever -2- in direction of arrow and unhook handbrake
cable -3-.
190
Prote
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Remove coil springs page 257 .
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Remove wheels.
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atio
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Unscrew hexagon bolt -1- and detach handbrake cable -2from brake cable bracket.

ility
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spec
a
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Unclip speed sensor wire from
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retainer -1-d-arrows-.
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Disconnect brake pipes, items-1- and -2-.
do
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191

Check whether marks (spots of paint) are present on flexible

coupling and final drive flange -arrows-. If no marks are
present, mark positions of flexible coupling and final drive
flange relative to each other -arrows-.
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Unscrew centre bearing bolts -arrows- two turns.
AG.
Prote
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192
rrectness of i
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nform
spec
at
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in t
his
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Unbolt rear propshaft
tube with flexible couplingnoand
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damper fromrisrear
final drive -arrows-.
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Support propshaft on tunnel support using a wooden block.
Push rear propshaft tube towards gearbox as far as possible.
Now secure vehicle to lifting platform on both sides using ten

sioning straps -T10038-.
WARNING
If the vehicle is not strapped down, there is a great danger

that
. Volkswagen AG
the vehicle will slip off the lifting platform!
gen AG
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Unscrew one hexagon bolt -1- or -2- on each side.
Only the left side of vehicle is shown to improve clarity.
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193

Unscrew remaining 2 bolts from subframe.
Carefully lower subframe with attachments.
Note
When lowering, ensure sufficient clearance of brake lines, elec

trical cables and centring pin to propshaft.
AG. Volkswagen AG d
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is following:
order. In the process, note the
r
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c
to rear final drive Final
ss drive 02D; Rep. Gr.

Install in reverse
Bleed brake system Rep. Gr. 47 ; Bleeding brake system

Rep. Gr. 47 .
Note
If an aluminium subframe is to be replaced by one made of steel,

then please proceed with the following work sequence
page 204 .
Subframe to body
Use new bolts
Specified torque
90 Nm + 90
180 Nm
50 Nm +45
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Use new bolts
Prote
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Attach propshaft
39 ; Removing and installing propshaft .

9.2
Repairing subframe

equipment required
Hydraulic press -VAS
6178 Engine and gearbox jack V.A.G 1383 A Assembly tool -T10263 Tensioning strap -T10038 Foot pump -VAS 6179 Locating pins -T10096-
Pulling out front or rear bonded rubber bushes

Remove rear wheels.
Remove coil springs page 257 .
rrectness of i
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spec
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Remove front and rear exhaust system silencer Rep. Gr.

26 ; Exhaust system; Removing and installing parts of the ex
haust system .
body.
Remove anti-roll bar page 265 .
Remove track rods.
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Remove brake line bracket from front mountings of subframe.

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195

Now secure vehicle to lifting platform on both sides using ten
sioning straps -T10038-.
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rrectness of i
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Unscrew one hexagon bolt -1- or -2- on each side.
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Only the left side of vehicle is shown to improve clarity.

Lower subframe 10 cm using engine and gearbox jack -V.A.G
1383 A- .
Using, e.g. a felt-tipped pen, mark installation position of bon
ded rubber bush relative to subframe.
196
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Position engine and gearbox jack -V.A.G 1383 A- with univer

sal gearbox support -V.A.G 1359/2- beneath subframe and
secure with strap.

Set up special tools as shown in figure.
1 - Nut -T10263/52 - Washer (commercial type)
3 - Subframe
4 - Tube -T10263/15 - Hydraulic press -VAS 61786 - Washer (commercial type)
7 - Nut -T10263/58 - Spindle -T10263/4 Take up play in special tools.
Pull out bonded rubber bush by actuating pump.
Pulling in front or rear bonded rubber bush
Install in reverse order. In the process, note the following:
The front and rear bonded rubber bushes differ slightly in height.
When installing, ensure the correct allocation Electronic parts
catalogue ETKA .
The bonded rubber bush must be installed in a certain direction;
note mark on subframe.
olkswagen AG
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rubber bush ondosubframe
as
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2 - Washer (commercial type)

3 - Thrust piece -T10263/34 - Subframe

6 - Thrust piece -T10263/27 - Hydraulic press -VAS 61788 - Washer (commercial type)
9 - Nut -T10263/510 - Spindle -T10263/4ht
rig
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Take up play in special tools and bonded rubber bush.
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1 - Nut -T10263/5-
rrectness of i
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Thrust piece -T10263/3- must be positioned so that lugs on

bonded rubber bush align with free aperture on thrust piece T10263/3- .
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Operate pump to carefully pull bonded rubber bush in until

collar lies flush on subframe.
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Specified torque
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Subframe to body
Use new bolts
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Specified torques
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90 Nm + 90
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198
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Assembly overview - subframe made from steel, final drive (four-wheel

drive)
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10
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1 - Subframe
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2 - Rear bonded rubber bush

Renewing page 205
3 - Front bonded rubber bush

Renewing page 205
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6 - Washer
Installed between final
drive and subframe.
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5 - Bolt
M12 x 105
60 Nm + 90 further
Renew each time after
removing
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4 - Final drive
Rep. Gr. 39 ; Remov
ing and installing rear fi
nal drive .
7 - Washer
Washer must be placed
with holes on lugs of
bonded rubber bush.
8 - Bolt
M12 x 105
60 Nm + 90 further
removing
10.1

10. Assembly overview - subframe made from steel, final drive (four-wheel drive)
199

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Engine/gearbox jack -V.A.G 1383 A-
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Note

body.
Remove clip -1-.

Note
Do not open brake line.
200
AG.
Remove rear exhaust system silencer Rep. Gr. 26 ; Ex

haust system; Removing and installing parts of the exhaust
system .
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Removing coil spring page 257 .
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Remove wheels.
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Please note that subsequent assembly work for which the hexa
gon or twelve-point bolt of the drive shaft has to be loosened
requires that the vehicle is stood on its wheels. Loosen hexagon
bolt page 274 or loosen twelve-point bolt of drive shaft
page 275 .

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Disconnect connector for rear left vehicle level sender -G76- .
rrectness of i
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spec
atio
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Check whether a mark is present on the flexible coupling and

the final drive flange (coloured dot) -arrows-. If no mark is
present, mark the position of the flexible coupling and the final
drive flange to one another -arrows-.
Disconnect connectors for rear right speed sensor -G44- and
rear left speed sensor -G46- .
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Unbolt rear propshaft tube with flexible coupling and vibration

damper from rear final drive -arrows-.
201

Unscrew centre bearing bolts -arrows- two turns.
pe
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Support propshaft -A- on tunnel support -1- using a wooden

block.
Disconnect Haldex coupling connector above final drive.
Now strap vehicle to the lifting platform arms on both sides of

the vehicle using tensioning straps -T10038- .
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If the vehicle is not strapped down there is a great danger that

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202
thi
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WARNING
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spec
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Push rear propshaft tube towards gearbox as far as possible.
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To secure the subframe in place, ensure that at positions -1- and

-2- the locating pins -T10096- are screwed in one after the other
on both sides of vehicle.
Unscrew one hexagon bolt -1- or -2- on both sides.
Note
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Replace the subframe securing bolts on both sides one after

the other with locating pins -T10096- and tighten to 20 Nm.
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be damaged.
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The position of the subframe is now fixed.

Carefully lower subframe with attachments about 2 cm.
Unclip brake lines on both sides -arrow-.
Note
203

Unclip brake line from clips -arrows- above drive shaft flange
on gearbox -1-.
Note

Carefully lower subframe with attachments.
Note
When lowering, ensure sufficient clearance between brake lines,

electrical cables and centring pin and the propshaft.
Install in reverse order. Note the following points:agen AG. Volkswagen AG d
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Make sure that the plate between wheel bearing housing and
oes
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shock absorber is also installed.
Renew the damaged brake line clips on the subframe.
rrectness of i
t to the co
nform
spec
a
t
i
h re
o
n in
wit
thi
s
If an aluminium subframe has to be replaced, a new brake line
must also be installed Braking systems; Rep. Gr. 47 ; Brake

line repair and Electronic parts catalogueETKA .
Attach propshaft to rear final drive Final drive 02D/0AV; Rep.

Gr. 39 ; Removing and installing propshaft .
Subframe to body
Use new bolts!
Specified torque
90 Nm + 90 further
AG.
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204
180 Nm
50 Nm + 45 further
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Use new bolts!
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Specified torques

- Edition 08.2009
Repairing subframe
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10.2
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equipment required
rrectness of i
t to the co
nform
spec
a
t
ion
h re
wit
in t
his
Tensioning strap -T10038 Locating pins -T10096 Assembly tool -T10263 Engine and gearbox jack V.A.G 1383 A Hydraulic press -VAS
6178- and thrust piece T10205/13 Foot pump -VAS 6179-
do
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Pulling out front bonded rubber bush page 205

Pulling in front bonded rubber bush page 207
Pulling out rear bonded rubber bush page 208
Pulling in rear bonded rubber bush page 210
Pulling out front bonded rubber bush
Remove rear wheels.
system .
body.
Remove anti-roll bar page 265 .
Remove track rods page 231 .
205

Remove clip -1-.
Note
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on both sides of
rrectness of i
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a
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Now strap vehicle to the lifting platform arms



secure with strap.
Prote
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by
206
AG.

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Golf 2004
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Note

be damaged.
1383 A- .
Mark installation position of bonded rubber bush relative to
subframe using e.g. a felt tip pen.
Prote
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by
3 - Tube -T10263/6-
AG.
2 - Washer , from -T10263-
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1 - Nut -T10263/5-
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Position special tools as shown in illustration.
rrectness of i
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spec
a
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wit
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, Golf Plus 2005

4 - Hydraulic press -VAS 6178- and thrust piece -T10205/135 - Nut -T10263/56 - Spindle -T10263/4 Take up play in special tools.
Pull out bonded rubber bush by actuating the pump.
Note
The outer ring of the bush shears off when pulling out the bonded
rubber bush. This occurs with a loud bang.
The bonded rubber bush must be removed from the tube T10356/6- once the bush has been pulled out.
Clamp tube -T10356/6- on the intended surfaces in a vice.
Insert a screwdriver between tube -T10356/6- and bonded
rubber bush and lever bush out of tube -arrow-. If necessary,
apply a drift to bush and drive out with light hammer blows.
Pulling in front bonded rubber bush
207

II - Rear bonded rubber bush
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I - Front bonded rubber bush
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Distinguishing features of bonded rubber
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bushes tho
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rrectness of i
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spec
a
t
i
h re
o
n in
wit
thi
s
The front bonded rubber bushes have two notches on the upper
side -arrows- and differ to the rear slightly in height Electronic
parts catalogue ETKA .
Insert bonded rubber bush -1- in subframe so that the nose

and the plate -arrows- face perpendicular to direction of travel.
Apply thrust piece -T10263/3- -2- so that flattened sides also
face perpendicular to direction of travel.
4 - Thrust piece -T10263/25 - Hydraulic press -VAS 6178- and thrust piece -T10205/136 - Nut -T10263/57 - Spindle -T10263/4 Pre-tension special tools with bonded rubber bush.
By actuating the pump, carefully draw bonded rubber bush in
until collar lies flush on subframe.
Install track rods page 231 .
Install anti-roll bar page 265 .
Join electrical connections between rear axle and body.
Install rear silencer of exhaust system Rep. Gr. 26 ; Exhaust
system; Removing and installing parts of the exhaust system .
Install coil springs page 257 .
Fit rear wheels.
Pulling out rear bonded rubber bush
Remove rear wheels.
system .
208
AG.
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2 - Thrust piece -T10263/3-
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1 - Nut -T10263/5-
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Insert special tools with bonded rubber bush into subframe as

shown.

Remove clip -1-.
Note

WARNING


secure with strap.
Note

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rrectness of i
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a
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h re
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209

Fix position of subframe using locating pins -T10096- .
Note

be damaged.
1383 A- .
Mark installation position of bonded rubber bush relative to
subframe using e.g. a felt tip pen.
Position special tools as shown in illustration.
1 - Nut -T10263/52 - Washer , from -T102633 - Tube -T10263/64 - Hydraulic press -VAS 6178- and thrust piece -T10205/135 - Nut -T10263/56 - Spindle -T10263/4
Note
rrectness of i
t to the co
nform
spec
a
t
ion
h re
wit
in t
his
The outer ring of the bush shears off when pulling out the bonded
rubber bush. This occurs with a loud bang.
ility
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an
pt
ce
The bonded rubber bush must be removed from the tube T10356/6- once the bush has been pulled out.
Clamp tube -T10356/6- on the intended surfaces in a vice.
Insert a screwdriver between tube -T10356/6- and bonded
rubber bush and lever bush out of tube -arrow-. If necessary,
apply a drift to bush and drive out with light hammer blows.
Pulling in rear bonded rubber bush
AG.
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210
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AG. Volkswagen AG d
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Take up play in special tools.
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Pull out bonded rubber
eo
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Distinguishing
features of bonded rubber bushesrante
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I-
tho
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Front
s
s
II - Rear bonded rubber bush
rrectness of i
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spec
a
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The front bonded rubber bushes have two notches on the upper
side -arrows- and differ to the rear slightly in height Electronic
parts catalogue ETKA .
Insert bonded rubber bush -1- in subframe so that the nose

and the plate -arrows- face perpendicular to direction of travel.
Apply thrust piece -T10263/3- -2- so that flattened sides also
face perpendicular to direction of travel.
do
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Insert special tools with bonded rubber bush into subframe as

shown.
AG.
1 - Nut -T10263/52 - Thrust piece -T10263/33 - Bonded rubber bush

4 - Thrust piece -T10263/25 - Hydraulic press -VAS 6178- and thrust piece -T10205/136 - Nut -T10263/57 - Spindle -T10263/4 Pre-tension special tools with bonded rubber bush.
By actuating the pump, carefully draw bonded rubber bush in
until collar lies flush on subframe.
Install rear silencer of exhaust system Rep. Gr. 26 ; Exhaust
system; Removing and installing parts of the exhaust system .
Install coil springs page 257 .
Fit rear wheels.
Specified torques
Component
Subframe to body
Use new bolts!
Specified torque
90 Nm + 90 further
211

11
Assembly overview - control arm, track rod (four-wheel drive, sub

frame made from aluminium and wheel bearing housing made from
cast steel)

1 - Eccentric bolt
whenever this compo
nent is loosened
page 305 .
Do not turn more than
90 in either direction
(i.e. from minimum to
maximum adjustment
position).
8 - Bolt
M12 x 1.5 x 125
90 Nm + 90 further
212
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AG.
7 - Subframe
Prote
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Note
do
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6 - Nut
M12 x 1.5
95 Nm
Self-locking
Always tighten threaded connections in unladen position page 187
agen
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Inner hole with lug
rrectness of i
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nform
spec
a
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ion
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his
4 - Eccentric bolt
whenever this compo
nent is loosened
page 305 .
maximum adjustment
position)
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Inner hole with lug
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2 - Nut
M12 x 1.5
95 Nm
Self-locking
moving
position page 187

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15 - Bolt
8 Nm
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16 - Nut
M14 x 1.5
130 Nm + 90 further
Self-locking
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17 - Bolt
AG.
13 - Spreader rivet
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10 - Nut
M12 x 1.5
90 Nm + 90 further
Self-locking
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19 - Washer
20 - Nut
M14 x 1.5
130 Nm + 90 further
Self-locking
Installing with wheel bearing housings made from aluminium is permissible Electronic parts catalogue
ETKA
Only wheel bearing housings made from aluminium are available as replacement parts. Therefore, cer
tain parts have to be exchanged and/or installed in addition when replacing page 235
22 - Washer
23 - Bolt
24 - Track rod
Closed in direction of travel
25 - Bolt
11. Assembly overview - control arm, track rod (four-wheel drive, subframe made from aluminium and wheel bearing housing made from
cast steel)
213

26 - Nut
M12 x 1.5
90 Nm + 90 further
Self-locking
11.1
Overview - rear left vehicle level sender -G76Note
The vehicle level sender is
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d
ran coupling
e a replacement part only complete with
availablerisas
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l purpos
hole
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Control unit for headlight range control -J4311 - Subframe

3 - Bolt
5 Nm
ng
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214
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VAS 5051
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ments
outwards
Renewing in vehicle
page 215
must be performed.
rod and upper and

11.2

Torque wrench -V.A.G 1331Removing
Remove bolts -2- and -3-.
Take out sender.
Installing
Lever on sender must face outwards.
Perform basic setting of headlights following replacement.
Specified torques
un
le
5 Nm
5 Nm

verse link
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Remove wheel.
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Removing
torque
rrectness of i
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f
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spec
atio
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wit
11.3
es, in part or in w
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hole
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Rear left vehicle level sender -G76- to subframe

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Component
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Specified
cast steel)
215

link.
Remove bolt -1-.
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rrectness of i
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Remove upper transverse link.

Installing

ing:
The threaded connections of the wishbone may only be tightened
when the dimension measured between the centre of wheel hub
and edge of wheel housing before starting the work has been at
tained page 187 .
ative to subframe.
do
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Note

Specified torques
Component
216
Specified torque
130 Nm + 90
Component

18 mm -T10179rrectness of i
t to the co
nform
spec
a
t
i
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wit
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11.4
95 Nm
1332- to 80 Nm.

verse link

do
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Use new nut
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olks Running gear, axles, steering
V
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Specified
torque
h
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Removing
Remove wheel.
cast steel)
217

Installing
ing:
The threaded connections of the wishbone may only be tightened
and edge of wheel housing before starting the work has been at
tained page 187 .
ative to subframe.
pe
rm
itte
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rrectness of i
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spec
atio
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ng

Use new nut
218
AG.

90 Nm + 90
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Specified torque
95 Nm
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Component
thi
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Specified torques
r
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Carry out basic setting of headlights Maintenance ; Booklet

38

11.5


rrectness of i
t to the co
nform
spec
at
i
h re
o
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wit
in t
his
d
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hole
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Remove wheel.
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Removing
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Measure distance from centre
of
wheel
to
lower
edge
of
wheel
h
t
or
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ac
a
housing page 187 . ss
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cast steel)
219

If the upper bolt of the anti-roll bar clamp on the right side of the
vehicle cannot be removed, then additional work must be per
formed page 220 .
AG. Volkswagen AG d
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For the right side of the vehicle only (depending on equipment)
rrectness of i
t to the co
n
f
o
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m
spec
atio
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n in
wit
WARNING
es, in part or in w
l purpos
hole
ercia
, is n
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com


ng
r
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Prote
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by
Installing
The track rod may only be bolted when dimension a has been
attained page 188 .
220
AG.
Remove track rod.
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Continuation for both sides of vehicle:
thi
sd
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cu
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Raise wheel hub with support -T10149- and engine and gear
box jack -V.A.G 1383 A- far enough that bolts of right anti-roll
bar clamp are accessible.

Bolt track rod -1- to subframe and tighten new nut -arrow- to
prescribed torque.

Remove tensioning strap -T10038- .

Note
kswagen AG
. Volbetween
Ensure that a washer is
the
and the wheel
gen AG
doenut
ainstalled
s no
bearing housing. y Volksw
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db
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or
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Connect
au coupling
ss
ara
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rod -2- to anti-roll bar and tighten nutor a-1-.

c
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es, in part or in w
l purpos
hole
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com

Specified torques
Component

Use new bolts
ht
rig
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Co
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ng

thi
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fo

rrectness of i
t to the co
n
f
o
r
m
spec
atio
h re
n in
wit
The threaded connections of the track rod may be tightened only

and lower edge of wheel housing before starting the work has
Specified torque
130 Nm + 90
90 Nm + 90
25 Nm +45
Prote
cted
by
c
o
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rig
ht.
C
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cast steel)
221

Component
Specified torque

Use new nut
45 Nm
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Prote
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by
cop
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.
Co
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rig
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Co
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do
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222
rrectness of i
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spec
a
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AG. Volkswagen AG d
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12
Assembly overview - control arm, track rod (four-wheel drive, sub

frame made from steel and wheel bearing housing made from alumi
nium)

1 - Eccentric bolt
whenever this compo
nent is loosened
page 305 .
maximum adjustment
position).
Inner hole with lug
rrectness of i
t to the co
nform
spec
a
t
ion
h re
wit
in t
his
Inner hole with lug
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4 - Eccentric bolt
whenever this compo
nent is loosened
page 305 .
maximum adjustment
position).
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f
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2 - Nut
M12 x 1.5
95 Nm
Self-locking
Can be loosened and
tightened up to 5 times
for adjustment work
removing
position page 187
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by
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.
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Note
do
c
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en
6 - Nut
M12 x 1.5
95 Nm
Self-locking
Can be loosened and tightened up to 5 times for adjustment work
12. Assembly overview - control arm, track rod (four-wheel drive, subframe made from steel and wheel bearing housing made from
aluminium)
223
pe
rm
itte
d
un
le
7 - Subframe
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AG. Volkswagen AG d
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Golf 2004 , Golf Plus 2005d
by
ara
e
nte
s
i
r
Edition
08.2009
o
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h
ut
ra
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c
s
s
es, in part or in w
l purpos
hole
ercia
, is n
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ot
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rrectness of i
t to the co
n
f
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mat
spec
ion
h re
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in
8 - Bolt
M12 x 1.5 x 125
90 Nm + 90 further
10 - Nut
90 Nm + 90 further
Self-locking
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13 - Spreader rivet
ht
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12 - Threaded rivet
M6
thi
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11 - Bolt
M12 x 1.5 x 75
15 - Hexagon bolt
M6 x 12
8 Nm
16 - Nut
Self-locking
17 - Washer
18 - Bolt
M14 x 1.5 x 115
130 Nm + 90 further
19 - Washer
21 - Washer
22 - Nut
Self-locking
Installing with wheel bearing housings made from cast steel is permissible Electronic parts catalogue
ETKA
24 - Washer
25 - Bolt
M14 x 1.5 x 115
224

130 Nm + 90 further
26 - Track rod
Various versions
Forwards closed (left and right track rods differ)
Downwards open (left and right track rods identical)
It is permitted to install mixed types.
27 - Bolt
M12 x 1.5 x 125
90 Nm + 90 further
28 - Bolt
M12 x 1.5 x 95
Renew each time after removing wagen AG. Volkswagen AG does
not
olks
gu187
yV
Always tighten threaded connections
in unladen position page
ar
db
an
tee
or
ac
e
ris
rrectness of i
t to the co
nform
spec
a
t
i
h re
o
n in
wit
thi
s
ole,
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is n
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29 - Nut
tho
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s
90 Nm + 90 further s
Self-locking
do
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Prote
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aluminium)
225

12.1
Overview - rear left vehicle level sender -G76Note
The vehicle level sender is available as a replacement part only complete with coupling rod and upper and

Control unit for headlight range control -J4311 - Subframe
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mat
spec
ion
h re
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es, in part or in w
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hole
ercia
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ments
outwards
Renewing in vehicle
page 226
must be performed.
un
le
3 - Bolt
M5 x 20
5 Nm
ng
Prote
cted
226
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12.2
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VAS 5051

Removing
Remove bolts -arrows- from subframe.
Remove rear left vehicle level sender -G76- .
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by
d
ran
ir se
tee
o
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or
The lever of rear left vehicle level sender -G76must face outside
ac
au
s
s
of vehicle.
Installing
Specified torques
Component
Specified torque

and subframe
12.3
5 Nm

verse link

rrectness of i
t to the co
nform
spec
atio
h re
n
wit
i
n
thi
sd
o
c
um
en
ole,
cial p
is n
mer
m
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erm
o
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t
itte
ir va
du
p
or
nl
f
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Following renewal, carry out basic setting of headlights

"Guided fault-finding" function of vehicle diagnosis, testing and
information system VAS 5051 .
ht
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Prote
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by
c
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rig
ht.
C
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Removing
Remove wheel.
aluminium)
227

link.
AG. Volkswagen
AG do
es n
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ran
tee
or
ac
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wage
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b
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ris
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ss
Remove bolt -1-.
Remove upper transverse link -1-.

Installing
Install upper transverse link on vehicle and tighten bolts hand

tight.
The transverse link may only be bolted when dimensiona has
Bolt upper transverse link -1- to subframe and tighten new nut
-arrow-.
rrectness of i
t to the co
nform
spec
a
t
ion
h re
wit
in t
his
do
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f
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by
c
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rig
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C
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ative to subframe.
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by
AG.

Note
Ensure that a washer is installed between the bolt and the wheel
bearing housing.
Attach speed sensor line -arrow A- from upper transverse link.
Check and adjust wheel alignment page 305 .
Specified torques
Component
228
Specified torque
130 Nm + 90 further

Component
Specified torque

Use new nut.
Tighten threaded connections
only when vehicle is in
es n
wage
the normal running
position
o
olks

18 mm -T10179-

verse link
ility
ab
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ce

Removing
agen
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by
Prote
cted
by
c
o
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rig
ht.
C
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ht
rig
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Co
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rrectness of i
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95 Nm
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12.4

AG.
aluminium)
229

Installing
Install lower transverse link on vehicle and tighten bolts hand
tight.
The transverse link may only be bolted when dimensiona has
ative to subframe.

Check and adjust wheel alignment page 305olk.swagen
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Component
Specified torque

90 Nm + 90 further

Use new nut.
95 Nm

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230
rrectness of i
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Specified torques
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AG. Volkswagen AG d
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12.5

Remove wheel.
rrectness of i
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wit
Removing
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formed page 231 .
aluminium)
231

WARNING


AG. Volkswagen AG d
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Remove track rod -1-.

Installing
Note
Note different versions of track rods: downwards open or forwards

closed.
The track rod may only be bolted when dimension a has been
attained page 188 .
Bolt track rod -1- to subframe and tighten new nut -arrow- to
prescribed torque.
AG.
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232
rrectness of i
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ility
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Note
Ensure that a washer is installed between the nut and the wheel
bearing housing.
swpage
agen A305
. Volk
Check and adjust wheelwaalignment
G do .
gen AG
e
s no
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Specified torque
130 Nm + 90 further
rrectness of i
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Specified torques
ris
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Componentss

90 Nm + 90 further

Use new bolts!
25 Nm + 45 further

Use new nut.
45 Nm
do
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aluminium)
233

13
Assembly overview - wheel bearing housing, trailing link (four-wheel

drive, subframe made from aluminium and wheel bearing housing

1 - Bolt
50 Nm +45 further
moving
3 - Bolt
M12 x 1.5 x 80
90 Nm + 90 further
moving
4 - Coupling rod
AG. Volkswagen AG d
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5 - Bolt
90 Nm + 90 further
moving
Only wheel bearing
housings made from
aluminium are available
as replacement parts.
Therefore, certain parts
have to be exchanged
and/or installed in addi
tion when replacing
page 235
rrectness of i
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6 - Trailing arm
page 243
Repairing page 248
7 - Drive shaft
Assembly overview
page 273 .
page 276
8 - Bolt
M12 x 1.5 x 45
70 Nm + 90 further
AG.
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11 - Bolt
9 Nm
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10 - Rear speed sensor -G44/G46-
do
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Installing with wheel bearing housings made from aluminium is permissible Electronic parts catalogue
ETKA

Renewing page 240
13 - Nut
45 Nm
Self-locking
14 - Cross-head screw
4 Nm
15 - Brake disc
16 - Bolt
Loosening and tightening hexagon bolt for drive shaft page 274
Loosening and tightening twelve-point bolt for drive shaft page 275
Note
This wheel bearing/wheel hub unit is maintenance free and has no play. Adjustments and repairs are not
possible!
18 - Bolt
10 Nm
e
wage
Only wheel bearing housings made from aluminium are
Therefore, cer
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V
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tain parts have to be exchanged and/or installed ein
d b addition when replacing page 235
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Changing from wheel housing bearing

made from cast steel to wheel bearing
housing made from aluminium
A wheel housing bearing made from cast steel has been changed
to a wheel bearing housing made from aluminium. Only wheel
bearing housings made from aluminium are available as replace
ment parts. Therefore, certain parts have to be exchanged and/
or installed in addition when replacing Electronic parts cata
logue ETKA .
The following parts have to be renewed and/or installed in addi
tion:
Bolts (qty. 2) for backing plate
Bolt, nut and washer for top control arm to wheel bearing
housing
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Bolt, nut and washer for track rod to wheel bearing housing
ht
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Brake carrier
rrectness of i
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13.1
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19 - Splash plate
ac
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13. Assembly overview - wheel bearing housing, trailing link (four-wheel drive, subframe made from aluminium and wheel bearing housing
AG.
235

Bolt and washer for shock absorber to wheel bearing housing
Bolts (qty. 2) for trailing link to wheel bearing housing
Cover plate with bolts (qty. 4) to wheel bearing housing
Caution
The additional washers that have to be installed must always

be placed between the component and the wheel bearing
housing.
Installing a wheel bearing housing made from aluminium on
one side of the vehicle and a wheel bearing housing made from
cast steel on the other is permissible Electronic parts
catalogueETKA.
13.2

housing

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Removing
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Loosen outer threaded connection for drive shaft

page 274 .
Remove wheel.
Remove brake carrier with brake caliper and tie to body with
wire Rep. Gr. 46 .

disc.
AG.
236
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Remove ABS speed sensor from wheel bearing housing.
do
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Note

Unbolt coupling rod from wheel bearing housing -arrow-.
agen AG
Volksw-arrows-.
n AG.bolts
Hold wheel bearing housing and unscrew
doe
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by trailing arm.
Remove coupling rod -1- from
ed
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Take out wheel bearing
au housing.
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rrectness of i
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ing:
ility
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Installing

bearing housing
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operations.
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237
olkswagen AG
en AG. V
does
not
gu
ara
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ra
using bolts
c
Golf 2004 , Golf Plus 2005 olkswag

V
by
Running gear, axles, steering -edEdition
08.2009
un
le
housing
pe
rm
itte
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Position trailing arm on

-2- but do not tighten yet.
ility
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yet.
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The threaded connections on the wheel bearing housing may be
tightened only when the dimension measured between the centre
of wheel hub and lower edge of wheel housing before work was
started has been attained page 188 .
Note

Specified torques
Component
238
Specified torque
130 Nm + 90

Component
Specified torque

90 Nm + 90

n AG. Volkswagen AG
pe
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does
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130 Nm + 90
ility
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Wheel bearingedhousing
to track rod
is
rnuts
Use new
and
bolts
o
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Tighten
threaded connections only
es, in part or in w
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rrectness of i
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wit

Use new bolts
Use new nut
Use new bolt
ht
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45 Nm
10 Nm
9 Nm
180 Nm
4 Nm
180 Nm + 180
70 Nm + 90
thi
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Use new bolt
90 Nm + 90
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239

13.3

equipment required
Press tool -30 - 506 B Drift sleeve -41 - 501 Sleeve -3160 Assembly tool -3301 Assembly tool -3346-
Remove wheel.
wire Rep. Gr. 46 .
240
AG.
Removing
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rrectness of i
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db
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or
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Co
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Assembly tool -3350-

Note

disc.
Remove backplate.
3 - -3301/34 - -41-5015 - -3350/16 - -3346/2-
rrectness of i
t to the co
nform
spec
a
t
i
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wit
thi
s
2 - -3301-
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1 - -3346/3-
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db
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Pull out bonded rubber bush by tightening spindle.
do
c
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Pulling in bonded rubber bush
Prote
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241

1 - -3346/32 - -33013 - -30-506 B4 - Bonded rubber bush
5 - -31606 - -3350/27 - -3346/2 Pull in bonded rubber bush by turning spindle.
Note
Do not use lubricant.
Install bonded rubber bush carefully so that it does not cant.
Installing
ing:
of wheel hub and lower edge of wheel housing before work
was
AG. Volkswagen AG d
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Specified torques
un
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Specified torque
ility
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Component
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ran
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or
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db
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90 Nm + 90
pe
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ercia
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com

13.4
10 Nm
4 Nm
Removing and installing wheel bearing/

wheel hub unit
ng
AG.
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242
thi
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rrectness of i
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f
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mat
spec
ion
h re
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in


Removing
Remove drive shaft page 276 .
wire Rep. Gr. 46 .
Note
Do not suspend the brake caliper from the brake hose.

disc.
Remove bolts -2-.
Pull wheel hub/wheel bearing unit out from wheel bearing
housing.
Installing
es, in part or in w
l purpos
hole
ercia
, is n
m
m
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erm
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t
a
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v
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p
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nl
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n
Component

Use new bolt
13.5
Specified torque
70 Nm + 90
4 Nm
Removing and installing trailing arm with

mounting bracket
rrectness of i
t to the co
nform
spec
at
i
h re
o
n
wit
in t
his
d
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en
Specified torques
ility
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es n
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Carry out installation in the reverse sequence, noting theedfollow
ran
s
i
tee
r
ing:
o
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t
or
ac
au
s
Use a new hexagon bolt and tighten page 274
s .
ht
rig
py
Co
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AG.
Prote
cted
by
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rig
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.
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243

Removing
Remove wheel.
Remove bolt -arrow- securing handbrake cable -1- to trailing
arm -2-.
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a
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ility
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es n
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V
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by
d
ran
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o
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ac
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s
s

rrectness of i
t to the co
nform
spec
a
t
ion
h re
wit
in t
his
Unbolt coupling rod -1- from trailing arm.
agen
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AG.
Prote
cted
by
c
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py
rig
ht
.
C
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ht
rig
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Co
t.
do
c
um
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244
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erm
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t
a
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riv
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p
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nl
f
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ng
ility
ab
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an
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ce
es n
wage
otPlus
olks
Golf 2004 , Golf
V
gu 2005
y
b
ar
d
nte
iseRunning gear, axles, steering - Editiona08.2009
r
o
eo
h
ut
ra
a
c
s
s
Remove trailing arm with mounting bracket.
rrectness of i
t to the co
nform
spec
a
t
ion
h re
wit
in t
his
If the trailing arm is to be renewed, the mounting bracket must be

removed from the longitudinal member.
The position of the mounting bracket must then be adjusted in
relation to the trailing arm.
Determining position of mounting bracket in relation to trailing arm

Dimension -a- is 34 mm.
2 - Trailing arm
AG.

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by
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rig
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ing:
ht
rig
py
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t.
Installing
do
c
um
en
Tighten bolt when dimension -a- is set.

bearing housing
operations.

yet.
Raise wheel suspension using engine and gearbox jack V.A.G 1383 A- and support -T10149- until mounting bracket
contacts body.
245

Tighten bolts -arrows- on position of old imprint.

Bolt handbrake cable -1- to trailing arm -2- -arrow-.
AG.
agen
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Prote
cted
b
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c
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t
.
Co
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246
rrectness of i
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spec
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erm
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t
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n
ility
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b
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ran
ise
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or
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ac
a
ss

Attach retainer -1- by pushing in inner pin of
ility
ab
y li
an
pt
ce
After installation, toe setting must be checked on wheel alignment

unit.
Component
Specified torque

Use new bolts
90 Nm + 90
Trailing arm to mounting bracket

Use new bolt
90 Nm + 90
45 Nm
AG.

50 Nm +45
agen
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Coupling rod to trailing arm.

Use new nut
Prote
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by
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ht
.
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Use new bolts
ht
rig
py
Co
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Specified torques
rrectness of i
t to the co
nform
spec
at
i
h re
o
n
wit
in t
his
d
o
cu
m
en
es, in part or in w
l purpos
hole
ercia
, is n
m
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erm
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t
a
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v
i
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p
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nl
f
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n
es n
wage
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V
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db
ran
e
rivet -arrow-.
ir s
tee
o
h
t
or
u
ac
a
ss
247

13.6
Repairing trailing arm

equipment required
Assembly tool -T10230 Removal tool -3372 Thrust plate -VW 401 Thrust plate -VW 402-
Remove trailing arm page 243 .
Prote
cted
by
AG.
agen
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Vo
by
cop
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.
Co
py
i
248
ht
rig
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Co
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rrectness of i
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spec
atio
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i
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thi
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o
c
um
en
ole,
cial p
is n
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erm
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t
itte
ir va
du
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nl
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n
ility
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AG. Volkswagen AG d
agen
oes
ksw
not
l
o
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yV
b
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is
r
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c
ss

1-
Tube -T10230/3-
2-
3-
Removal tool -3372-
4-
5-
Press out bonded rubber bush.

Place trailing arm on a flat surface.
Mark a vertical line on trailing arm bush.
AG. Volkswagen AG d
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There are two different types of bonded rubber bushes. On both

types, the marked line must be between the projections -1- after
being pressed in.
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Dimension -A- = 114 mm
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249

1-
Tube -T10230/5-
2-
Thrust plate -T10230/12- (chamfer must face bonded rubber

bush)
3-
Bonded rubber bush
4-
Removal tool -3372-
5-
Press bonded rubber bush in flush.

Attach mounting bracket to trailing arm page 245 .
Install trailing arm page 243 .
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4 - Coupling rod
bearing housing
5 - Bolt
90 Nm + 45 further
Observe tightening se
quence page 254
removing
Prote
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3 - Bolt
M12 x 1.5 x 80
90 Nm + 90 further
removing
AG.
2 - Cover
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Assembly overview - wheel bearing housing, trailing link (four-wheel

drive, subframe made from steel and wheel bearing housing made
from aluminium)
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AG. Volkswagen AG d
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Golf 2004 , Golf Plus 2005 e or a
ut
a
c
s
sRunning
gear, axles, steering - Edition 08.2009
6 - Trailing arm
page 243
Repairing page 248
7 - Drive shaft
Assembly overview
page 273
page 276
M14 x 1.5 x 45
70 Nm + 90 further
removing
Installing with wheel bearing housings made from cast steel is permissible Electronic parts catalogue
ETKA
10 - Rear right speed sensor -G44- / rear left speed sensor -G46 Can be checked in guided fault finding of the vehicle diagnosis, testing and information system -VAS
5051 Before inserting sensor, clean inner surface of hole and coat with lubricating paste -G 000 650- .
11 - Hexagon socket head bolt
M6 x 16
8 Nm
14. Assembly overview - wheel bearing housing, trailing link (four-wheel drive, subframe made from steel and wheel bearing housing made
from aluminium)
251

Renewing page 240
13 - Nut
M12 x 25
45 Nm
Self-locking
14 - Bolt
M10 x 35
50 Nm + 45 further
15 - Bolt
4 Nm
16 - Brake disc
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Note

rrectness of i
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17 - Bolt
Loosening and tightening hexagon bolt for drive shaft page 274
Loosening and tightening twelve-point bolt for drive shaft page 275
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This wheel bearing/hub unit is maintenance and adjustment free. Adjustments and repairs are not possible!
AG.

housing

252
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20 - Backplate
do
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19 - Bolt
M6 x 12
12 Nm

Removing
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Remove wheel.
wire Rep. Gr. 46 .
Remove ABS speed sensor from wheel bearing housing.
Unscrew bolts -arrows- and remove splash plate -1-.
rrectness of i
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spec
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Loosen the outer drive shaft threaded

page 274 .
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Remove coupling rod from wheel bearing housing -arrow-.
from aluminium)
253

Remove coupling rod -1- from trailing arm.
Hold wheel bearing housing and unscrew bolts -arrows-.
Take out wheel bearing housing.
Installing
ing:
Note
Ensure that a plate/washer is installed between the track rod, up

per control arm, shock absorber and wheel bearing housing
respectively.
bearing housing
Install coil spring page 257
. . Volkswagen AG d
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It is important to keep
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Tighten trailing arm bolts -arrows- to specified torque, ensur
ing that components are positioned as required page 254 .
tightened only when the dimension between the centre of wheel
hub and lower edge of wheel housing has been attained
page 188 .
Gr. 46 .
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Component

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254
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Specified torques
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Fit trailing arm to wheel bearing housing with bolts -arrowsbut do not tighten yet.
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Specified torque
130 Nm + 90 further

Component
Specified torque

90 Nm + 90 further

Wheel bearing housing to track rod
130 Nm + 90 further

Use new bolts!
90 Nm + 45 further

Use new nut.
45 Nm

es n
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Brake disc to wheel bearing
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Drive shaft to wheel
ir se hub hexagon bolt
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Use new bolt
t
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page 240
14.3
Removing and installing wheel bearing/

wheel hub unit

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Renewing bonded rubber bush for

wheel bearing housing
70 Nm + 90 further
rrectness of i
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nform
spec
a
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ion
h re
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14.2
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Use new bolt
12 Nm
8 Nm
180 Nm
4 Nm
180 Nm +180 further
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from aluminium)
255

Removing
Remove drive shaft page 276 .
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Remove brake carrier with brake caliper and tie to bodyy Vwith
b
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wire Rep. Gr. 46 .
ise
un
le
Do not suspend the brake caliper from the brake hose.

Remove bolt for brake disc and remove brake disc.
Remove bolts -2-.
Pull wheel hub/wheel bearing unit out from wheel bearing

housing.
Installing

ing:
256
70 Nm + 90 further
AG.

Use new bolt
Specified torque
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Component
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Specified torques
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Use a new hexagon bolt and tighten page 274 .
4 Nm
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Note
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15
Assembly overview - shock absorber, coil spring (four-wheel drive,

subframe made from aluminium and wheel bearing housing made
from cast steel)

2 - Coil spring
Note different running
gear versions
page 257
3
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End of coil spring
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4 - Bolt
M14 x 1.5 x 70
180 Nm
5 - Bolt
50 Nm +45 further
6 - Shock absorber
page 259
Repairing page 260
of running gear
page 317 , vehicle
data plate
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page 236
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page 217

Suspension strut clamp -V.A.G 1752-
15. Assembly overview - shock absorber, coil spring (four-wheel drive, subframe made from aluminium and wheel bearing housing made
from cast steel)
257

Adapter -V.A.G 1752/9- , not illustrated

Removing
Remove wheel.
Insert spring compressor -3-.
WARNING
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V.A.G 1752/4- (risk of accident).
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s
Use a spanner or a reversible ratchet handle
to compress
spring compressor.
Compress coil spring until it can be removed.

1-
Adapter -V.A.G 1752/9-
2-
3-
Installing
rrectness of i
t to the co
nform
spec
a
t
ion
h re
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his
Remove spring.

ing:
End of spring -arrow- must lie against stop on bottom spring seat.
Install spring together with spring seat.
The bottom spring seat has a pin.
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258

Insert this pin in holes in lower transverse link -arrows-.
Then insert top spring seat into upper end of spring.
Release tension from spring. When doing so, locate upper
spring seat onto lug on body.
15.2

ers gen AG. Volkswagen AG d
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Special toolsd band
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ut
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wit
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Removing
Remove wheel.
Remove wheel housing liner Rep. Gr. 66 .
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from cast steel)
259

Installing
The shock absorber may be bolted to the wheel bearing housing
only when the dimension measured between the centre of wheel
hub and edge of wheel housing before assembly has been at
tained page 188 .
. Volkswagen AG
gen AG
Specified torques
Specified torque
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Component
does
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Use new bolts
50 Nm + 45 further
rrectness of i
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spec
a
t
ion
h re
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his
15.3
180 Nm
1 - Shock absorber
page 259
of running gear
page 317 , vehicle
data plate

For shock absorbers
with support ring
Item 4 (page 177)
7 - Nut
M10 x 1.0
25 Nm
moving
ing page 261
260
AG.
5 - Bump stop
For shock absorbers
with support ring
Item 4 (page 260)
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4 - Support ring
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3 - Protective tube
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2 - Protective cap

8 - Cover
10 - Bump stop
Special tools and work
shop equipment re
quired
Torque wrench V.A.G 1332-
Shock absorber set T10001-
rrectness of i
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spec
a
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h re
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ing threaded connection
for shock absorber
mounting
1 - Commercially availa
ble ratchet handle
2 - Socket -T10001/93 - Ratchet handle T10001/11-
4 - Socket -T10001/1-
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from cast steel)
261

16
Assembly overview - shock absorber, coil spring (four-wheel drive,

subframe made from steel and wheel bearing housing made from alu
minium)
1 - Lower spring seat

End of coil spring turned
to stop
2 - Assembly aid
Not necessary to rein
stall once removed
3 - Coil spring
gear versions; see
page 317 , vehicle
data sticker
page 257
5 - Bolt
M14 x 1.5 x 70
180 Nm
un
le
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6 - Bolt
AG. Volkswagen AG d
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Renew each
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7 - Shock absorber
page 262
Repairing page 260
gear versions; see
page 317 , vehicle
data sticker
8 - Washer
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AG.
262
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page 257
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16.1
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Removing
Remove wheel.
Remove wheel housing liner General body repairs, exterior;

Rep. Gr. 66 .
cop
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Prote
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Installing
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AG. Volkswagen AG d
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b
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h
ut
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ss

The shock absorber may only be bolted to the wheel bearing
housing when dimension a has been attained page 188 .
Install shock absorber and tighten bolts -arrows-.
16. Assembly overview - shock absorber, coil spring (four-wheel drive, subframe made from steel and wheel bearing housing made from
aluminium)
263

Note
Make sure that the plate between wheel bearing housing and
shock absorber is also installed.
Install wheel housing liner General body repairs, exterior;
Rep. Gr. 66 .
Specified torques
Component
Specified torque

Use new bolts!
50 Nm + 45 further
16.3
180 Nm
page 260
AG.
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264
rrectness of i
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spec
at
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Assembly overview - anti-roll bar (four-wheel drive, subframe made

from aluminium and wheel bearing housing made from cast steel)
do
c
um
en
AG.
Prote
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by
4 - Bolt
25 Nm + 90 further
Tighten evenly.
moving
position page 187
agen
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3 - Clamp
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.
Co
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2 - Bush
Always renew bushes
on both sides of the ve
hicle.
rrectness of i
t to the co
nform
spec
a
t
ion
h re
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in t
his
1 - Anti-roll bar
of running gear
page 317 , vehicle
data plate
page 265
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17
AG. Volkswagen AG d
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6 - Nut
45 Nm
Self-locking
moving
When tightening, coun
terhold on multi-point
socket head of bolt
Item 7 (page 265) or
coupling rod
Item 8 (page 265)
7 - Bolt
8 - Coupling rod
Connects anti-roll bar to trailing arm and wheel bearing housing
9 - Subframe
17.1
17. Assembly overview - anti-roll bar (four-wheel drive, subframe made from aluminium and wheel bearing housing made from cast steel)
265

Removing
Remove rear wheels.
Note
AG. Volkswagen
anti-roll
AG do
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spec
a
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h re
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his

formed page 266 .
AG.
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266
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Remove nut -1- and pull
agen
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Vol
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b
couplingedrod -2- out of
ris
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AG. Volkswagen AG d
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WARNING
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or
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db
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Installing
ng
Prote
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.
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Install wheel and tighten. page 288
Specified torques
Component
Use new bolts!
Specified torque
25 Nm + 90 further

17. Assembly overview - anti-roll bar (four-wheel drive, subframe made from aluminium and wheel bearing housing made from cast steel)
267

Component
Specified torque
45 Nm
AG. Volkswagen AG d
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Use new nut

18
Assembly overview - anti-roll bar (four-wheel drive, subframe made

from steel and wheel bearing housing made from aluminium)

1 - Anti-roll bar
gear versions; see
page 317 , vehicle
data sticker
page 269
2 - Bearing
Always renew mount
ings on both sides of the
vehicle.
3 - Clamp
M8 x 28
25 Nm + 45 further
removing
6 - Nut
M10 x 55
45 Nm
Self-locking
removing
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removing
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9 - Subframe
18.1
rrectness of i
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spec
a
t
ion
h re
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his
8 - Coupling rod
bearing housing
do
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18. Assembly overview - anti-roll bar (four-wheel drive, subframe made from steel and wheel bearing housing made from aluminium)
269

rrectness of i
t to the co
nform
spec
a
t
ion
h re
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his
Removing
Remove rear wheels.

Note
Note
Do not loosen bolt -arrow- for track rod -3-.
ht
rig
py
Co
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Prote
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formed page 270 .
270
do
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WARNING


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Installing
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his

Install wheel and tighten. page 288
do
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rig
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Specified torques
Component
Use new bolts!
Specified torque
25 Nm + 45 further

18. Assembly overview - anti-roll bar (four-wheel drive, subframe made from steel and wheel bearing housing made from aluminium)
271

Component
Specified torque
45 Nm
es n
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272
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Use new nut.

19
Assembly overview - drive shaft

Renew only as com
plete unit
Removing page 280
plastic mallet
Checking page 283
rrectness of i
t to the co
nform
spec
a
t
i
h re
o
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wit
thi
s
Note
3 - Drive shaft
4 - Hose clip
moving
Tightening page 282
5 - Boot
Material: (polyester elastomer).
AG.
8 - Thrust washer
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7 - Dished spring
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6 - Hose clip
Tightening page 282
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2 - Bolt
M16 x 1.5 x 80
ing hexagon bolt for
drive shaft page 274
Volkswagen AG
12-point bolt, 70
Nm
AG. +
does
agen
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90 further
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Loosening
and tighten
nte
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h twelve-point bolt for
ing
t
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c
ss drive shaft page 275
moving
9 - Retaining ring
Material: Hytrel
19. Assembly overview - drive shaft
273

Coat sealing surface of constant velocity joint with -D 454 300 A2- before installing.
11 - Hose clip
Tightening page 283
12 - Locking plate
13 - Bolt
40 Nm
14 - Retaining ring
Remove and install with circlip pliers -VW 161 A15 - Seal
Checking page 284
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Loosening and tightening drive shaft

hexagon bolt

Prote
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by
274
AG.
Procedure for loosening hexagon bolt.
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rrectness of i
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19.1
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17 - Dished spring
With inner splines

Loosening hexagon bolt
For vehicles which are still standing on their wheels, loosen
the hexagon bolt a maximum of 90, as the wheel bearing will
otherwise be damaged.
Remove hexagon bolt -arrow-.
Tightening hexagon bolt
Renew hexagon bolt.
Note
aged.
AG. Volkswagen AG d
agen
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Tighten hexagon bolt to 180
oNm.
yV
19.2
rrectness of i
t to the co
nform
spec
a
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ion
h re
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his
Loosening and tightening 12-point bolt

for drive shaft
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Socket AF 24 -T10361-
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b
ed
riswheels.
Lower vehicle onto its
o
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au
Turn hexagon bolt
ss 180 further.
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.
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275

Procedure for loosening 12-point flange bolt.

as this would damage the wheel bearing. If the vehicle does have
to be moved, always note the following points:
Fit an outer joint in place of the drive shaft.
Tighten the outer joint to 120 Nm.
Loosening 12-point bolt
With vehicle still standing on its wheels, loosen the twelvepoint bolt a maximum of 90, as the wheel bearing will other
wise be damaged.
Remove 12-point bolt -arrow-.
AG.
Note
agen
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Prote
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by
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.
C
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Renew 12-point bolt.
aged.
Tighten 12-point bolt to 70 Nm.
Turn 12-point bolt 90 further.
19.3
Removing and installing drive shaft
Removing
276
ht
rig
py
Co
t.
Fitting 12-point bolt
rrectness of i
t to the co
nform
spec
atio
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n
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by
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h be subjected to load after bolt securing
Wheel bearings must not
t
or
ac
au
s
drive shaft to wheel hub
has
been
loosened.
s

Remove wheel.
Unscrew bolts securing track rod -1- and lower transverse link
-3- from wheel bearing housing -4-.

Loosen drive shaft at gearbox flange.
Swing wheel bearing housing out and pull drive shaft out of
inner splines.
Remove drive shaft.
Installing
olksw
agen AG
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n AGfollow
Carry out installation in the reverse sequence, noting
does
agethe
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not
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ing:
gu
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se
Install wheel and tighten page 288tho.ri

au
ss
wheel
Ensure that the washer between wheel bearing housing and

shock absorber is also installed on vehicles with aluminium wheel
bearing housing.
Specified torque
180 Nm + 180
r
te o
iva
r
rp
fo

Use new bolt
ng
40 Nm
Initially tighten diagonally to 10 Nm
Prote
cted
by
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AG.
Drive shaft to flange shaft/gearbox

Use new bolts!
70 Nm + 90
thi
sd
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en

Use new bolt
agen
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Component
ht
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Co
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Specified torques
rrectness of i
t to the co
n
f
o
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mat
spec
ion
h re
wit
in
Note
es, in part or in w
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hole
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The threaded connections on the

bearing housing may be
of wheel hub and lower edge of wheel housing before work was
or
ac
277

19.4
Dismantling and assembling drive shaft

equipment required
Thrust plate -VW 401 Thrust plate -VW 402 Press tool -VW 408 A Press tool -VW 411 Tube -VW 416 B Thrust plate -VW 447 H-
AG.
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Co
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278
rrectness of i
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spec
a
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wit
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db
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ss

Circlip pliers -VW 161 A Torque wrench -V.A.G
1332 Special pliers -V.A.G 1682 Assembly tool -T10065-
rrectness of i
t to the co
nform
spec
a
t
i
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wit
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sd
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AG. Volkswagen AG d
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279

Puller -T10382-
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puller
plate ss

Fold back boot.
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Set puller -T10382- up so that smooth side of

T10382/1- points to spindles -T10382/2- .
1-
2-
Spindles -T10382/2-
rrectness of i
t to the co
nform
spec
a
t
i
h re
o
n in
wit
thi
s
Thrust washer

Dismantling
280
AG.
2-
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Dished spring
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1-
do
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joint

Assembling
rrectness of i
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a
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AG. Volkswagen AG d
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Dished spring
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Note

-arrows B-.
281

not cant pliers).
Note
material of the joint boot (compared to rubber), it is possible to

tighten the hose clip only with special pliers -V.A.G 1682- .

ility
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is applied.

Assembling
Dished spring
2-
Thrust washer
Press joint on to stop.

Install retaining ring.
282
Prote
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1-
AG.
b
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.
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outer joint
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rrectness of i
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at
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If the thread is tight (e.g. due to dirt), the required
clamping
ss

Note

-arrows B-.

not cant pliers).
Note
material of the joint boot (compared

to rubber), it is possible to
olkswagen AG
AG. V
tighten the hoseswclip
only
with
special dpliers
agen
oes -V.A.G 1682- .
k
Vol
not
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th
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Useautorque
wrench -C- with adjustment range 5 50oNm,
(e.g.
c
s
s
by
Specified
25 Nm.
dtorque:
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a
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is applied.
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19.5

damage.
agen
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283

Removing
joint body.
G. Volkswagen
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db
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The six balls fors aeach
joint belong to a tolerance group. Check r ac
s
Installing

Press in opposing balls one after the other; the original position
of the hub relative to the cage and joint body must be restored.
The constant velocity joint is correctly assembled if the ball hub
can be moved by hand backwards and forwards over its entire
Checking inner constant velocity joint

agen
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p
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Removing
ht
rig
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19.6

soiled, and to check the running surfaces and the balls for wear
and damage.
Prote
cted
by
AG.
284
rrectness of i
t to the co
nform
spec
a
t
i
h re
o
n in
wit
thi
sd
o
cu
m
en
traces of seizing. Too much circumferential backlash in the joint

becomes noticeable during load change jolts; in such cases, the
joint must be renewed. Smoothing and traces of wear of the balls
are no reason to change the joint.
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A
AG do
agen
Swing segment of hub into
square
cage window.
es n
lksw

Press out joint body in direction of arrow.
Press balls out of cage.
Note
The ball hub and joint body are paired. Do not interchange them.
Tip ball hub out of ball cage via ball track -arrows-.
Check joint body, ball hub, ball cage and balls for pitting and
traces of seizing.
Excessive circumferential backlash in the joint is noticeable dur
ing load change jolts. In this case the joint must be replaced.
Smoothing and traces of wear of the balls are no reason to renew
the joint.
Installing
The ball hub has two different distances between the ball tracks:
a smaller one and a larger one.
ility
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pt
ce
rrectness of i
t to the co
nform
spec
a
t
ion
h re
wit
in t
his
Insert hub complete with cage and balls into joint body, making
sure that a smaller gap -b- faces open side of joint body.
Also make sure that chamfer on inner circumference of ball
hub is visible after swinging it into place.
do
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AG. Volkswagen AG d
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Insert hub into cage
c
s a via the two chamfers. The hub can be
s
installed in any position. Press balls into cage.
ht
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Co
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Prote
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c
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C
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285

Swing ball hub into place by swinging hub out of cage as
shown in figure -arrows-.
Swivel in hub with balls by applying firm pressure to cage

-arrow-.
The constant velocity joint is correctly assembled if the ball hub
can be moved by hand backwards and forwards over its entire
agen
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AG.
Prote
cted
b
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c
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.
Co
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i
ht
rig
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Co
t.
do
c
um
en
286
rrectness of i
t to the co
nform
spec
a
t
i
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wit
thi
s
ole,
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44
Wheels, tyres, vehicle geometry
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1. Appraisal of accident vehicles
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287

Torque settings for wheel bolts
Wheel bolt to wheel hub for all vehicles
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AG.
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Rep. Gr.44 - Wheels, tyres, vehicle geometry
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288
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Fitting wheel and tyre
3.1
General information
Since model year 2005, new wheel rims with a modified contour
have been used in all vehicles.
The tyre fitting unit must be fitted with the tyre fitting head de
signed for these wheels.
WARNING
Otherwise there is a danger that the wheel will be damaged.

If the tyre fitting unit has not been modified, please contact the
manufacture of the unit.
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3. Fitting wheel and tyre
289
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Edition
08.2009
t
or
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ac
a
ss
Removing and fitting tyres (wheels

with tyre pressure monitoring)
4.1
Notes on safety and conditions for re

moving and fitting tyres (wheels with tyre
pressure monitoring)
It is extremely important to adhere to the instructions and

warnings in the following descriptions.
Check whether the tyre pressure sensor should also be re

placed Vehicle diagnosis, testing and information system
VAS 5051.
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The tyre pressure sensor must not come into contact with wa
AG.
4.2
Wheel change
If the wheels are changed (e.g. switch from summer to winter

tyres), the wheel electronics transmit data as soon as the speed
of the new wheels exceeds 25 km/h. The new wheel electronics'
ID numbers are automatically detected and entered by the control
unit.
The acceleration data are additionally checked against the vehi
cle speed. This process takes approx. 7 minutes.
The tyre pressure monitor control unit -J502- must first switch to
learning mode before it can automatically learn the wheel elec
tronics.
To do this, the vehicle must remain stationary for 20 minutes.
Following the detection of a flat tyre, this time is 5 minutes.
If the stationary time is not maintained and the control unit con
sequently does not switch to learning mode, the system detects
interference in transmission and will learn the wheel electronics
automatically only after a stationary period of 20 minutes.
Note
When changing wheels, note that only Volkswagen-approved
wheel and tyre combinations with the tyre inflation pressure

specified in the tank flap may be installed.
If unapproved wheel and tyre combinations are installed, they
must possess a certificate from the responsible technical in

spection authority (in Germany, TV) for the respective vehi
cle, and a second wheel set must be learned via the Vehicle
diagnosis, testing and information system -VAS 5051B page 291 .
Learning is also necessary if the tyre inflation pressure devi
ates from the tyre inflation pressure specified in the tank flap
page 291 .
290
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ter or be blown upon with compressed air when the wheel rim
is cleaned.
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during removal or fitting.
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Ensure that the tyre does not contact the tyre pressure sensor
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Tyre sets with other specified tyre inflation pressures
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Nominal tyre inflation pressures for the second wheel set must be
specified to the system with the Vehicle diagnosis, testing and
information system -VAS 5051B- .
The wheel electronics for the wheels of the second wheel set are
not automatically detected and learned by the TPM system (unlike
the wheel electronics for the wheel set with Volkswagen-ap
proved wheel and tyre combinations).
The following work has to be performed to switch to the second
wheel set:
Read ID numbers (IDs) of the wheel electronics (tyre pressure
sensors) prior to installation.
Switch the TPM to wheel set 2.
Enter the necessary nominal tyre pressures and the IDs of the
wheel electronics in the system.
Pressing tyre off wheel rim
AG.
Deflate tyre by unscrewing nickel-plated valve insert.
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Comply with the notes on safety and conditions

page 290
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Caution
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4.3
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If a vehicle is fitted with tyres requiring nominal tyre inflation pres
yV
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sures other than those specified on the tank flap sticker, these
is
or
tyres (second wheel set) can also be monitored with theuthTPM
a
system.
ss
When pressing off a tyre using tyre fitting equipment with a

press-off plate, always ensure that the tyre valve/ tyre pres
sure sensor -arrow- is directly opposite the bead breaker -1-.
The bead breaker must be positioned no more than 2 cm from
wheel rim flange.
Remove balance weights and excessive dirt from wheel.
Press both tyre beads off all round and liberally coat tyre and
wheel rim flange with tyre assembly paste -arrow-.
4. Removing and fitting tyres (wheels with tyre pressure monitoring)
291

4.4
Removing tyre from wheel

Caution

page 290
The assembly head must never be within area -a- of tyre
valve/tyre pressure sensor, or the assembly head will
damage the tyre pressure sensor .
Fitting tyre
Turn wheel on tyre fitting unit so that tyre valve/ tyre pressure
sensor is in front of the assembly head.
Position assembly head near tyre valve/ tyre pressure sensor
so that an assembly lever can be inserted approx. 30 next to
the tyre valve/ tyre pressure sensor .
Now lever tyre bead over assembly finger on assembly head
using assembly lever then remove assembly lever.
. Volkswagen AG
Run tyre fitting machine clockwise until upper bead lies com kswagen AG
Vol
pletely above wheel rim flange.
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Check that the tyre pressure sensor is not loose or damaged.
If the screwed connection is loose, replace the union nut, the

valve insert, the seal, the sealing washer and the valve cap
with new parts from the repair set Electronic parts catalogue
ETKA .
If the tyre pressure sensor is damaged, then replace the com
plete item page 304 .
4.5
Fitting tyre to wheel rim

Caution
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292
Prote
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First fit inner side of tyre.
AG.
Coat wheel rim flanges, tyre beads and inside of upper tyre
bead generously with tyre assembly paste.
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When a tyre is changed, it is recommended also to change the

set of seals for the tyre pressure sensor.
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Note
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page 290

sensor -arrow- is directly opposite assembly head.
Press tyre into drop centre in -direction of arrow- between tyre
valve with tyre pressure sensor and assembly head.
Run tyre fitting machine clockwise.
Stop the fitting of lower bead before reaching tyre valve/ tyre
pressure sensor to prevent damage to tyre pressure sensor .
The tyre bead will now slide over the wheel rim flange. The wheel
rim may be turned only until the assembly head is just before the
tyre valve/ tyre pressure sensor .
Check to ensure that tyre bead is seated correctly on assembly
head and run tyre fitting machine clockwise.
Stop the fitting of upper bead before reaching tyre valve/ tyre
pressure sensor to prevent damage to tyre pressure sensor .
rim may be turned only until the assembly head is just before the
tyre valve/ tyre pressure sensor .
Inflate tyre to a pressure of max. 3.3 bar (bead seating pres
sure)
Caution
Never increase the inflation pressure when the tyre bead does
not lie completely against the wheel rim flange.
This would lead to damage to the tyre and/or the wheel rim.
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When the tyre bead does not lie completely against the
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rim flange: deflate the tyre, press tyre bead off wheel
rim
ed
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and generously coat again with tyre assemblythopaste.
au
If the tyre beads seat perfectly against the shoulder of the

wheel rim, increase pressure to 4 bar to seat the tyre.
Fit a new nickel-plated valve insert and inflate tyre to prescri
bed inflation pressure.
Then balance wheel.
Install wheel and tighten bolts to specified torque

page 288 .
rrectness of i
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Inflate tyre to a pressure of max. 3.3 bar (bead
seating pres
sure)
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4. Removing and fitting tyres (wheels with tyre pressure monitoring)
293

Removing and fitting tyres with runflat capability to wheel rims
5.1
Notes on safety
Only specially trained mechanics may remove or install tyres

with run-flat capability.
The special tools required must be in a perfect condition and

must not be damaged. For information about appropriate ad
ditional tools, directly contact the manufacture of the tyre fitting
equipment in your workshop. The recommended optional ad
ditional tools can be located under the VAS number of the
listed tyre fitting equipment.
Use assembly paste recommended by the tyre manufacturer

if necessary.
The procedure for removing and fitting may differ depending

on the type of equipment used and the manufacture of the
equipment.
The subsequent procedure describes in general the principles

of removing and fitting tyres with run-flat capabilities. It is im
portant that you can identify a "run-flat" tyre before starting to
remove or fit a tyre in order to follow the respective procedure.
Distinguishing features: the tyre can be identified by one of the

swagenRSC,
G. VolkROF,
following abbreviations DSST, Euforia,
AG do SSR
n ARFT,
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or ZP. The abbreviation is located
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V
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lowing the tyre designation
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er.
eo
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ss
It is extremely important
to adhere to the instructions and
warnings in the following descriptions.
Check whether the tyre pressure sensor should also be re

placed (if present) Vehicle diagnosis, testing and information
system VAS 5051.
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rrectness of i
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nform
spec
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wit
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s
Note
Ensure that the tyre does not contact the tyre pressure sensor
during removal or fitting.
The tyre pressure sensor must not come into contact with wa
ter or be blown upon with compressed air when the wheel rim
is cleaned.
5.2
Installation conditions
Warming cold tyres to minimum installation temperature

Note
Prote
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AG.
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294
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This instruction also applies to ultra-high performance tyres

(height/width ratio less than or equal to 45 % and speed symbol
greater than or equal to V).
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WARNING
The minimum installation temperature of a tyre is 15 C and

the temperature in the core of the tyreeshould
not be more than
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30 C.
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Rubber is a poor conductor of heat, therefore a cold tyre must

be left in an area with the correct temperature for a sufficiently
long period so the inner rubber layers can warm up to at least
15 C.
The surface temperature of the tyre during the warming up

phase is no indication of its internal temperature.
To enable cold tyres to absorb heat from the ambient air as

quickly as possible, they should not be stacked on top of one
another but instead stored individually in order to allow the
warm air to flow around them effectively.
Tyres must never be placed in front of a radiator or hot air

blower for warming, since this can very quickly lead to critical
surface temperatures.
Except for warming with warm water or warm ambient air

(max. 50 C), there is no process available for warming tyres
without damaging the tyre!
When cold tyres (below 0 C) are transferred to a warm envi

ronment (above 0 C), a layer of condensation immediately
forms on the surface of the tyre. This layer of condensation
indicates that the tyre is intensively absorbing heat from its
environment through the process of water vapour in the air
condensing out on the tyre surface.
If the layer of condensation is in liquid form and leads to mois

ture on the surface, it should be dried off with a cloth otherwise
the continuation of the warming process might be curtailed by
cold due to evaporation.
rrectness of i
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This internal temperature is referred to as the core tempera

ture.
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bead to at least 15 C.
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To install tyres without
damage, it is especially important to
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warm the upper part of the sidewall and the inside of the upper
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Warming times:
Assuming a minimum room temperature of 19 C and a tyre
temperature of 0 C or more, a tyre should be kept at least at
19 C for at least 2 hours
Assuming a minimum room temperature of 19 C and a tyre
temperature of below 0 C, a tyre should be kept at least at 19
C for at least 2.5 hours
Warming recommendations:
If possible, the tyres should be kept in the workshop for 1 day
before installation (preparation for the job).
Store on an insulated base, pallet or the like, as high up as
possible
Position the tyres individually to allow the warm air to flow
around them effectively
Wipe off condensation
Never heat with a radiator or hot air blower!
5. Removing and fitting tyres with run-flat capability to wheel rims
295

5.3
Pressing tyre off wheel rim

Caution
Follow the notes on safety page 294

Deflate tyre by unscrewing nickel-plated valve insert.
es n
wage
ot g
olks
V
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When pressing off a tyre using tyre fitting equipment
by with a
d
ran
e
s
i
tee
r
press-off plate, always ensure that the tyre valve/
tyre
pres
o
h
t
or
sure sensor -arrow- is directly opposite theaubead breaker -1-.
ac
s
s
Remove balance weights and excessive dirt from wheel.
Press both tyre beads off all round and liberally coat tyre and
wheel rim flange with tyre assembly paste -arrow-.
296
AG.
Caution
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Prote
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Removing tyre from wheel
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5.4
rrectness of i
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at
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The bead breaker must be positioned no more than 2 cm from

wheel rim flange.

sensor -2- is directly in front of assembly head -1-.
Caution
The assembly head -1- must never be within area -a- of tyre
valve/tyre pressure sensor, or the assembly head will damage
the tyre pressure sensor .
Position assembly head -1- near tyre valve/ tyre pressure sen
sor so that an assembly lever can be inserted approx. 30 next
to the tyre valve/ tyre pressure sensor -2-.
Seat depressor -3- on wheel rim opposite assembly head
-1-.
using assembly lever then remove assembly lever.
Run tyre fitting machine clockwise until upper bead lies com
pletely above wheel rim flange.
Volkswa
gen AG
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does
This action will push the depressor -1- up against
wagethe assembly
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head. This allows it to be removed easily.
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sensor -2- is directly in front of assembly head -1-.
Caution
The assembly head -1- must never be within area -a- of tyre
valve/tyre pressure sensor, or the assembly head will damage
the tyre pressure sensor .
AG.
Prote
cted
Remove assembly lever -3-.
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Additionally insert a plastic assembly lever -4-.
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using assembly lever -3-.
do
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Position assembly head -1- near tyre valve/ tyre pressure sen
sor so that an assembly lever can be inserted approx. 30 next
to the tyre valve/ tyre pressure sensor -2-.
297

Hold bead over wheel rim flange from outside using plastic
assembly lever -1- and run tyre fitting machine clockwise until
tyre is pulled completely off wheel rim.
Note
Check that the tyre pressure sensor is not loose or damaged.
If the screwed connection is loose, replace the union nut, the

valve insert, the seal, the sealing washer and the valve cap
with new parts from the repair set Electronic parts catalogue
ETKA .
If the tyre pressure sensor is damaged, then replace the com
plete item page 304 .
5.5
Fitting tyre to wheel rim

Caution
Follow the instructions for warming cold tyres to minimum

installation temperature page 294
Coat wheel rim flanges, tyre beads and inside of upper tyre
bead generously with tyre assembly
e
wagepaste.
s no
t
ks
Vol
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y
Turn wheel rim on tyre fitting
d b unit so that tyre valve/ tyre pres uara
nte
se
i
r
sure sensor -1- is directly
opposite assembly head -2-.
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tho
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c
rrectness of i
t to the co
nform
spec
a
t
ion
h re
wit
in t
his
Stop the fitting of lower bead before reaching tyre valve/ tyre
pressure sensor -arrow- to prevent damage to tyre pressure
sensor .
rim may only be turned until the assembly head is just before the
tyre valve/ tyre pressure sensor -arrow-.
AG.
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Prote
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298
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f
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ility
ab
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ss
Run tyre fitting machine
clockwise.

Turn wheel rim on tyre fitting unit so that tyre valve/ tyre pres
sure sensor -1- is directly opposite assembly head -2-.
Fit depressor -3- on wheel rim.
AG. Volkswagen AG d
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Check to ensure that tyre bead is seated correctly on assembly

head and run tyre fitting machine clockwise.
rrectness of i
t to the co
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f
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m
spec
atio
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n in
wit
es, in part or in w
l purpos
hole
ercia
, is n
m
ot
com
Stop the fitting of upper bead before reaching tyre valve/ tyre
pressure sensor -arrow- to prevent damage to tyre pressure
sensor .
rim may only be turned until the assembly head is just before the
tyre valve/ tyre pressure sensor -arrow-.
Remove depressor from wheel rim.

sure)
Caution
This would lead to damage to the tyre and/or the wheel rim.
ng
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sure)
ht
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t.
When the tyre bead does not lie completely against the wheel
rim flange: deflate the tyre, press tyre bead off wheel rim flange
and generously coat again with tyre assembly paste.
thi
sd
o
cu
m
en
r
te o
iva
r
rp
fo
Never increase the inflation pressure when the tyre bead does
not lie completely against the wheel rim flange.
Prote
cted
by
If the tyre beads seat perfectly against the shoulder of the

wheel rim, increase pressure to 4 bar to seat the tyre.
Fit a new nickel-plated valve insert and inflate tyre to prescri
bed inflation pressure.
Then balance wheel.
Install wheel and tighten bolts to specified torque
page 288 .
299

Tyre monitor display
General notes:
The tyre pressure monitor system is part of the software in the
ABS control unit -J104- . The system is used to detect slow tyre
pressure loss from a wheel. Fault memory entries for the tyre
monitor display are stored in the ABS control unit -J104- . The tyre
pressure display compares the wheel speeds and consequently
the rolling circumference of the individual wheels via the ABS
sensors.
After the following work or modifications, the tyre pressure mon
itor display button -E492- must be pressed and held until a
confirmation is sounded.
Change in tyre pressure
Changing one or more wheels
Interchanging wheels, e.g. from front to rear
A change in the wheel's rolling circumference will be indicated by
AG. Volkswagen AG d
the TPM warning lamp -K220- lighting up in the instrument cluster.
agen
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A tyre's rolling circumference may change as a result of: Volksw
g
Insufficient tyre inflation pressure.
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One-sided loading of vehicle.
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Wheel renewal.
System fault in the ABS system.
rrectness of i
t to the co
n
f
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m
spec
atio
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wit
Spare wheel installed.
es, in part or in w
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Increased load on one axle, e.g. due to towing a trailer.

Use of snow chains.
or
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Structural tyre damage.
by
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au
If a fault in the ABS is displayed by the ESP and TCS warning

lamp -K155- or the traction control system warning lamp -K86- ,
then the tyre pressure monitor warning lamp -K220- -arrow- will
also light up. However, no fault will be stored in the system for the
tyre monitor display.
The warning lamp cannot be extinguished by pressing the TPM
button -E492- . In this case, please carry out the following steps:
ng
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fo
Functions
Tyre pressure monitor display / Tyre pressure warning
Follow instructions on screen to perform basic setting.

Perform basic setting
300
AG.
Anti-lock brake system ABS/TCS Mark 70 or anti-lock

brake system ABS/EDL/TCS/ESP Mark 60 EC
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Brake system
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Running gear
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Connect vehicle diagnosis, testing and information system VAS 5051- and select Guided fault finding Vehicle diag
nosis, testing and information system VAS 5051.

Following any change to the wheels, with the ignition switched on
and the vehicle stationary, press the SET button -2- until an au
dible signal sounds. The audible signal confirms basic setting.
rrectness of i
t to the co
nform
spec
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AG. Volkswagen AG d
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6. Tyre monitor display
301

Tyre pressure monitor (TPM)
AG. Volkswagen AG d
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For detailed information on the tyre pressure monitor (TPM), refer
Vol
to Self-study programme No. 347 ; Tyre Pressure Monitoringsed by
ri
Systems .
tho
au
At regular intervals, the wheel electronics transmit data which the

central locking and anti-theft alarm system aerial receives and
forwards to the tyre pressure monitor control unit -J502- .
This control unit is integrated with its own diagnostic address into
the convenience system central control unit -J393- .
The tyre pressure specifications (monitoring air pressures) are set
in the control unit as factory defaults.
The pressures, noted on the tank flap sticker, are valid for a set
of wheels with the Volkswagen-approved tyres.
The nominal tyre pressures for this set of wheels are specified for
the partially and fully laden vehicle and must not be changed.
The driver can switch between partial and full load, poll the status
and switch the TPM system on or off via a SET button -2- in the
centre console.
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This button is not available for the North American region

(NAR). Therefore, the function described above is omitted in
this region.
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Caution
Messages and warnings are indicated via the lamp in the dash
panel insert and texts in the dash panel insert display.
7.1
Button behaviour
This table shows the button's behaviour in the case of various

states or actions under consideration of different functions.
Caution
This button is not available for the North American region

(NAR).
State or action
Time for which the button is pressed

3-7 seconds
8-10 seconds
Switch
Confirm
Up to 2 seconds
Actual state
Messages:
Desired functions:
Switch from full to
partial load
Full tyre load moni

tored
(gong)
Switch from partial to Partial tyre load
full load
monitored
(gong)
Switching on
TPM off!
302
Messages:
Partial tyre load on!
Full tyre load on!
Messages:
On release:
Confirmation of
switching via gong
On release:
Confirmation of
switching via gong
On release:
Confirmation of
switching via gong
11-15 seconds
Deactivation
Messages:
rrectness of i
t to the co
nform
spec
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ss
The tyre pressure monitor system includes wheel electronics
mounted on each wheel.
not
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Up to 2 seconds
Actual state
State or action
Deactivation
Full tyre load moni

tored
or
Partial tyre load
monitored
(gong)
For example:
TPM off!
or
Partial tyre load
monitored
(gong)
Status query
7.2
Time for which the button is pressed

3-7 seconds
8-10 seconds
Switch
Confirm
or
Full tyre load on!
11-15 seconds
Deactivation
TPM off!
(gong)
After releasing:
Press longer to acti
vate!
or
Press longer to
switch or deactivate!
Assembly overview - tyre pressure sensor
1 - Tyre pressure sensor

Supplied complete as
spare part.
page 304
Replace complete tyre
pressure sensor when
battery is dead
After using breakdown
set, wipe clean hole for
valve and opening for
. Volkswagen AG
gen AG
does
pressure sensor
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2 - Valve core
ed
ris
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Allocation autElectronic
parts catalogue
ETKA
ss
Always renew when
changing tyre
rrectness of i
t to the co
n
f
o
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mat
spec
ion
h re
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in
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hole
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Note
3 - Sealing washer
4 - Sealing ring
Will be slightly deformed
when the union
Item 6 (page 303) nut
is tightened
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6 - Union nut
8 Nm
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5 - Wheel
Fitting tyres of wheels
with tyre pressure mon
itoring page 290
Fitting tyres with run-flat
capabilities page 294
7 - Valve cap
Use only genuine valve caps from repair set Electronic parts catalogue ETKA .
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7. Tyre pressure monitor (TPM)
303
Removing and installing tyre pressure

sensor
Removing
rrectness of i
t to the co
nform
spec
a
t
i
h re
o
n in
wit
thi
s
7.3
Unscrew union nut -1-.
Remove tyre pressure sensor -2- from bed of wheel rim.

Installing
Caution
Before installing tyre pressure sensor , clean valve hole.
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Install tyre pressure sensor -2- along with a new seal and
sealing washer and push it into wheel rim at the points marked
by -arrows-.
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Do not use convenience valve caps or metal valve caps.
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AG. Volkswagen AG d
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steering
Edition
08.2009
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Press tyre pressure sensor -2- into the wheel rim at the points
marked by -arrows-.
AG.
Screw union nut -1- onto tyre pressure sensor from outside.
Press tyre pressure sensor -1- onto bed of rim at the points
marked by -arrows- and tighten union nut to 8 Nm.
Caution
Tighten nut only to specified torque.

The sealing washer -2- will be deformed slightly when
tightened.
The sealing washer may be installed only once. Install a
new sealing washer with rubber seal every time the part
is fitted.
Further tightening of the union nut is not permitted be
cause the seal may be damaged, leading to leaks.
Specified torque
Component
Union nut to tyre pressure sensor
304
Specified torque
8 Nm

AG. Volkswagen AG d
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Wheel alignment
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equipment required
rrectness of i
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f
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spec
atio
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wit
Wheel alignment computer

-V.A.G 1813- or VW/Audiapproved wheel alignment
computer
Brake pedal actuator V.A.G 1869/2 Tool insert 18 mm -T10179 Shock absorber set T10001-
thi
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8.1
General
Wheel alignment must always be checked with VW/Audi-ap

proved wheel alignment equipment.
Whenever wheels are aligned, both the front and rear axles must
be measured.
Otherwise, the steering rack may not be centred!
Perform all measurements with wheel alignment computer.
All the information required to perform alignment can be found in
the wheel alignment computer.
Current data updates are located on VW Service Net.
VW ServiceNet; Systems; Wheel alignment computer soft
ware; Wheel alignment; Beissbarth
ware; Wheel alignment; Hunter
ware; Wheel alignment; Corghi
8. Wheel alignment
305

ware; Wheel alignment; John Bean
Note
Wheel alignment should not be checked before the vehicle has
completed 1,000 to 2,000 km because the coil springs must

settle.
When making adjustments, adhere to the relevant specifica
tions as closely as possible.
Wheel alignment is necessary if:

The vehicle does not handle properly.
Vehicle has been involved in an accident and components
have been renewed.
Axle components are removed or renewed.
Tyres are worn unevenly.
Components have been renewed.
Front axle component re
newed
Alignment necessary
Yes
Rear axle component re

newed
No
Yes
Lower suspension link

X
Lower transverse link
1)
Bonded rubber bush
Upper transverse link
X
for suspension link
Wheel bearing housing
X
Track rod
Track rod/track rod ball joint
X
Steering box
X
Subframe
Subframe
X
Coil spring
Suspension strut
X
Shock absorber
es n
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Subframe bracket
X
Anti-roll
bar
yV
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db
ran
1)
ir se
Anti-roll bar
Trailing
arm
tee
X
o
th
au
1) Prerequisite:
ss the
or
ac

Track rod/track rod ball
joint
Steering box
Subframe
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Yes
1)

Subframe
X
X
1)
Coil spring
Shock absorber
X
X
X 1)
Anti-roll bar
Trailing arm
AG.
Alignment necessary
X
X
Upper transverse link

Track rod
Anti-roll bar
X
X
X
X
X
X
X
X
Lower transverse link
1)
Suspension strut
Subframe bracket
306
No
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Lower suspension link

moved and reinstalled
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Yes
X
X
No
X
X
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Alignment necessary
rrectness of i
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spec
a
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ion
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Components removed and installed
No
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positions of the subframe and brackets fixed

before they were removed page 16 .

moved and reinstalled
Alignment necessary
X
X

1)
Prerequisite: the positions of the subframe and brackets fixed

before they were removed page 16 .
8.2
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wheel
bearing,
steering
and
steering
link
ss
Test prerequisites
Tread depth difference of no more than 2 mm on one axle.
Tyres inflated to correct pressure.
Vehicle unladen.
Fuel tank must be full.
Spare wheel and vehicle tools are stowed in correct locations.
The fluid reservoir for the windscreen/headlight washer sys

tem must be full.
When checking wheel alignment, ensure that sliding plates

and turn tables are not touching end stop.
Please note!
The test equipment must be properly adjusted and attached

to the vehicle; observe device manufacturer's operating in
structions.
If necessary, contact the manufacturer for familiarisation with the

proper use of the wheel alignment equipment.
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Wheel alignment platforms and alignment units and computers

should be checked and adjusted as necessary during inspection
and maintenance at least once per year!
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Wheel alignment platforms and wheel alignment units and com

puters can lose their calibration over a period of time.
do
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rrectness of i
t to the co
nform
spec
a
t
i
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o
n in
wit
thi
s
Check suspension,
age for excessive play and damage.
ility
ab
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AG.
Treat these highly sensitive units carefully and conscientious

ly!
8.3
Test preparations

Brake pedal actuator -V.A.G 1869/2-
The existing lateral runout of the wheel must be compensated for.

Otherwise, the result of the measurement will be incorrect.
If runout compensation is not performed, it is not possible to adjust
toe-in correctly!
Observe information provided by the manufacturer of the wheel
alignment unit.
Carry out wheel run-out compensation.
8. Wheel alignment
307

Fit brake pedal actuator -V.A.G 1869/2- .
Use brake pedal depressor to depress brake pedal.
8.4
Wheel alignment specifications, Golf
These specifications apply to all engines.

Explanation of PR Nos. can be found here page 317 .
The ride heights shown in the table refer to dimension -a-.
Front axle
Standard running
gear
PR numbers
Sports running
gear
with 18' wheels
Heavy-duty run
ning gear
G02, G05, G07,

2UC
2UB
10' 10
-41 30
10' 10
-14 30
max. 30
max. 30
140 20
138 20
7 47 30
max. 30
7 17 30
max. 30
367 10 mm
402 10 mm
Sports running
gear R32
BlueMotion
G08
Sports running
gear GTI US ver
sion
G11
G09
G04/2UC
10' 10
10' 10
10' 10
10' 10
-44 30
-30 30
-43 30
-41 30
max. 30
max. 30
max. 30
max. 30
138 20
120 20
140 20
7 34 30
max. 30
7 47 30
max. 30
7 47 30
max. 30
2UA
Sports running
gear
except 18'
wheels
2UC
1)
Toe-out on turns can be displayed as a negative value on the

wheel alignment computer, depending on the manufacturer.
Sports running
gear GTI
Total toe (wheels not press

ed)
Camber (in straight-ahead
position)
Maximum permissible differ
ence between sides
Prote
cted
by
308
122 20
AG.
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Toe-out on turns 1) at 20 left

and right lock
Caster
ence between sides
7 47 30
max. 30
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PR numbers
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Front axle
rrectness of i
t to the co
nform
spec
atio
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Total toe (without load)

10' 10
10' 10
. Volkswagen AG
G
A
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does -41 30
Camber (in straight-aheadkswag
-30 30
not
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position)
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Maximum permissible
differ
max.
30
max.
30
o
eo
h
t
ra
ence betweens ausides
c
s
138 20
140 20
and right lock
Caster
7 34 30
7 47 30
max. 30
max. 30
ence between sides
Ride height
382 10 mm
367 10 mm

Front axle
Sports running
gear GTI
PR numbers
G08
Sports running
gear GTI US ver
sion
G11
Ride height
360 10 mm
382 10 mm
Sports running
gear R32
BlueMotion
G09
G04/2UC
362 10 mm
367 10 mm
1)

Rear axle, front-wheel drive
and 4WD
Camber
ence between sides
Total toe (at specified cam
ber)
Max. permissible deviation
from direction of travel
Ride height

and 4WD
Standard running
gear
Sports running
gear
except 18'
wheels
Sports running
gear
with 18' wheels
Heavy-duty run
ning gear
-1 20 30
max. 30
-1 20 30
max. 30
-145' 30'
max. 30
-120' 30'
max. 30
+10 12.5
+10 12.5
+10 12.5
+10 12.5
max. 20
max. 20
max. 20
max. 20
380 10 mm
365 10 mm
365 10 mm
400 10 mm
Sports running
gear GTI
Sports running
gear GTI US ver
sion
Sports running
gear R32
BlueMotion
lksw
+10 12.5

365 10 mm
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ng
Wheel alignment specifications, Golf

Plus, CrossGolf
max. 20
rrectness of i
t to the co
nform
spec
a
t
i
h re
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n in
wit
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8.5
-1 20 30
max. 30
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Camber
-145' 30'
does -145' 30'
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max.
max. 30
max.
ara 30
ed
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i
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ence between sides
o
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c
Total toe (at specified cam ss a +10 12.5
+10 12.5
+10 12.5
ber)
max. 20
max. 20
max. 20
Ride height
365 10 mm
380 10 mm
360 10 mm
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8. Wheel alignment
309

The ride heights shown in the table refer to dimension -a-.
Front axle
Standard running
gear
PR numbers
2UA

and right lock
Caster
ence between sides
Ride height
Vol
not
g
10' 10
-41 30
ara
10' u10
nte
-14 30 e or a
max. 30
max. 30
max. 30
138 20
140 20
140 20
138 20
7 34 30
max. 30
7 47 30
max. 30
7 47 30
max. 30
7 17 30
max. 30
383 10 mm
368 10 mm
368 10 mm
403 10 mm
1)
ss
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max. 30
by
10' s10
ed
ri
o
th 30
-41
au

10' 10
-14 30
max. 30
138 20
10' 10
-37 30
max. 30
127 20
1)

310
AG.
7 17 30
max. 30
400 10 mm
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Toe-out on turns 1) at 20 left and right lock

Caster
Maximum permissible difference between sides
Ride height
Golf Plus BlueMotion

G06
Prote
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.
Co
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Total toe (wheels not pressed)

Camber (in straight-ahead position)
CrossGolf
2UB
ht
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Co
t.
Front axle
PR numbers
7 40 30
max. 30
373 10 mm
rrectness of i
t to the co
nform
spec
a
t
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n in
wit
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10' 10
-30 30
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Total toe (without load)

Camber (in straight-ahead
position)
ence between sides
Sports running
Sports running Heavy-duty run
gear
gear
ning gear
except 18'
with 18' wheels
wheels
AG. Volkswagen
2UC
G02,
agen G07, 2UC AG does 2UB
ksw

and 4WD
Standard running Sports running

Sports running
AG. Volkswagen A
G do
gear
gear
gear
agen
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except 18'ot gu with 18' wheels
yV
b
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wheels
nt
ris
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-1 20 30
max. 30
30'
max. 30
+10 10
+10 10
+10 10
max. 20
max. 20
max. 20
max. 20
378 10 mm
363 10 mm
363 10 mm
398 10 mm
Rear axle, front-wheel drive and 4WD
CrossGolf
Camber
Total toe (at specified camber)
Max. permissible deviation from direction of
travel
Ride height
-120' 30'
max. 30
+10 10
max. 20
-1 20 30
max. 30
+10 10
max. 20
395 10 mm
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Overview - wheel alignment procedure

AG.
Observe instructions on your wheel alignment device.
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Always adhere to the following procedure!
+10 10
Golf Plus BlueMotion
370 10 mm
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8.6
-120' 30'
max. 30
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Camber
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Total toe (at specified cam
ber)
Ride height
Heavy-duty run
ning gear
Alignment procedure
Start
Carry out wheel run-out

compensation.
Bounce springs.
Turn steering wheel to

straight-ahead position
and lock in place 1)
Check front axle camber
Measure vehicle height.
Fit brake pedal depressor -V.A.G

1869/2- .
No
Is actual value within toler

ance?
Yes
Adjust page 312 .
8. Wheel alignment
311
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Check rear axle toe

ance?
Yes
Check front axle caster.

ance?
Yes
No
Inspect axle components and

body
No

ance?
Yes
Adjust page 316 .
If steering wheel is not centred, it must be straightened after

wheel alignment is finished. Then perform basic settings for steer
ing angle sensor -G85- using vehicle diagnosis, testing and in
formation system -VAS 5051- .
Correcting front axle camber

312
Adjust page 315 .

ance?
Yes
1)
8.7
No
AG.
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Check front axle toe
Adjust page 314 .
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a
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Check rear axle camber
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Note
Camber correction is necessary
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camber is not adjustable, but can be equalized by moving the

brackets and/or the subframe.
Move subframe only to left or right, but never in or opposite to
rrectness of i
t to the co
nform
spec
a
t
i
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wit
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direction of normal travel!
Remove noise insulation.
Loosen bolts -1- for bracket attachment and subframe to body

on both sides.
The camber adjustment range is limited by the tolerances within
the bores in the brackets and the subframe. If the specified value
is not reached by moving the components, these and the body
must be inspected page 1 .
Specification for camber may be adjusted by moving subframe
at brackets.
Tighten bolts for subframe and brackets to body to specified
torque plus extra turn angle.
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Remove securing nuts -arrows- and remove footwell trim.
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Following the movement of the subframe and, consequently, the

steering box, clearance between the steering column universal
joint and the notch in the bulkhead must be checked.
AG.
There must be a clearance of 5 mm all round between universal

joint -2- and recess in bulkhead.
Specified torques
Component
Specified torque
Subframe to body
Use new bolts
70 Nm + 90
Bracket to body
Use new bolts
70 Nm + 90
8. Wheel alignment
313

8.8
Adjusting camber on rear axle

Shock absorber set -T10001-
Tool insert 18 mm -T10179-
rrectness of i
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spec
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Loosen upper transverse link nut -A- on subframe.
AG.
314
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The maximum adjustment range is 90 to the left or right of centre.
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Note
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Adjust camber by turning eccentric bolt -B- with 18 mm socket

-T10001- .
rrectness of i
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spec
a
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Use socket (18 mm) -T10179-
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Tighten nut -A-.
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Check camber value again after tightening nut -A-.
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Specified torques
Component
Specified torque
Upper transverse link to subframe (vehicles with frontwheel drive)

Use new nut

Upper transverse link to subframe (vehicles with frontwheel drive)

Use new nut

8.9
95 Nm
1332- to 80 Nm
18 mm -T1017995 Nm
1332- to 80 Nm
18 mm -T10179-
Adjusting toe at rear axle

8. Wheel alignment
315

Loosen nut -1-.
Turn eccentric bolt -2- until specification is attained.
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Now tighten nut.
Specified torque
Component
Specified torque

Use new nut
95 Nm
ng
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Tool insert 24 mm -V.A.G 1332/11 Loosen lock nut -3- while counterholding on head of track rod
-2-.
Pull spring-type clip -1- off boot.
Adjust toe by turning left and/or right track rod.
To do this, use an open jaw spanner on hexagon flats on track
rod.
After turning track rods, ensure that boots are not twisted.
Twisted boots wear out quickly.
316
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Adjusting front axle toe
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Tighten lock nut using tool insert 24 mm -V.A.G 1332/11- while
counterholding on track rod ball joint -1-.
Check toe values again.
It is possible that the value will change slightly when lock nut is
tightened.
However, if the measured toe value lies within the tolerance, the
adjustment is correct.
Fit spring-type clip to boot.
Specified torques
Component
Specified torque
Track rod ball joint to track rod
8.11
50 Nm
Basic setting for steering angle sender n AG. Volkswagen AG do

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Vehicle data sticker
Explanation of PR numbers on vehicle data sticker

Various types of running gear are installed depending on engine
and equipment level. These are identified by the PR numbers.
The PR numbers are critical in determining the wheel alignment
specifications.
The running gear version fitted in the vehicle is indicated on the
vehicle data sticker by the PR number for the front axle.
The vehicle data sticker can be found in the spare wheel well and
in the service booklet.
Example of a vehicle data sticker
In this example the vehicle is equipped with the standard running
gear G02 -arrow-.
rrectness of i
t to the co
nform
spec
a
t
ion
h re
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his
8.12
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Select Select function/component by pressing Go to button.
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If steering wheel was
tee
ris realigned, basic settings for steering angle
hobe checked. Perform basic settings in gui
t
or
sensor -G85- must
u
a
ded fault findingss using vehicle diagnosis, testing and information ac
system -VAS 5051- .
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8. Wheel alignment
317

Wheels, tyres
9.1
Models with breakdown set
Golf models are equipped with either a spare wheel or a break

down set.
The breakdown set is located in the luggage compartment where
normally the spare wheel would sit. It consists of a compressor
and a bottle of tyre sealant.
9.2
Tyre sealant
The tyre sealant in the bottle has a limited shelf-life.
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The bottle therefore has an expiry date -arrow-.
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In this example, the expiry date of 05/2003 has been exceeded

and the bottle must be renewed.
9.3
Removing a tyre
rrectness of i
t to the co
nform
spec
a
t
ion
h re
wit
in t
his
If the bottle has been opened, e.g. to repair a tyre, then it must
also be renewed.
Tyres which have been filled or sealed using tyre sealant must be
drained before removal.
WARNING
318
Prote
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Remove valve insert of tyre valve.
AG.
Place wheel on a flat surface.
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Wear eye protection and protective gloves whilst working

on the tyre.
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It is a health hazard and may cause eye irritation and al

lergies.
do
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Avoid eye and skin contact with tyre sealant.

Use a suitable drill or mill to carefully drill a hole in shoulder
area of tyre.
Hold wheel over a suitable container and drain sealant.
Remove tyre from wheel rim.
Clean wheel rim with, for example, a moist cloth.
9.4
Fitting a new tyre
Ensure that the wheel rim is clean.
Insert new tyre valve with -VAS 6459- -1-.

Remove valve insert.
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Inflate tyre to approx. 3 bar . . . 4 bar. The bead of the tyre must
ua
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slip audibly over the hump of the rim.
tee
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Screw in valve insert.
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Correct inflation pressure to prescribed pressure.
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spec
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9.5
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Balance wheel.
Tyre sealant disposal
Tyre sealant or residue must not be mixed or disposed of with

other fluids.
Excess tyre sealant must be collected and stored in a plastic
container. The plastic container can be disposed of through
the disposal system along with the breakdown set (when the
expiry date is exceeded).
Request information through your service provider or the dis

posal representative at your distribution centre or importer.
ng
Alloy wheels with metal valves
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As of model year 2005, hollow-chamber wheels have been fitted

as part of certain equipment variants. These hollow-chamber
wheels are fitted with metal valves instead of the usual rubber
valves. Metal valves must be renewed completely each time a
tyre is changed.
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9.6
9. Wheels, tyres
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The items can be returned or disposed of through the existing

workshop disposal system.
319

1 - Wheel
2 - Valve cap
3 - Nut
4 Nm
4 - Washer
5 - Sealing ring
AG. Volkswagen AG d
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6 - Metal valve

10
Instructions for changing or fitting

wheels
WARNING
Perform the checks and follow the instructions listed below.

This is important to ensure that the wheel bolts and the wheels
are properly secured.
Check to ensure that contact surfaces -arrows- on brake disc
are free of corrosion and dirt.
Check to ensure that contact surface -arrow- on centring seat

of brake disc are free of corrosion and dirt.
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ensure sthat
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s a contact surface -arrow- on inner side of
The spherical caps * in the holes for the wheel bolts and the
threads of the wheel bolts must also be free of corrosion and
dirt, oil or grease.
*
A spherical cap is the curved surface of a section of a sphere

cut by a plane.
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rrectness of i
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a
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Check to
wheel (rim) and also centring seat of rim are free of corrosion
and dirt.
10. Instructions for changing or fitting wheels
321
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Running gear, axles, steering - Edition
08.2009
r
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Check whether the wheel bolts can be easily screwed in by
hand. The thread of the wheel bolts must not come into contact
the bore in the brake disc -arrow-.
rrectness of i
t to the co
nform
spec
a
t
i
h re
o
n in
wit
thi
s
If the thread of the wheel bolt touches the hole -arrow-, turn the
brake disc relative to the wheel hub accordingly.
Remove dirt and corrosion, oil or grease from the contact surfa
ces, threads in the wheel hub and/or wheel bolts as necessary.
WARNING
Damaged, badly corroded or difficult to remove wheel bolts

must be renewed.
10.1
Fitting wheels
Preserve wheel centring seat page 323 .
3-
Lower the vehicle to the floor and tighten all wheel bolts di
agonally to the specified torque using the torque wrench
page 288 .
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WARNING
Do not use an impact driver when screwing in the bolts!
322
AG.
Tighten the wheel bolts in diagonal sequence to approx. 30

Nm.
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When fitting the wheel, screw in all wheel bolts uniformly by

hand.
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1-

11
Protecting wheel centring seat

against corrosion
Valid for light alloy and steel wheels

When a wheel is installed, wheel centring seat should be waxed
with
Wax spray -D 322 000 A2to prevent corrosion between the wheel centring seat and the
wheel rim.
Remove wheel.
Clean wheel centring seat of hub and centring ring of wheel
. Volkswagen AG
rim.
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Ensure that only centring ring -arrow- but not contact
surface of
tho
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a
wheel rim has been waxed. Otherwise, the brakes
will be soiled,
ss
oes
not
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Apply wax to centring ring -arrow- with a brush.
rrectness of i
t to the co
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m
spec
atio
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WARNING
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which would reduce the braking efficiency.
Wheel bolts, contact surfaces of wheel hub and wheel rim and
wheel hub threads must not be waxed. Never treat wheel se
curing bolts with lubricant or corrosion protection materials!
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11. Protecting wheel centring seat against corrosion
323

12
Rough running due to wheels/tyres causes and rectification
Causes of rough running page 324

Balancing wheels page 324
Conducting a road test before balancing wheels page 325
Balancing wheels on stationary wheel balancing machine
page 325
Vibration control system -VAS 6230- page 327
Finish balancer page 327
Radial and lateral run-out on wheels and tyres page 328
Checking radial and lateral runout on wheels and tyres with tyre
gauge -V.A.G 1435- page 328
Checking radial and lateral run-out on wheel rim page 329
Matching page 330
Flat spots caused by storage or handling page 331
12.1
Causes of rough running
Rough running can have a number of different causes. It can also

swagen AG
Volkalways
be caused by tyre wear. Tyre wear caused by driving
G.not
n Ais
does
wage
evenly spread across the entire running surface
not
olks of the tyre. This
V
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b
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causes slight imbalances which affect ethe
d smooth running of a
nte
ris
wheel which was previously exactlyhobalanced.
e
t
au
optimal safety,
smoothest possible running and
even wear
throughout a tyre's service life, we recommend having the wheels

and tyres balanced at least twice during the tyre's service life.
12.2
Balancing wheels
Before you start balancing the wheels, the following requirements

must be met.
The tyre tread must not show one-sided wear and should be
at least 4 mm deep.
The tyre must not show any signs of damage, for example
cuts, piercing, foreign bodies, etc.
The wheel suspension, steering and steering linkage, includ

ing the shock absorbers, must be in perfect condition.
You must have conducted a road test.
AG.
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324
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The tyre pressure must be OK.
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To ensure
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Recommendation
or
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Minor imbalances will not be feltss at the steering wheel, but that
does not mean that they are not there. They increase wear on the
tyre and thus reduce the tyre service life.
Conducting a road test before balancing

wheels
If a customer brings a vehicle to the workshop complaining about

vibration, a road test is essential prior to balancing the wheels.
This will give you information about the nature of the rough
running.
You will be able to determine in which speed range the rough
running occurs.
Raise the vehicle on a lifting platform immediately after the
road test.
Mark the positions of the tyres on the vehicle.
Marked with ...
FL
FR
RL
RR
Remove wheels from vehicle.
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12.4
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Balance the wheels.
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Tyre position
Front left tyre

Front right tyre
Rear left tyre
Rear right tyre
rrectness of i
t to the co
nform
spec
at
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12.3

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AG. Volkswagen AG d
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Running gear,
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Balancing wheels on stationary wheel

balancing machine
Road test has been carried out page 325 .
Clamp wheel into wheel balancing machine

Note
When balancing wheels, please remember that cleanliness is ab

solutely essential, as indeed it is in the case of any other repair
work you carry out. Only then can you attain a flawless result!
Dirt and rust in the area of the contact surfaces and centre of the
wheel distort the result.
Clean the contact surfaces, the centre of the wheel and the
recess on the inside of the wheel before mounting the wheel
on the wheel balancer.
Mount the wheel with tyre on the wheel balancer.
12. Rough running due to wheels/tyres - causes and rectification
325

Note
To clamp the wheel, use e.g. centring system for wheel bal
ancing machines -VAS 5271- .
This ensures that the wheel is 100% centred and that the
wheel will be clamped without damage!
The wheel cannot be centralised 100% with conical clamping
elements on the wheel balancing machine.
A deviation of 0.1 mm from the centre results in an imbalance
of 10 grams at the wheel/rim.
Procedure for balancing wheels and tyres

Rotate wheel and tyre on wheel balancer.
Check that the indicator lines on the sidewall of the tyre near
the wheel rim flange run evenly.
Check that the body of the tyre runs evenly while the wheel
and tyre are rotating.
Note
If one-sided wear, flat spots from braking or severely washed out

spots are apparent, balancing cannot achieve smooth running. In
this case, the tyre must be renewed.
Check the true running of the wheel and tyre. If the wheel and
tyre do not run true although there are no flat spots, radial or
lateral runout may be the cause.
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Check the wheel for radial
328 .
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If radial and lateral
d b runout are within the specified tolerance,
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balance thethowheel and tyre.
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Note
More than 60 grams of weight per tyre should not be used.
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If more weight is required, you may be able to achieve smooth
er running by "matching" the tyre and rim. Matching tyres

page 330 .
The wheel balancer display should indicate 0 gram.

As an alternative to match mounting, you could use the vibra
tion control system -VAS 6230- page 327 .
Bolt the wheel to the vehicle.

First hand-tighten the lowest wheel bolt to about 30 Nm.
Then tighten the remaining wheel bolts diagonally to about
30 Nm. This process centres the wheel on the hub.
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Carry out road test
After balancing the wheels and tyres, carry out a road test.
AG.
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326
do
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Now use a torque wrench to tighten the wheel bolts to the

specified torque in diagonal sequence.
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If you detect vibration during the road test, it may be due to tol
erance in the wheel centring.
In unfavourable circumstances, the component tolerances of
wheels and hubs could cumulate. This too can lead to vibration.
This can be alleviated using a finish balancer. page 327
12.5
Vibration control system -VAS 6230-
. Volkswagen AG 6230- you can perform

Using the vibration control
gen AG system -VAS
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balancing.
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A specialorifeature
of this system is the testing of theanradial
force of
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the wheel
and tyre while rolling.
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Radial and lateral runout in the wheel and tyre and differences in
the stiffness of the tyre cause the vertical force of the wheel to
vary.
rrectness of i
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f
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spec
atio
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wit
The -VAS 6230- detects and stores the position of the maximum
measured radial force in the tyre. Then the position of the smallest
distance between the wheel rim flange and the centre of the rim
is measured.
12.6
Finish balancer
ng
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A roller presses against the wheel with a force of about 635 kg.
This simulates the vertical tyre force against the road surface
during travel.
Before working with a finish balancer , the mechanic needs to

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have been instructed by the manufacturer of the balancer.
To balance the wheels, set the wheels of the driven axle on

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the sensor platforms (only the front wheels of a front-wheel

drive vehicle, all four wheels of a four-wheel drive vehicle).
AG.
If you determine a residual imbalance greater than 20 grams

when balancing the wheels, you should rotate the mounting po
sition of the wheel on the hub.
Mark the point at which the imbalance is indicated.
Unbolt the wheel and rotate its position on the hub so that the
marking points downwards.
Note
The hub must not rotate during this procedure.

First hand-tighten the lowest wheel bolt to about 30 Nm.
Then tighten the remaining wheel bolts diagonally to about
30 Nm. This process ensures that the wheel is centred prop
erly on the hub.
Check whether the imbalance is less than 20 grams using the
finish balancer.
327

Note
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If necessary, remove the wheel bolts again.
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The imbalance should always be less than 20 grams before you

change the balance weight.
Rotate the wheel relative to the hub once more, turning it one
or two wheel bolt holes further.
Tighten the wheel bolts using the method described above.
Note
Do not try to reduce the imbalance using balance weights until

the imbalance is less than 20 grams.
Balance the wheels until the imbalance is less than 5 grams.
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Prote
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Radial and lateral runout of wheels and

tyres
AG.
12.7
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Always tighten wheel bolts to specified torque using a torque

wrench!
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WARNING
Radial and lateral runout occur when the wheel and tyre do not
run absolutely true.
For technical reasons, 100% true running is not possible.
Therefore, the manufacturers of these components allow a pre
cisely determined tolerance.
Mounting the tyre in an unfavourable position on the wheel can
cause the maximum allowed tolerance for wheel with tyre to be
exceeded.
The table shows the maximum permissible tolerances for a wheel
with mounted tyre.
Tolerances for radial and lateral runout of wheels with tyres
12.8
Wheel with tyre
Radial runout (mm)
Lateral runout (mm)
Passenger cars
0.9
1.1
(1.3 in vicinity of lettering)
Checking radial and lateral runout on

wheels and tyres with tyre gauge -V.A.G
1435-
Checking lateral runout

Preload tyre gauge about 2 mm.
328
thi
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en
Tighten wheel bolts to specified torque if you have not already

done so.

Set tyre gauge against sidewall of tyre.
Slowly rotate the wheel.
Note the smallest and the largest dial readings.
Note
If the difference is greater than 1.3 mm, the lateral runout is too
great.
In this case, you can reduce lateral runout by match mounting the
tyre page 330 .
Extreme values on the tyre gauge due to small irregularities in the
rubber may be disregarded.
Checking radial runout
Set the tyre gauge against the tyre tread.
Note
If the difference is greater than 1 mm, the radial runout is too great.
In this case, you can reduce radial
runout by match mounting the
AG. Volkswagen AG d
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tyre page 330 .
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Checking radial and lateral runout on

wheel
Mount the wheel on the wheel balancer .

S - Lateral runout
H - Radial runout
Compare the measured values with the specifications in the
table page 329 .
Note
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Specifications for radial and lateral runout on wheel
do
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Extreme values on the tyre gauge due to small irregularities may

be disregarded.
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spec
a
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ion
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his
Use the wheel balancing machine centring system -VAS

5271- .
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12.9
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Radial runout (mm)
Lateral runout (mm)
0.5
0.5
329

Wheel
Radial runout (mm)
Lateral runout (mm)
Alloy wheel
0.5
0.8
Note
Matching
When radial or lateral runout of the wheel and tyre coincide, the
imbalance of the wheel is amplified by the tyre.
For technical reasons, 100% true running is not possible
page 328 .
Before match mounting the used wheels which are fitted on the
vehicle, run the tyres warm. This will eliminate any flat spots
caused by storage or handling, page 331 .
Procedure for match mounting
Deflate the tyre.
Press the tyre beads off the rim flanges.
Coat the tyre bead all round with tyre fitting paste .
Rotate the tyre 180 relative to the wheel.
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Mount the wheel with tyre on the wheel balancer.
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Inflate the tyre to approx. 4 bar.

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Check true running, that is, radial and lateral runout.

AG.
Note
If the specified values for radial and lateral runout are not ex
ceeded, the wheel can be balanced to 0 gram. Specified

values appear on page 328 .
If the radial and lateral runout is not within the specifications,
the tyre must be rotated again.
Deflate the tyre and press off the tyre beads from the rim
flanges.
Rotate the tyre 90 with respect to the wheel (1/4 of a turn).
Inflate the tyre to 4 bar again and check true running.
Note
If the specified values for radial and lateral runout are not ex
ceeded, the wheel can be balanced to 0 gram.
If the radial and lateral runout are not within the specified val
ues, the tyre must be rotated again.
Press the tyre off the rim flanges again as described above.
Rotate the tyre 180 with respect to the wheel (1/2 a turn).
330
rrectness of i
t to the co
nform
spec
a
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i
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n in
wit
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General
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If the measured value
exceeds
the
specification,
acceptably
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smooth running
h cannot be attained.
t
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If the radial and/or lateral runouts are still not within the specifi
cations, check the radial and/or lateral runouts of the wheel:
page 329 .
If the measured values for radial and lateral runout of the wheel
are within the specified values, the tyre has an impermissibly high
radial or lateral runout. In this case, the tyre must be renewed.
Note
After fitting the tyres there will be fitting lubricant between the
tyres and the rim flanges.
Therefore, severe braking and acceleration manoeuvres must
be avoided for the first 100 or 200 km driven. The tyres may
otherwise rotate on the rims and your work will have been in
vain.
12.11
Flat spots caused by storage or handling
What is a flat spot?

The term flat spot describes a type of wear where one patch or
spot of the tyre has become flat.
Flat spots caused by storage or handling also cause vibration in
the same way as incorrectly balanced wheels do. It is important
that flat spots on the tread are identified as such.
Flat spots caused by storage or handling cannot be balanced and
they can reoccur at any time due to various circumstances. Flat
spots caused by storage or handling can be eliminated without
complicated special tools. Assuming it is not a flat spot caused by
full-on braking Wheel and Tyre Guide - Series; Rep. Gr. 44 ;
Rolling noises due to tyres, locked brake flat spots .
Note
pe
rm
itte
d
un
le
Reasons for flat spots caused by storage or handling:
The tyre inflation pressure is too low.

The vehicle was placed in a paint shop drying booth after being
painted.
The vehicle was parked with warm tyres in a cool garage or
similar for a long period of time. In this case, a standing flat
spot may even occur overnight.
Eliminating flat spots caused by storage or handling
Flat spots caused by storage or handling cannot be eliminated
from the tyre using workshop equipment.
The method described below is not recommended in cold and

wintry weather.
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Check and, if necessary, correct inflation pressures.

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Requirements and conditions:
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Flat spots caused by storage or handling can be removed only

by running the tyres warm.
rrectness of i
t to the co
n
f
o
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mat
spec
ion
h re
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The vehicle has been left standing in one place without being
moved for several weeks.
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Flat spots caused by hard
d
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must be renewed. thor
or
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331

Drive the car on a motorway where possible.
Traffic and road conditions permitting, drive a 20 to 30 km
stretch at a speed of 120 to 150 km/h.
WARNING
Do not endanger yourself or other road users during this

road test.
Observe the highway code and speed limitations in force
when performing the road test.
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Remove the wheels from
ho
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Balance the wheels
ss on a stationary wheel balancer
s
olkfollowing
Raise the vehicle immediately
the road test.
yV
page 325 .
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332
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Steering

AG. Volkswagen
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1. Appraisal of accident vehicles
333

General repair instructions
To achieve the desired results when performing repairs on the

steering box it is important to work with the greatest possible care
and cleanliness, and to use proper tools in good condition. Also
note the basic rules on safety when performing repair procedures.
A number of general notes on the individual repair procedures,
which were otherwise repeated in the relevant sections of the
manual, are summarised here. They apply for this particular work
shop manual.
For a description of the design and function of the steering as
sembly, see Self-study programme No. 317 ; The electrome
chanical power-assisted steering with double pinion .
2.1
Steering box
Thoroughly clean all unions and the adjacent areas before

disconnecting.
When installing the steering box, make sure that dowel
sleeves between bracket and steering box are seated correct
ly.
Place removed parts on a clean surface and cover them to
prevent them from getting dirty. Use sheeting and paper for
this purpose. Use only lint-free cloths.
Fit only clean parts; remove new parts from their packaging
only immediately prior to fitting.
Use only the grease and sealants with specified part numbers.
If repairs cannot be carried out immediately, carefully cover or
seal open components.
Two different types of steering boxes were fitted in model year
2004. Notes on identification page 398 . . Volkswage
n AG
wage
n AG d
oe
ks
olgeneration,
From model year 2009, a new, 3rd
steering box iss not gu
yV
ara
db
being used. Notes on differentiating
between
2nd
and 3rd
e
nte
is
eo
generations page 399 u.thor
ra
c
a
ss
Always renew gaskets and seals.
rrectness of i
t to the co
nform
spec
a
t
i
h re
o
n in
wit
thi
s
After removing all seals, inspect the contact faces on housings

and shafts for burrs and damage and remove all which are
found.
Completely remove all residue from liquid sealants from the
sealing surfaces, making sure that no residual sealant gets
into the steering box housing.
2.3
Nuts and bolts
Loosen and tighten bolts and nuts securing covers and hous
ings diagonally.
Avoid canting sensitive parts such as servo motor with control
unit. Loosen and tighten them diagonally in stages.
Specified torques given are for unlubricated nuts, bolts and
screws.
Always renew self-locking nuts and bolts.
AG.
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Rep. Gr.48 - Steering
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334
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Gaskets and seals
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2.2

2.4
Electrical components
At some point, you have probably received an electric shock when

touching a metal object. This is due to the electrostatic charge
accumulated by the human body. This charge can cause mal
functions if you touch the electric steering box components.
n AG. Volkswagen A
does
age
Before working on electrical ocomponents,
touch anGearthed
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object, such as a water pipe
ar
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e
s
i electrical connectors with bare hands. ante
the contact pins of the
r
o
e
Guided fault-finding, vehicle self-diag

nosis and test instruments
Before performing repair work on the electromechanical steer

ing box, determine the cause of damage as precisely as
possible using the vehicle diagnosis, testing and information
system -VAS 5051- in guided fault finding, vehicle self-di
agnosis and test instruments operating modes.
do
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2. General repair instructions
335

Steering wheel
3.1
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or
workshop
equipment required
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Removing and installing steering wheel
Special tools and
rrectness of i
t to the co
nform
spec
a
t
i
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o
n in
wit
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s
Removing
Remove driver side airbag unit Rep. Gr. 69 ; Airbag; Re

moving and installing driver side airbag unit .
Separate connections -1 and 2- for coil connector.
AG.
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rrectness of i
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Set steering wheel onto steering column.
AG.
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Centre markings of steering wheel and steering column

-arrows- must align.
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Installing
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Remove bolt -3- and pull steering wheel from steering column.
do
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Centre steering wheel (wheels in straight-ahead position).
3. Steering wheel
337

rrectness of i
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nform
spec
a
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Guide connector for steering angle sender -G85- into intended

opening in the base of steering wheel.
Join connector -1- with connector -2- of steering angle sender
-G85- .
Secure steering wheel with bolt -3-.
Specified torque
Component
Steering wheel to steering column
Always renew bolt
338
Specified torque
30 Nm + 90 further
Steering column, Golf
4.1
Assembly overview: steering column
Note
rrectness of i
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spec
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Running
gear,
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s
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1 - Bolt
20 Nm
2 - Cross member for steering

column
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ht
.
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4 - Bolt
20 Nm
moving
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page 346
5 - Steering column
page 339
6 - Handle
7 - Bolt
3 Nm
8 - Crash bar for brake pedal
9 - Crash bar for clutch pedal
10 - Bolt
30 Nm
moving
11 - Strut
page 348
12 - Bolt
20 Nm
13 - Bolt
20 Nm
4.2
Removing and installing steering col

umn
4. Steering column, Golf
339

Removing
Only the complete steering column is supplied as a replacement

part. Repair is not possible.
The steering lock housing can be transferred Electrical system;
Rep. Gr. 94 ; Ignition switch and lock cylinder .
Prote
cted
by
Wheels must be in straight-ahead position.

Failure to comply with these precautions may lead to subse
quent failure of the airbag system!
Turn wheels to straight-ahead position.
Pull down lever beneath steering column.
Swing steering column down as far as possible and pull out.
Press lever under steering column back up.
Remove airbag in steering wheel General body repairs, in
terior; Rep. Gr. 69 ; Airbag; Removing and installing driver
side airbag unit .
Remove steering wheel page 336 .
Remove steering column switch trim General body repairs,
interior; Rep. Gr. 68 ; Compartments, covers and trims; Re
moving and installing steering column trim .
340
AG.
Disconnect earth strap from battery Electrical system;

Rep. Gr. 27 ; Battery; Disconnecting and reconnecting
battery
agen
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.
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py
i
The following are prerequisites before starting work on the

electrical system and removing the steering wheel:
ht
rig
py
Co
t.
WARNING
rrectness of i
t to the co
nform
spec
atio
h re
n
wit
i
n
thi
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um
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a
c
ss

Remove left trim on driver side General body repairs, inte
rior; Rep. Gr. 68 ; Compartments, covers and trims; Removing
and installing left driver side trim .
Remove steering column switch Electrical system; Rep. Gr.
94 ; Steering column switch; Removing and installing steering
column switch .
Remove footwell vent below steering column Heating, air
conditioning; Rep. Gr. 80 ; Repairing heating .
Remove cable duct -1- below steering column. To do this,

raise lugs -arrow- slightly on both sides and pull cable duct out
from guide on steering column.
ility
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y li
an
pt
ce
ht
rig
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ng
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rrectness of i
t to the co
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m
spec
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n in
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l purpos
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Unscrew
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securing
nuts
-arrowsand
remove
footwell
trim
-1-.ee or
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341

kswagen Acol
Remove earth cable -arrow- and cable g-1G. Volsteering
Afrom
G do
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umn.
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Remove bolts -2-.
ua
ran
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or
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Remove ground cable -arrow- and cable -1- from steering col
umn.
Remove bolts -2-.
Prote
cted
by
c
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rig
ht
.
C
op
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agen
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by
Remove bolt -3- and remove crash bar for brake pedal -4-.
AG.
Lower steering column slightly and carefully pull out upwards.

Installing
Hook steering column into installation aid on mounting brack
et.
Align steering column to mounting bracket.

In the process, the pins -arrows A- of mounting bracket must be
aligned with and inserted into the holes -arrows B- of the steering
column
The steering column's correct installation position to the mounting
bracket is guaranteed only in this way.
342
ht
rig
py
Co
t.
Remove bolt -1- and remove crash bar for clutch pedal -2-.
rrectness of i
t to the co
nform
spec
a
t
i
h re
o
n in
wit
thi
sd
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en
es, in part or in w
l purpos
hole
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erm
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Vehicles with crash bars ss
by
ed
ris
o
th
au

Tighten steering column bolts -2-.
Attach earth wire -arrow- and wire -1- to steering column.
Vehicles with crash bars
Fit crash bar for clutch pedal -2- and tighten bolt -1-.
Fit crash bar for brake pedal -4- and tighten bolt -3-.
rrectness of i
t to the co
nform
spec
a
t
i
h re
o
n in
wit
thi
s
Attach ground cable -arrow- and cable -1- to steering column.
do
c
um
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Prote
cted
by
c
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p
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C
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343

Fit universal joint -2- onto steering box pinion and tighten bolt
-1-.
ility
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ce
rrectness of i
t to the co
nform
spec
a
t
ion
h re
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in t
his
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f
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Install footwell trim -1- and secure with nuts
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or
-arrows-. aut
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ss
Install cable duct -1- below steering column.
The lugs -arrow- must engage in the guide on both sides.
Install steering wheel page 336 .

Install airbag in steering wheel General body repairs, inte
rior; Rep. Gr. 69 ; Airbag; Removing and installing driver side
airbag unit .
Perform basic settings for steering angle sensor -G85- using
vehicle diagnosis, testing and information system -VAS
5051B- .
344
Prote
cted
Install left trim on driver side General body repairs, interior;

Rep. Gr. 68 ; Compartments, covers and trims; Removing and
installing left driver side trim .
AG.
Install steering column switch trim General body repairs,

agen
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c
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.
Co
py
i
Install steering column switch Electrical system; Rep. Gr.

column switch .
ht
rig
py
Co
t.
Install footwell vent below steering column Heating, air con

ditioning; Rep. Gr. 80 ; Repairing heating .
do
c
um
en
Join connector -1-.

Specified torques
Component
Specified torque

Use new bolt
30 Nm
Steering column to mounting bracket
20 Nm
4.3
Basic setting for steering angle sensor

G85 steering angle sender must be
checked after the following repair work:
When vehicle steering angle sensor -G85- is removed or re

newed,
If steering column was removed or renewed;
If steering lock housing with steering column switch was re
moved or renewed;
If steering box was removed or renewed;
If steering wheel was repositioned.
4.4
Handling and transporting steering col

umn
WARNING
Adherence to proper steering column handling is essen

tial.
Improper handling of steering column may damage the
steering column, leading to safety risks.
un
le
pe
rm
itte
d
ng
ht
rig
py
Co
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Prote
cted
by
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rig
ht.
C
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thi
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rp
fo
rrectness of i
t to the co
n
f
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m
spec
atio
h re
n in
wit
es, in part or in w
l purpos
hole
ercia
, is n
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com
universal joint.
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AG. Volkswagen AG d
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Proper steering column handling and transport
gu
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b
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Use both hands to transport steering column.
h
t
u
ra
c
sa
s
Hold steering column upper jacket tube and in area of upper
345

Improper handling of steering column
Transportation using the following parts leads to primary steering
column damage:
Clamping lever
2-
Weight compensation springs
3-
Deformation element
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by
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or
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s
s
rrectness of i
t to the co
n
f
o
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m
spec
atio
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n in
wit
es, in part or in w
l purpos
hole
ercia
, is n
m
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ility
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pt
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un
le
1-
Improper handling of steering column with safety risks

The following methods of handling will damage the universal joint
bushes of the lower steering column bearing:
Transporting the steering column with one hand on the jointed
shaft.
ng
Check all steering column parts for damage.

Checking function
Check that steering column turns smoothly and easily.
Check that steering column can be adjusted in reach and
height.
4.6
Removing and installing mounting

bracket
346
AG.
Visual check
agen
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Prote
cted
by
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ht
.
C
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Checking steering column for damage
ht
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4.5
thi
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rp
fo
Bending the joints more than 90.

Removing
Remove steering column page 351 .
en AG
G. Volkswagsystem;
Remove dash panel insert
AElectrical
doesRep. Gr. 90 ;
agen
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not
Dash panel insert; Removing
and installing dash
panel
insert .
Vol
g
y
db
ua
ran
tee
se
ri-arrows Remove bolts
under bracket.
ho
or
ac
Unscrew bolt -arrow A-.

Remove bolts -arrows B- securing bracket to body.
Note
ht
rig
py
Co
t.
Bolts -arrows B- are screwed in from cross member.
rrectness of i
t to the co
nform
spec
a
t
i
h re
o
n in
wit
thi
s
Push connector -1- in -direction of arrow- and remove from

support in mounting bracket.
do
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erm
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t
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ss
agen
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Prote
cted
by
c
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rig
ht
.
C
op
yi
Unscrew bolts -1- and -2- and remove mounting bracket from
body.
AG.
Installing
347

Insert mounting bracket and screw in bolts -1- and -2-.
Install bolts -arrows B-.

Note
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AG. Volkswagen AG d
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ss
Screw in bolt -arrow A-.
Insert connector -1- into support in mounting bracket and push

to stop opposite -direction of arrow-.
Install bolts -arrows- under bracket.
Install steering column page 354 .
Install dash panel insert Electrical system; Rep. Gr. 90 ;

Dash panel insert; Removing and installing dash panel insert .
5051B- .
Removing and installing strut
348
Prote
cted
by
4.7
AG.

Strut to mounting bracket
agen
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.
Co
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Component
ht
rig
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Co
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Specified torques
Specified torque
20 Nm
20 Nm
20 Nm
rrectness of i
t to the co
nform
spec
at
i
h re
o
n
wit
in t
his
d
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en
es, in part or in w
l purpos
hole
ercia
, is n
m
m
ot p
r co
erm
o
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t
a
itte
v
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du
p
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nl
f
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g
n
Bolts -arrows B- are screwed in from cross member.

ole,
cial p
is n
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a
itte
ir v
du
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f
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Removings a
s
Remove plenum chamber bulkhead General body repairs,

exterior; Rep. Gr. 50 ; Assembly overview - plenum chamber
bulkhead .
rrectness of i
t to the co
nform
spec
a
t
i
h re
o
n in
wit
thi
s
Remove bolt -arrow- in plenum chamber.

Remove bolts -1-.
ht
rig
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Prote
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.
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Installing
do
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Remove bolt -2- and remove strut -3-.
Secure strut to body by tightening bolt -arrow-.
349

Install securing bolt -2- and tighten.
Tighten bolt -1- for strut -3-.
Install plenum chamber bulkhead General body repairs,
bulkhead .
5051B- .
AG.
ole,
cial p
is n
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m
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a
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Prote
cted
by
c
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rig
ht.
C
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rrectness of i
t to the co
nform
spec
a
t
i
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n in
wit
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s
20 Nm
do
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350
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Strut to body
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Specified torque
o
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c
20 Nm
ss
ht
rig
py
Co
t.
Specified torques

Steering column, Golf Plus, Cross

Golf
5.1
Assembly overview: steering column

Note

1 - Bolt
20 Nm
2 - Cross member for steering
column
page 358
4 - Bolt
. Volkswagen AG
gen AG
does
swa
not
20 Nm by Volk
gu
ara
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s
Always
renew after re
ri
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moving
ra
a
ss
un
le
6 - Handle
rrectness of i
t to the co
n
f
o
r
mat
spec
ion
h re
wit
in
7 - Bolt
3 Nm
8 - Crash bar for brake pedal
9 - Crash bar for clutch pedal
10 - Bolt
30 Nm
moving
ng
AG.
Prote
cted
by
5.2
agen
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13 - Bolt
20 Nm
ht
rig
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12 - Bolt
20 Nm
thi
sd
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en
11 - Strut
page 360
r
te o
iva
r
rp
fo
es, in part or in w
l purpos
hole
ercia
, is n
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ot
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pe
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itte
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ility
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5 - Steering column
page 351
Removing and installing steering col

umn

5. Steering column, Golf Plus, CrossGolf
351

ility
ab
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rrectness of i
t to the co
nform
spec
a
t
ion
h re
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in t
his
Removing
AG. Volkswagen AG d
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erm
o
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t
a
itte
riv
du
p
r
o
nl
f
e
ng
Only the complete steering column is supplied as a replacement

part. Repair is not possible.
The steering lock housing can be transferred Electrical system;
Rep. Gr. 94 ; Ignition switch and lock cylinder .
WARNING
Prote
cted
by
Turn wheels to straight-ahead position.

Pull down lever beneath steering column.
Swing steering column down as far as possible and pull out.
Press lever under steering column back up.
Remove airbag in steering wheel General body repairs, in
terior; Rep. Gr. 69 ; Airbag; Removing and installing driver
side airbag unit .
Remove steering wheel page 336 .
Remove steering column switch trim General body repairs,
352
AG.
Failure to comply with these precautions may lead to subse

quent failure of the airbag system!
agen
lksw
Vo
by
cop
yri
gh
t
.
Co
py
i
Wheels must be in straight-ahead position.
ht
rig
py
Co
t.
Disconnect earth strap from battery Electrical system;

Rep. Gr. 27 ; Battery; Disconnecting and reconnecting
battery
do
c
um
en
The following are prerequisites before starting work on the

electrical system and removing the steering wheel:

Remove left trim on driver side General body repairs, inte
rior; Rep. Gr. 68 ; Compartments, covers and trims; Removing
and installing left driver side trim .
Remove steering column switch Electrical system; Rep. Gr.
column switch .
Remove footwell vent below steering column Heating, air
conditioning; Rep. Gr. 80 ; Repairing heating .
pe
rm
itte
d
es n
wage
ot g
olks
V
ua
by
d
ran
ir se
tee
o
h
t
or
ac
au
s
s
es, in part or in w
l purpos
hole
ercia
, is n
m
ot
com
rrectness of i
t to the co
n
f
o
r
m
spec
atio
h re
n in
wit
Remove cable duct -1- below steering column. To do this,

raise lugs -arrow- slightly on both sides and pull cable duct out
from guide on steering column.
ility
ab
y li
an
pt
ce
un
le
ht
rig
py
Co
t.
ng
thi
sd
o
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m
en
r
te o
iva
r
rp
fo
Unscrew securing nuts -arrows- and remove footwell trim -1-.
agen
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Vo
by
AG.
Prote
cted
by
c
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py
rig
ht.
C
op
yi
353

Remove earth cable -arrow- and cable -1- from steering col
umn.
Remove bolts -2-.
ility
ab
y li
an
pt
ce
Remove bolts -2-.
rrectness of i
t to the co
nform
spec
a
t
ion
h re
wit
in t
his
Remove bolt -1- and remove crash bar for clutch pedal -2-.
Remove bolt -3- and remove crash bar for brake pedal -4-.
Lower steering column slightly and carefully pull out upwards.
Hook steering column into installation aid on mounting brack
et.
agen
lksw
Vo
by
AG.
Prote
cted
by
c
o
p
yri
gh
t.
C
op
yi
Align steering column to mounting bracket.
In the process, the pins -arrows A- of mounting bracket must be

aligned with and inserted into the holes -arrows B- of the steering
column
The steering column's correct installation position to the mounting
bracket is guaranteed only in this way.
354
ht
rig
py
Co
t.
Installing
do
c
um
en
ole,
cial p
is n
mer
m
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c
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t
a
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f
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Remove ground cableuth-arrowand cable -1- from steering col
ra
a
c
umn.
ss

Attach earth wire -arrow- and wire -1- to steering column.
Fit crash bar for clutch pedal -2- and tighten bolt -1-.
Fit crash bar for brake pedal -4- and tighten bolt -3-.
rrectness of i
t to the co
nform
spec
at
i
h re
o
n
wit
in t
his
d
o
cu
m
en
es, in part or in w
l purpos
hole
ercia
, is n
m
m
ot p
r co
erm
o
e
t
a
itte
v
i
r
du
p
or
nl
f
e
ng
Attach ground cable -arrow- and cable -1- to steering column.
ility
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pt
ce
es n
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AG.
Prote
cted
b
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c
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t
.
Co
py
i
355

Fit universal joint -2- onto steering box pinion and tighten bolt
-1-.
rrectness of i
t to the co
n
f
o
r
mat
spec
ion
h re
wit
in
es, in part or in w
l purpos
hole
ercia
, is n
m
ot
com
pe
rm
itte
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un
le
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Install footwell
AG. Volkswagen AG d
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h
t
u
ra
a
c
trim
ss -1- and secure with nuts -arrows-.
Install cable duct -1- below steering column.
ng
ht
rig
py
Co
t.
agen
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AG.
Prote
cted
by
c
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C
op
yi
Join connector -1-.

Install footwell vent below steering column Heating, air con
ditioning; Rep. Gr. 80 ; Repairing heating .
Install steering column switch Electrical system; Rep. Gr.
column switch .
Install steering column switch trim General body repairs,
Install left trim on driver side General body repairs, interior;
Rep. Gr. 68 ; Compartments, covers and trims; Removing and
installing left driver side trim .
Install steering wheel page 336 .
Install airbag in steering wheel General body repairs, inte
rior; Rep. Gr. 69 ; Airbag; Removing and installing driver side
airbag unit .
5051B- .
356
thi
sd
o
cu
m
en
r
te o
iva
r
rp
fo
The lugs -arrow- must engage in the guide on both sides.

Specified torques
es n
wage
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olks
V
ua
by
d
ran
Universal joint to steering
box
ir se
tee
o
Use new boltth
or
ac
au
s
s
Component
When vehicle steering angle sensor -G85- is removed or re

newed,
If steering column was removed or renewed;
If steering lock housing with steering column switch was re
moved or renewed;
If steering box was removed or renewed;
If steering wheel was repositioned.
Handling and transporting steering col

umn
Prote
cted
by
c
o
py
rig
ht.
C
op
yi
WARNING
ht
rig
py
Co
t.
5.4
do
c
um
en
ole,
cial p
is n
mer
m
ot p
o
c
r
erm
o
e
t
a
itte
iv
du
pr
r
o
nl
f
e
ng
Basic setting for steering angle sensor

G85 steering angle sender must be
checked after the following repair work:
20 Nm
rrectness of i
t to the co
nform
spec
a
t
ion
h re
wit
in t
his
5.3
30 Nm
ility
ab
y li
an
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ce
Specified torque
agen
lksw
Vo
by
Adherence to proper steering column handling is essen

tial.
AG.
Improper handling of steering column may damage the

steering column, leading to safety risks.
Proper steering column handling and transport
Use both hands to transport steering column.
Hold steering column upper jacket tube and in area of upper
universal joint.
357

Improper handling of steering column
Transportation using the following parts leads to primary steering
column damage:
1-
Clamping lever
2-
Weight compensation springs
3-
Deformation element
Improper handling of steering column with safety risks

Following methods of handling will damage universal joint bushes
of lower steering column bearing:
Transporting steering column with one hand on jointed shaft.
Bending joints more than 90.
ole,
cial p
is n
mer
m
ot p
o
c
r
erm
o
e
t
a
itte
iv
du
pr
r
o
nl
f
e
ng
rrectness of i
t to the co
nform
spec
a
t
ion
h re
wit
in t
his
5.5
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Checking steering column for damage
Visual check
Check all steering column parts for damage.

Checking function
Check that steering column turns smoothly and easily.

Check that steering column can be adjusted in reach and
height.
5.6
Removing and installing mounting

bracket
AG.
Prote
cted
by
agen
lksw
Vo
by
cop
yri
gh
t
.
Co
py
i
ht
rig
py
Co
t.
358
do
c
um
en

ole,
cial p
is n
mer
m
ot p
r co
erm
o
e
t
itte
ir va
du
p
or
nl
f
e
ng
ility
ab
y li
an
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ce
AG. Volkswagen AG d
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a
c
Removing
ss
rrectness of i
t to the co
nform
spec
a
t
i
h re
o
n in
wit
thi
s
Remove dash panel insert Electrical system; Rep. Gr. 90 ;

Remove bolts -arrows- under bracket.
agen
lksw
Vo
by
AG.
Prote
cted
by
cop
yri
gh
t
.
Co
py
i
Note
ht
rig
py
Co
t.
Remove bolts -arrows- from bracket to body.
do
c
um
en
Push connector -1- in -direction of arrow- and remove from

support in mounting bracket.
Bolts -arrows- are screwed in from cross member.
Unscrew bolt -1- and remove mounting bracket from body.

Installing
359

Insert mounting bracket and screw bolt -1- in.
Install bolts -arrows-.

Note
Bolts -arrows- are screwed in from cross member.
ility
ab
y li
an
pt
ce
pe
rm
itte
d
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le
AG. Volkswagen AG d
agen
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not
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Insert connector -1- into support in mounting
bracket and push
V
gu
by
ara
d
to stop opposite -direction of arrow-.
nte
ir se
o
eo
h
t
u
ra
a
c
ss
rrectness of i
t to the co
n
f
o
r
m
spec
atio
h re
n in
wit
es, in part or in w
l purpos
hole
ercia
, is n
m
ot
com
Install bolts -arrows- under bracket.

Install dash panel insert Electrical system; Rep. Gr. 90 ;
5051B- .
r
te o
iva
r
rp
fo
Specified torque
ng

360
AG.
Removing and installing strut
agen
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Vo
by
Prote
cted
by
c
o
py
rig
ht.
C
op
yi
5.7
thi
sd
o
cu
m
en
Component
20 Nm
20 Nm
20 Nm
ht
rig
py
Co
t.
Specified torques

Removing
Remove plenum chamber bulkhead General body repairs,
bulkhead .
Remove bolt -arrow- in plenum chamber.
olkswagen AG
en AG. V
does
not
gu
ara
nte
eo
ra
c
wag 351 .
Remove steering column o
lkspage
rrectness of i
t to the co
nform
spec
a
t
i
h re
o
n in
wit
thi
s
ole,
cial p
is n
mer
m
ot p
o
c
r
erm
te o
a
itte
ir v
du
p
or
nl
f
e
ng
ility
ab
y li
an
pt
ce
yV
db
ise
r
tho
au
s
s
Remove bolt -1-.

Remove strut -2-.
Installing
do
c
um
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ht
rig
py
Co
t.
b
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c
op
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.
Co
py
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Secure strut to body by tightening bolt -arrow-.

agen
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Vo
by
AG.
Prote
cted
361


5051B- .
cop
yri
gh
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.
Co
py
i
362
20 Nm
20 Nm
Prote
cted
by

Strut to body
Specified torque
AG.
Component
agen
lksw
Vo
by
Specified torques
rrectness of i
t to the co
nform
spec
at
i
h re
o
n
wit
in t
his
d
o
cu
m
en
es, in part or in w
l purpos
hole
ercia
, is n
m
m
ot p
r co
erm
o
e
t
a
itte
v
i
r
du
p
or
nl
f
e
g
n
ility
ab
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an
pt
ce
Install plenum chamber bulkhead General

bulkhead .
ht
rig
py
Co
t.
Install securing bolt -1- and tighten.
AG. Volkswagen AG d
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body repairs,

Electromechanical steering box up to

model year 2008
AG. Volkswagen AG d
agen
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Assembly overview - electromechanical steering box, left-hand drive (1st

and 2nd generations) up to model year 2008
ility
ab
y li
an
pt
ce
Note
There are no 2nd generation steering boxes available as spare parts.
If the steering box has to be replaced, a new 3rd generation steering box will have to be fitted.
rrectness of i
t to the co
nform
spec
a
t
ion
h re
wit
in t
his
ole,
cial p
is n
mer
m
ot p
o
c
r
erm
o
e
t
a
itte
riv
du
p
r
o
nl
f
e
ng
6.1
In addition, the electrical wiring harness from the E-box to the steering box will then also have to be renewed.
This is included with the order for the new steering box via the Electronic parts catalogueETKA .
The electrical wiring harness will be delivered with the cable for the service interval display.
In vehicles without a service interval display, the unused 3-pin connector must be sealed by a flat contact
housing with connector position assurance -1J0 973 803- Electronic parts catalogueETKA .
agen
lksw
Vo
by
AG.
Prote
cted
by
4 - Power steering box

With power steering
control unit -J500 With electromechanical
power steering motor V187 With steering moment
sender -G269 Can be checked using
guided fault finding with
the vehicle diagnosis,
testing and information
system -VAS 5051/ Exchanging 1st genera
tion steering box for 2nd
generation steering box
page 400
page 366
Observe notes
page 363 .
c
o
p
yri
gh
t.
C
op
yi
3 - Wiring
do
c
um
en
2 - Hexagon bolt
30 Nm
moving
ht
rig
py
Co
t.
1 - Universal joint

6 - Nut
M12 x 1.5
20 Nm + 90 further
Self-locking
moving
6. Electromechanical steering box up to model year 2008
363

7 - Subframe with brackets
8 - Bolt
50 Nm + 90 further
Always renew clamp for steering box
9 - Shield
10 - Bolt
6 Nm
Self-locking
agen
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AG.
Prote
cted
by
cop
yri
gh
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.
Co
py
i
ht
rig
py
Co
t.
do
c
um
en
364
rrectness of i
t to the co
nform
spec
a
t
i
h re
o
n in
wit
thi
s
ole,
cial p
is n
mer
m
ot p
r co
erm
o
e
t
itte
ir va
du
p
or
nl
f
e
ng
ility
ab
y li
an
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ce
AG. Volkswagen AG d
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a
c
ss

6.2
Assembly overview - electromechanical steering box, right-hand drive (2nd

generation) up to model year 2008
Note
There are no 2nd generation steering boxes available as spare parts.

If the steering box has to be replaced, a new 3rd generation steering box will have to be fitted.
In addition, the electrical wiring harness from the E-box to the steering box will then also have to be renewed.
This is included with the order for the new steering box via the Electronic parts catalogueETKA .
The electrical wiring harness will be delivered with the cable for the service interval display.
In vehicles without a service interval display, the unused 3-pin connector must be sealed by a flat contact
housing with connector position assurance -1J0 973 803- Electronic parts catalogueETKA .
1 - Universal joint
4 - Shield
rrectness of i
t to the co
nform
spec
a
t
ion
h re
wit
in t
his
5 - Torx bolt
6 Nm
Self-locking
ility
ab
y li
an
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ce
3 - Wiring
AG. Volkswagen AG d
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m
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r
erm
o
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t
a
itte
riv
du
p
r
o
nl
f
e
ng
2 - Bolt
M8 x 35
30 Nm
moving
6 - Clamp
moving
do
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um
en
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AG.
Prote
cted
by
cop
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gh
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.
Co
py
i

With power steering
power steering motor V187 With steering torque
sender -G269 Can be checked in gui
ded fault finding of the
vehicle diagnosis, test
ing and information sys
tem -VAS 5051B Removing and installing
page 374
Observe notes
page 365 .
ht
rig
py
Co
t.
7 - Rubber mounting
9 - Connecting piece
11 - Nut
M12 x 1.5
50 Nm
365

Self-locking
12 - Subframe
13 - Bolt
M10 x 70
50 Nm + 90 further
6.3
Removing and installing steering box, left-hand drive (1st and 2nd genera
tions) up to model year 2008

equipment required
1331-
ole,
cial p
is n
mer
m
ot p
r co
erm
o
e
t
itte
ir va
du
p
or
nl
f
e
g
n
AG.
Prote
cted
by
c
o
py
rig
ht
.
C
op
yi
rrectness of i
t to the co
nform
spec
atio
h re
n
wit
i
n
thi
sd
o
c
um
en
366
ility
ab
y li
an
pt
ce
agen
lksw
Vo
by
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wage
ot g
olks
V
ua
by
d
ran
ir se
tee
o
h
t
or
ac
au
s
s
ht
rig
py
Co
t.

1332-

Removing steering box
Note
There are no 2nd generation steering boxes available as spare
parts.
If the steering box has to be replaced, a new 3rd generation
steering box will have to be fitted.
In addition, the electrical wiring harness from the E-box to the
steering box will then also have to be renewed. This is included

with the order for the new steering box via the Electronic
parts catalogueETKA .
The electrical wiring harness will be delivered with the cable
for the service interval display.
In vehicles without a service interval display, the unused 3-pin
connector must be sealed by a flat contact housing with con

nector position assurance -1J0 973 803- Electronic parts
catalogueETKA .
Disconnect battery. Rep. Gr. 27 ; Battery; Disconnecting

and reconnecting battery.
rrectness of i
t to the co
nform
spec
a
t
ion
h re
wit
in t
his
ly.
Caution
do
c
um
en
ole,
cial p
is n
mer
m
ot p
o
c
r
erm
o
e
t
a
itte
riv
du
p
r
o
nl
f
e
ng
ility
ab
y li
an
pt
ce
AG. Volkswagen AG d
agen
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h
ut
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c
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ht
rig
py
Co
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agen
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Vo
by
AG.
Prote
cted
b
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c
op
yri
gh
t
.
Co
py
i
367

Press track rod ball joint off wheel bearing housing with
-3287A-.

-14-.
Remove exhaust system retainer on subframe.
ole,
cial p
is n
mer
m
ot p
o
c
r
erm
o
e
t
a
itte
riv
du
p
r
o
nl
f
e
ng
agen
lksw
Vo
by
AG.
Prote
cted
by
c
o
py
rig
ht
.
C
op
yi
rrectness of i
t to the co
nform
spec
a
t
ion
h re
wit
in t
his
do
c
um
en
368
ility
ab
y li
an
pt
ce
Remove
ht
rig
py
Co
t.
Remove
es n
wage
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olks
V
y
ua
db
ran
e
ir s shield.
bolts -arrows- on heat
tee
o
h
t
or
u
ac
a
heat shield from
ss subframe.

Volkswa
gen AG
G. steering
gen Afor
Now remove bolts -3, 6, 11 and
boxdand
oes antiwa16not
olks
V
roll bar.
gu
by
a
d
se
ran
tee
or
ac
ri
Fix position of subframe
and brackets. page 16
tho

and subframe.
rrectness of i
t to the co
nform
spec
a
t
i
h re
o
n in
wit
thi
s

frame.
do
c
um
en
ole,
cial p
is n
mer
m
ot p
r co
erm
o
e
t
itte
ir va
du
p
or
nl
f
e
ng
ility
ab
y li
an
pt
ce
au
ss
ht
rig
py
Co
t.
agen
lksw
Vo
by
AG.
Prote
cted
by
c
o
py
rig
ht
.
C
op
yi

369

Remove heat shield -1- over steering box.
Remove cable guide from subframe -arrow-.
. Volkswagen AG
gen AG
does
not
gu
y
b
ara
d
e
nte
is
Disconnect all electrical connections
on
steering
box.
r
o
eo
h
ut
ra
a
c
s
Lower subframe using engine
and
gearbox
jack
-V.A.G
1383
s
a
Unclip all remaining cable clips on steering
ksw box.
Vol
A- far enough that the steering box can be removed.
ility
ab
y li
an
pt
ce
ng
AG.
agen
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Vo
by
Prote
cted
by
c
o
py
rig
h
t
.
Co
py
i
ht
rig
py
Co
t.
370
thi
sd
o
cu
m
en
r
te o
iva
r
rp
fo
rrectness of i
t to the co
n
f
o
r
mat
spec
ion
h re
wit
in
es, in part or in w
l purpos
hole
ercia
, is n
m
ot
com
pe
rm
itte
d
un
le

Set steering box down as illustrated.
This prevents damage to the control unit -1-.
Installing steering box
Threaded sleeves of steering box must seat in holes in left brack
et.
Note
erwise, this can result in water leaks and/or noise.

Before inserting subframe bolts, position steering box on sub
frame and insert bolts for steering box and anti-roll bar.
Connect electrical connections to steering box.
Note

Bolt universal joint ntoAG
steering
. Volkswagbox.
en A
G do
es
ge
swa
not
olk
Connect bbattery.
Rep. Gr. 27 ; Battery;
Disconnecting
and
gu
yV
ara
d
e
reconnecting
battery.
nte
ris
tho
eo
ole,
cial p
is n
mer
m
ot p
r co
erm
o
e
t
itte
ir va
du
p
or
nl
f
e
ng
ility
ab
y li
an
pt
ce
ra
au out basic setting for -G85 - steering angle sender Carry
using
c
ss
vehicle diagnosis, testing and information system -VAS 5051 Vehicle diagnosis, testing and information system VAS
5051.
rrectness of i
t to the co
nform
spec
a
t
i
h re
o
n in
wit
thi
s
After installation, position of steering wheel must be checked dur

ing road test.
If steering wheel is not in straight-ahead position or if a new steer
ing box was installed, front axle tracking must be checked and if
necessary adjusted!
Check wheel alignment. page 305
If new steering box has been installed, adapt power steering con
trol unit -J500- using vehicle diagnostic, testing and information
system -VAS 5051- .
Carry out basic setting for power steering control unit -J500using vehicle diagnosis, testing and information system -VAS
5051- Vehicle diagnosis, testing and information system
VAS 5051.
do
c
um
en
ht
rig
py
Co
t.
agen
lksw
Vo
by
AG.
Prote
cted
b
y
c
op
yri
gh
t
.
Co
py
i
371

Note
If parking aid 2 is fitted in the vehicle, the power steering con
trol unit -J500- must be recoded following the installation of a

new steering box Vehicle diagnosis, testing and information
system VAS 5051.
Parking aid 2 is fitted only in vehicles having 2nd generation
steering boxes.
Specified torques
Component
Specified torque
Subframe to body
Use new bolts
70 Nm + 90

Use new bolts
20 Nm + 90

Use new nut
65 Nm

Use new nuts
60 Nm

link
Use new nuts
100 Nm
Shield to subframe
6 Nm

Use new bolts
50 Nm + 90
Always renew clamp
6 Nm
un
le

Use new nut
20 Nm + 90
AG.
agen
lksw
Vo
by
Prote
cted
by
c
o
py
rig
ht.
C
op
yi
372
ht
rig
py
Co
t.
r
fo
ng

Engine; Rep. Gr. 26
rrectness of i
t to the co
nform
spec
a
t
i
h re
o
n in
wit
thi
sd
o
cu
m
en
ole,
cial p
is n
mer
m
ot p
r co
erm
o
e
t
a
itte
v
i
r
d
p
Shield to steering box

30 Nm
gu
ara
nte
eo
ra
c
ility
ab
y li
an
pt
ce

Use new bolt
by
ed
ris
o
th
au
ss
AG. Volkswagen AG d
agen
oes
ksw
not
l
o
V

Caution
Rep. Gr. 34 .
boxes.
Bolt
Specified torque

Use new bolt
40 Nm + 90 further
M10 x 35 strength
Use new bolt
50 Nm + 90 further
es n
wage
ot g
olks
V
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ua
b
class 10.9
d
ran
ise
tee
r
o
h
t
or
u
ac
a
ss
40 Nm + 90 further
ole,
cial p
is n
mer
m
ot p
o
c
r
erm
o
e
t
a
itte
iv
du
pr
r
o
nl
f
e
ng
ility
ab
y li
an
pt
ce

Use new bolt
50 Nm + 90 further
rrectness of i
t to the co
nform
spec
a
t
ion
h re
wit
in t
his

Use new bolt
do
c
um
en
ht
rig
py
Co
t.
agen
lksw
Vo
by
AG.
Prote
cted
by
c
o
py
rig
ht
.
C
op
yi
373

6.4
Removing and installing steering box, right-hand drive (2nd generation) up

to model year 2008

equipment required
es n
wage
ot g
olks
V
y
ua
b
d
ran
ise
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Removing
Note
There are no 2nd generation steering boxes available as spare
parts.
If the steering box has to be replaced, a new 3rd generation
steering box will have to be fitted.
es n
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steering box will then also have to be renewed. Thisd bisy Vincluded
ran
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with the order for the new steering box via the o
tee
ris Electronic
h
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parts catalogueETKA .
ac
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ss
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In addition, the electrical wiring harness from the E-box
towathe
olks
for the service interval display.
In vehicles without a service interval display, the unused 3-pin
connector must be sealed by a flat contact housing with con

nector position assurance -1J0 973 803- Electronic parts
catalogueETKA .
Disconnect battery Rep. Gr. 27 ; Battery; Disconnecting

and reconnecting battery .
Remove nuts -1- and remove footwell trim -2-.
agen
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cop
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.
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Prote
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Remove bolt -1- for universal joint and pull universal joint -2off steering box.
rrectness of i
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nform
spec
atio
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n
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n
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The electrical wiring harness will be delivered with the cable
ly.
Caution
Leave nut screwed a few turns onto pin to protect thread.
375

joint puller -3287A- and remove nut now.
rrectness of i
t to the co
nform
spec
a
t
ion
h re
wit
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his
ole,
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ility
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Prote
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376
AG.
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-13-.
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Remove coupling rod from anti-roll bar.
AG. Volkswagen AG d
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Remove bolts -5- and -6- for steering box.
rrectness of i
t to the co
nform
spec
a
t
ion
h re
wit
in t
his
Remove bolts -7- and -8- for anti-roll bar.

do
c
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by
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377

Position
engine and gearbox jack -V.A.G 1383 A- under subframe.
Remove bolts -9- and -10- and lower subframe slightly. In the
process, observe electrical wiring.
rrectness of i
t to the co
n
f
o
r
m
spec
atio
h re
n in
wit
es, in part or in w
l purpos
hole
ercia
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Unclip all remaining cable clips on steering box.

Disconnect connectors from steering box.
ng
AG.
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Prote
cted
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.
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378
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fo
Lower subframe carefully with engine/gearbox jack -V.A.G

1383 A- .

Now lift anti-roll bar -1- forwards over subframe -2- and down
while turning anti-roll bar slightly.
es n
wage
ot g
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V
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by
d
ran
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au
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rig
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by
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ht.
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fo
rrectness of
i
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o
rma
spec
tion
h re
wit
in
es, in part or in w
l purpos
hole
ercia
, is n
m
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com
pe
rm
itte
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ility
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un
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Unbolt steering box from subframe.
379

Installing
Threaded sleeve of steering box must be located in subframe
hole.
Note
After fitting the steering box to the universal joint, make sure
that the seal is not kinked when lying against the assembly
plate and that the opening to the footwell is correctly sealed.
Otherwise, this can result in water leaks and/or noise.

frame and insert bolts for steering box and anti-roll bar.
Bolt universal joint to steering box.
Connect battery Rep. Gr. 27 ; Battery; Disconnecting and
reconnecting battery .
Carry out basic setting for steering angle sender -G85- using
5051.
ing road test.
n AG. Volkswagen A
G do
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ran
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or
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swa
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If steering wheel is crooked or a new steering boxbwas
y V installed,
d
e
wheels must be aligned.
ris
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Perform wheel alignment page 305 .ss au

pe
rm
itte
d
system -VAS 5051- .
es, in part or in w
l purpos
hole
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Note
ng
AG.
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380
70 Nm + 90
Prote
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Subframe to body
Use new bolts
Specified torque
thi
sd
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en
Component
ht
rig
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Co
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Specified torques
r
te o
iva
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rp
fo
If parking aid 2 is fitted in the vehicle, the power steering control

unit -J500- must be recoded Vehicle diagnosis, testing and in
formation system VAS 5051.
rrectness of i
t to the co
n
f
o
r
m
spec
atio
h re
n in
wit
VAS 5051.

Component
Specified torque

Use new bolts
20 Nm + 90

Use new nut
65 Nm

Use new nuts
60 Nm

link
Use new nuts
100 Nm
Shield to subframe
6 Nm

Use new bolts
50 Nm + 90
Always renew clamp

Use new bolt
30 Nm

AG. Volkswagen AG d
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Vol
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db
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Caution
Rep. Gr. 34 .
boxes.
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by
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.
C
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Use new bolt
ht
rig
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Co
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Use new bolt
do
c
um
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Bolt
rrectness of i
t to the co
nform
spec
a
t
ion
h re
wit
in t
his
ole,
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is n
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m
ot p
o
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r
erm
o
te
itte
iva
r
du
p
or
nl
f
e
ng

Engine; Rep. Gr. 26
20 Nm + 90
ility
ab
y li
an
pt
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r
Track rod ballthojoint
to wheel bearing housing
u
a
Use new
nut
s
s
6 Nm
gu
ara
nte
eo
ra
c
Specified torque
40 Nm + 90 further
50 Nm + 90 further

Use new bolt
40 Nm + 90 further

Use new bolt
50 Nm + 90 further
381

AG.
agen
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Prote
cted
by
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ht
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382
rrectness of i
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at
i
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en
es, in part or in w
l purpos
hole
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erm
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t
a
itte
v
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nl
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ility
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db
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o
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or
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ac
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ss

Electromechanical steering box after

model year 2009
7.1
oes
wa
nobox,
Assembly overview - electromechanical
steering
left-hand drive (3rd
olks
t gu
yV
b
ara
d
e
nte
generation) after model
is year 2009
or
e
un
le
or
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rm
itte
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2 - Universal joint
th
au
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1 - Wiring
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thi
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With power steering
power steering motor V187 With steering angle
sender -G85 With steering torque
sender -G269 Can be checked in gui
ded fault finding of the
page 385
rrectness of i
t to the co
n
f
o
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mat
spec
ion
h re
wit
in
4 - Torx bolt
6 Nm
Self-locking
es, in part or in w
l purpos
hole
ercia
, is n
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com
3 - Bolt
M8 x 35
30 Nm
moving
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.
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7 - Wheel bearing housing left

8 - Nut
M12 x 1.5
20 Nm + 90 further
Self-locking
9 - Bolt
50 Nm + 90 further
10 - Subframe
11 - Wheel bearing housing right
7. Electromechanical steering box after model year 2009
383

7.2
Assembly overview - electromechanical steering box, right-hand drive (3rd

generation) after model year 2009
1 - Universal joint
2 - Bolt
M8 x 35
30 Nm
moving
3 - Wiring
4 - Shield
5 - Torx bolt
6 Nm
Self-locking
7 - Wheel bearing housing left

8 - Nut
M12 x 1.5
20 Nm + 90 further
Self-locking
9 - Bolt
50 Nm + 90 further
10 - Subframe
11 - Wheel bearing housing right
AG.
agen
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cted
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384
rrectness of i
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nform
spec
atio
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n
wit
i
n
thi
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en
ole,
cial p
is n
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r co
erm
o
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t
itte
ir va
du
p
or
nl
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n
ility
ab
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With power steering
power steering motor V187 With steering angle
sender -G85n AG. Volkswagen AG do
es n
wage
With steering torque
ot g
olks
V
ua
sender -G269by
d
ran
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o
Can be checked in gui
h
t
or
ac
au
ded fault finding ofssthe
page 391

Volkswaaxles,
gen AGsteering - Edition 08.2009
. gear,
Running
G
A
n
e
g
d
oes
not
gu
ara
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Removing and installing steering box, left-hand drive (3rd generation) after
model year 2009
ility
ab
y li
an
pt
ce
ole,
cial p
is n
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m
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o
c
r
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o
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t
a
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riv
du
p
r
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nl
f
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ng
7.3
wa
olks
yV
b
ed
ris
tho
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a
ss

equipment required

1332-
rrectness of i
t to the co
nform
spec
a
t
ion
h re
wit
in t
his

1331-
Engine and gearbox jack V.A.G 1383 A Ball joint puller -3287 A-
do
c
um
en
ht
rig
py
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t.
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by
AG.
Prote
cted
b
y
c
op
yri
gh
t
.
Co
py
i
Removing steering box

Disconnect battery. Rep. Gr. 27 ; Battery; Disconnecting
and reconnecting battery.
385

ly.
Caution
Press track rod ball joint off wheel bearing housing with
-3287A-.

-14-.
ole,
cial p
is n
mer
m
ot p
r co
erm
o
e
t
itte
ir va
du
p
or
nl
f
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n
AG.
agen
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Prote
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by
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ht
.
C
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386
rrectness of i
t to the co
nform
spec
atio
h re
n
wit
i
n
thi
sd
o
c
um
en
ility
ab
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an
pt
ce
es n
wage
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V
y
ua
db
ran
e
ir s
tee
o
h
t
or
u
ac
a
ss
ht
rig
py
Co
t.
Remove exhaust system retainer on subframe.

Remove bolts -3- and -6- for steering box.
Remove bolts -11- and -16- for anti-roll bar.

Fix position of subframe and brackets. page 16
rrectness of i
t to the co
nform
spec
at
i
h re
o
n
wit
in t
his
d
o
cu
m
en
es, in part or in w
l purpos
hole
ercia
, is n
m
m
ot p
r co
erm
o
e
t
a
itte
v
i
r
du
p
or
nl
f
e
g
n
ility
ab
y li
an
pt
ce
es n
wage
ot g
olks
V
y
ua
b
d
ran
ise
tee
r
o
h
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or
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ac
a
ss

frame.
and subframe.
ht
rig
py
Co
t.
agen
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Vo
by
AG.
Prote
cted
by
c
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py
rig
ht
.
C
op
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387


Disconnect all electrical connections on steering box.

Lower subframe using engine and gearbox jack -V.A.G 1383
A- far enough that the steering box can be removed.
AG.
agen
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Vo
by
Prote
cted
b
y
c
op
yri
gh
t
.
Co
py
i
388
ht
rig
py
Co
t.
rrectness of i
t to the co
nform
spec
at
i
h re
o
n
wit
in t
his
d
o
cu
m
en
es, in part or in w
l purpos
hole
ercia
, is n
m
m
ot p
r co
erm
o
e
t
a
itte
v
i
r
du
p
or
nl
f
e
ng
ility
ab
y li
an
pt
ce
es n
wage
s
k
l
ot g
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yV
ua
b
d
ran
e
tee
ris
o
h
t
or
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ac
a
ss

Installing steering box
Threaded sleeves of steering box must seat in holes in left brack
et.
Note
erwise, this can result in water leaks and/orAGnoise.
. Volkswagen A
gen
swa
k
Vol
by

Note

Bolt universal joint to steering box.
Connect battery. Rep. Gr. 27 ; Battery; Disconnecting and
reconnecting battery.
Carry out basic setting for -G85-Geber fr Lenkwinkel- using
5051.
ing road test.
agen
lksw
Vo
by
AG.
Prote
cted
by
c
o
py
rig
ht.
C
op
yi
Check wheel alignment. page 305
ht
rig
py
Co
t.
If steering wheel is not in straight-ahead position or if a new steer

ing box was installed, front axle tracking must be checked and if
necessary adjusted!
rrectness of i
t to the co
nform
spec
atio
h re
n
wit
i
n
thi
sd
o
c
um
en
ole,
cial p
is n
mer
m
ot p
r co
erm
o
e
t
itte
ir va
du
p
or
nl
f
e
g
n
Connect electrical connections to steering box.
ility
ab
y li
an
pt
ce
ed
ris
ho
t
Before inserting subframe bolts,
position steering box on
au
ss
frame and insert bolts for steering
box and anti-roll bar.
G do
es n
ot g
ua
ran
tee
or
sub
ac
system -VAS 5051B- .
5051B- Vehicle diagnosis, testing and information system
VAS 5051.
Specified torques
Component
Subframe to body
Use new bolts
Specified torque
70 Nm + 90
389
ole,
cial p
is n
mer
m
ot p
o
c
r
erm
o
e
t
a
itte
iv
du
pr
r
o
nl
f
e
ng
Component
ility
ab
y li
an
pt
ce
AG. Volkswagen AG d
agen
oes
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not
l
o
V
gu
by
ara
d
e
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s
i
r
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ho 2005
t
u
ra
a
c
ss steering - Edition 08.2009
Specified torque
20 Nm + 90
rrectness of i
t to the co
nform
spec
a
t
ion
h re
wit
in t
his

Use new bolts

Use new nut
65 Nm

Use new nuts
60 Nm

link
Use new nuts
100 Nm
6 Nm

Use new bolts
50 Nm + 90
AG.
Prote
cted
by

Use new nut
agen
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Vo
by
c
o
p
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t.
C
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ht
rig
py
Co
t.

Use new bolt
do
c
um
en
Shield to subframe
30 Nm
6 Nm
20 Nm + 90

Engine; Rep. Gr. 26

Bolt
Specified torque
M10 x 35
Use new bolt
50 Nm + 90 further
M10 x 75
Use new bolt
50 Nm + 90 further
390

Removing and installing steering box, right-hand drive (3rd generation) after
model year 2009

1332-
ht
rig
py
Co
t.
agen
lksw
Vo
by
AG.
rrectness of i
t to the co
nform
spec
atio
h re
n
wit
i
n
thi
sd
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c
um
en

1331-
ility
ab
y li
an
pt
ce

equipment required
ole,
cial p
is n
mer
m
ot p
r co
erm
o
e
t
itte
ir va
du
p
or
nl
f
e
g
n
7.4
es n
wage
ot g
olks
V
ua
by
d
ran
ir se
tee
o
h
t
or
ac
au
s
s
Prote
cted
by
c
o
py
rig
ht
.
C
op
yi
Removing
Disconnect battery Rep. Gr. 27 ; Battery; Disconnecting
and reconnecting battery .
Remove nuts -1- and remove footwell trim -2-.
391

Remove bolt -1- for universal joint and pull universal joint -2off steering box.
ly.
Caution
joint puller -3287A- and remove nut now.
Remove coupling rod from anti-roll bar.

-14-.
AG.
agen
lksw
Vo
by
Prote
cted
by
c
o
py
rig
ht
.
C
op
yi
ht
rig
py
Co
t.
392
rrectness of i
t to the co
nform
spec
atio
h re
n
wit
i
n
thi
sd
o
c
um
en
ole,
cial p
is n
mer
m
ot p
r co
erm
o
e
t
itte
ir va
du
p
or
nl
f
e
g
n
ility
ab
y li
an
pt
ce
es n
wage
ot g
olks
V
y
ua
db
ran
e
is
tee
r
o
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t
or
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ac
a
ss


. Volkswagen AG
gen AG
d
gu
ara
nte
eo
ra
c
ht
rig
py
Co
t.
ng
thi
sd
o
cu
m
en
r
te o
iva
r
rp
fo
rrectness of i
t to the co
n
f
o
r
mat
spec
ion
h re
wit
in
es, in part or in w
l purpos
hole
ercia
, is n
m
ot
com
pe
rm
itte
d
ss
by
ed
ris
o
th
au
ility
ab
y li
an
pt
ce
un
le
a
oes
Remove bolts
-5ksw and -6- for steering box.
not
Vol
agen
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Vo
by
AG.
Prote
cted
by
c
o
py
rig
ht
.
C
op
yi
393

olkswagen AG
Running gear, axles, steering - Edition 08.2009swagen AG. V
does
not
gu
ara
nte
eo
ra
c
ole,
cial p
is n
mer
m
ot p
o
c
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erm
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ility
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Remove bolts -11- and -16- for anti-roll bar.oris
h
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Fix position of subframe page 16 . ss a
rrectness of i
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spec
a
t
ion
h re
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AG.
394
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Remove bolts -4- and -5- and lower subframe slightly. In the
process, observe electrical wiring.
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do
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Position
engine and gearbox jack -V.A.G 1383 A- under subframe.


Disconnect connectors from steering box.
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Lower subframe carefully with engine/gearbox jack -V.A.G

1383 A- .
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Now lift anti-roll bar -1- forwards over subframe -2- and down
while turning anti-roll bar slightly.
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Unbolt steering box from subframe.
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395

Installing
Threaded sleeve of steering box must be located in subframe
hole.
Note
After fitting the steering box to the universal joint, make sure
that the seal is not kinked when lying against the assembly
plate and that the opening to the footwell is correctly sealed.
Otherwise, this can result in water leaks and/or noise.

swaganti-roll
. Volkand
en AG
n AGbox
frame and insert bolts for steering
doebar.
wage
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Attach lower noise
ed insulation Rep. Gr. 50 ; Assemblyranover
s
i
tee
r
view - noise tinsulation
.
o
h
or
ac
au

ing road test.
If steering wheel is crooked or a new steering box was installed,
wheels must be aligned.
system -VAS 5051- .
VAS 5051.
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Note
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5051.
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Connect battery Rep. Gr. 27 ; Battery; Disconnecting and

reconnecting battery .
ility
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an
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ss
Bolt universal
joint to steering box.
If parking aid 2 is fitted in the vehicle, the power steering control

unit -J500- must be recoded Vehicle diagnosis, testing and in
formation system VAS 5051.
AG.
Specified torques
Component
Subframe to body
Use new bolts
396
Specified torque
70 Nm + 90

Component
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Use new bolts
AG. Volkswagen AG d
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l
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20
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Use new nut
65 Nm
rrectness of i
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spec
atio
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i
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thi
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Use new nuts
60 Nm

link
Use new nuts
100 Nm
Shield to subframe
6 Nm

Use new bolts
50 Nm + 90

Use new bolt
30 Nm

6 Nm
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AG.

Engine; Rep. Gr. 26
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Use new nut
20 Nm + 90

Bolt
Specified torque
M10 x 35
Use new bolt
50 Nm + 90 further
M10 x 75
Use new bolt
50 Nm + 90 further
397
wagen AG
G. Volks
Golf 2004 , GolfwaPlus
gen A2005
does
ks
not
l
o
V axles, steering - Edition 08.2009
Running gear,
gu
y
b
At the start of production of the Golf 2004 , the 1st generation

steering box was fitted. During the 2004 model year, this was re
placed with the 2nd generation steering box.
Vehicles fitted with a 1st generation steering box can be retrofitted
with a 2nd generation steering box page 400 .
To identify the type of steering box while it is fitted, count the
number of screws on the steering pinion bearing cover.
Raise vehicle.
Turn steering in both directions to count the number of screws

-1-.
The 1st generation steering box has 4 bolts for the bearing cover
and the 2nd generation steering box has 2.
The figure shows a 1st generation steering box.
Continuation with 1st generation steering box page 401 .
Continuation with 2nd generation steering box page 406 .
AG.
Prote
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398
rrectness of i
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spec
at
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or
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Distinguishing between steering boxc

es (1st and 2nd generations), Golf
ility
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au
ss

Differentiating between 2nd and 3rd

generation steering boxes
From model year 2009, a new, 3rd generation, steering box is

being used. It replaces the 2nd generation steering box.
To identify the type of steering box while it is fitted, count the
number of bolts with which the steering box is attached to the
subframe.
Raise vehicle.
The 2nd generation steering box is attached to the subframe with
4 bolts and the 3rd generation steering box is attached with 3.
rrectness of i
t to the co
nform
spec
at
i
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o
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l purpos
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AG. Volkswagen AG d
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9. Differentiating between 2nd and 3rd generation steering boxes
399

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Exchanging 1st generation ysteering
Vol
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box for 2nd generation osteering
box,
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Golf
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l purpos
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spec
atio
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wit
There are no new 1st generation steering boxes available as
parts for renewing 1st generation steering boxes.
Therefore, 2nd generation steering boxes must be fitted.

For some vehicles, a few other parts in addition to the steering
box must be exchanged. Which vehicles are affected and the

procedure to be followed are described below.
The parts in the following list must be renewed when a 1st gen
eration steering box is exchanged:
The wiring harness generally must be exchanged.
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AG.
The allocation of the respective parts can be determined in the

Electronic parts catalogue ETKA .
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For right-hand-drive vehicles, the left bracket from Part No.

1K0.199.295 through and including 1K0.199.295.C must be
exchanged. Brackets from Part No. 1K0.199.295.D need not
be exchanged.
ht
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For left-hand-drive vehicles, the right bracket from Part No.

1K0.199.296 through and including 1K0.199.296.C must be
exchanged. Brackets from Part No. 1K0.199.296.D need not
be exchanged.
thi
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Subframes from Part No. 1K0.199.369 through and including

1K0.199.369.E. must be exchanged. Subframes from Part No.
1K0.199.369.F need not be exchanged. To order parts via the
Electronic parts catalogue ETKA , the assembly
1K0.199.313 must be ordered with the respective index.

11
Repairing electromechanical steer

ing box (1st generation), Golf
At present, there is no provision for performing repairs on the

steering box (1st generation).
11.1
Removing and installing boot

equipment required
1332 Tool insert 24 mm -V.A.G
1332/11 Locking pliers for Phaeton
steering box -VAS 6199-
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Removing
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If boot is defective, moisture and dirt will enter steering box. There
must be a palpable film of grease in the area of the teeth on the
steering rack. If there is no film of grease, the steering box must
be renewed. The steering box must also be renewed if corrosion,
damage or wear to the steering rack is present.
Turn steering wheel to straight-ahead position.
Remove wheel.
Clean outside of steering box in vicinity of boot.
11. Repairing electromechanical steering box (1st generation), Golf
401

No dirt must enter the steering box through the damaged boot
during this work.
Mark position of nut -3- on steering rack.
Loosen nut -3- while counterholding on head of track rod -2-.
Loosen hose clip -1- from boot using hose clip pliers -V.A.G
1275- and push onto track rod.
Remove hose clip and pull boot from steering box housing.
Now turn track rod out of track rod head.
Pull boot with spring-type clip off track rod.
AG. Volkswagen AG d
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r
If the steering rack shows
o
eo
h
t
u
ra
soiling, renew the complete
steering box.
a
c
ss
Note
un
le
es, in part or in w
l purpos
hole
ercia
, is n
m
ot
com
rrectness of i
t to the co
n
f
o
r
mat
spec
ion
h re
wit
in
Installing
pe
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steering box must be renewed.
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Likewise, if there is no film of grease on the steering rack, the
Caution
Do not grease steering rack.

Thread new clamps and rubber boot onto track rod.
Screw in track rod to mark made during removal.
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Push rubber boot -2- onto track rod -1- as shown in figure.
Secure spring-type clamp on rubber boot using hose clip pliers
-V.A.G 1275- .
Lightly lubricate seal point between boot and steering box with
grease -G 052 168 A1- (from repair kit Fuchs Renolit JP1619).
Push rubber boot onto steering box housing to stop.
402
ht
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Lightly lubricate seal point between boot and track rod with
thi
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Tighten lock nut -3- to specified torque while counterholding

track rod ball joint -2-.

Install new clamp, as shown in figure, with locking pliers for
Phaeton steering box -VAS 6199- .
Install wheel and tighten. page 288 .
Check wheel alignment after completing the installation.
Check wheel alignment page 305 .
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Carry out basic setting for steering angle sender -G85Vol using
by
d
vehicle diagnostic, testing and information rsystem
-VAS
ise
ho
5051B- , guided fault finding .
ut
sa
Specified torque
50 Nm
Open jaw insert, 38 mm V.A.G 1923 Locking pliers for Phaeton

AG.

1332-
do
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1275-
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equipment required
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11.2
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erm
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t
a
itte
iv
du
pr
r
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nl
f
e
ng
Component
rrectness of i
t to the co
nform
spec
a
t
ion
h re
wit
in t
his
Specified torques
ility
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s
Then carry out basic setting for steering using
vehicle di
agnostic, testing and information system -VAS 5051B- , gui
ded fault finding .
403

Removing track rod
Clean outside of steering box in vicinity of boot.
Loosen nut -3-, counterholding on track rod ball joint -2-.
Remove front wheel.
AG. Volkswagen AG d
ly.
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Leave nut screwed on a few turns to protect
bythread on pin.
ed
rrectness of i
t to the co
nform
spec
a
t
i
h re
o
n in
wit
thi
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ole,
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erm
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a
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f
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ility
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ris
ho
ut
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ss
joint puller -3287 A- and now remove nut.
Loosen spring-type clamp (item -1- in figure N44-10005
page 404 ) on rubber boot using hose clip pliers -V.A.G
Installing track rod

Caution

404
AG.
soiling, renew the complete steering box.
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If the steering rack shows signs of corrosion, damage, wear or
ht
rig
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Co
t.
Note
do
c
um
en
Unscrew track rod from steering rack using open jaw insert,
38 mm -V.A.G 1923- .

Screw track rod into track rod ball joint until dimension -a- is
attained.
Dimension -a- = 371 1 mm
Screw track rod into steering rack and tighten.
Push rubber boot -2- onto track rod -1-, making sure that boot
is correctly positioned.
Secure spring-type clip on rubber boot using hose clip pliers V.A.G 1275- .

Install wheel and tighten. page 288 .

vehicle diagnostic, testing and information system -VAS
5051B- , guided fault finding .
Then carry out basic setting for steering using vehicle di
agnostic, testing and information system -VAS 5051B- , gui
ded fault finding .
Specified torque

Use new nut
AG.
Prote
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by
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rig
ht
.
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Track rod to steering rack in steering box
50 Nm
20 Nm + 90
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Component
ht
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Specified torques
rrectness of i
t to the co
nform
spec
atio
h re
n
wit
i
n
thi
sd
o
c
um
en
ole,
cial p
is n
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m
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r co
erm
o
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t
itte
ir va
du
p
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nl
f
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db
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or
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ss
100 Nm
405
AG. Volkswagen AG d
agen
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Vol 2005
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ran
Running gear, raxles,
ise
t
At present, there is no provision for performing repairs on the

steering box (2nd and 3rd generations).
12.1
Removing and installing boot

equipment required
1332 Tool insert 24 mm -V.A.G
1332/11 Locking pliers for Phaeton
steering box -VAS 6199ht
rig
py
Co
t.
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Prote
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by
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Removing boot
Note
If boot is defective, moisture and dirt will enter steering box. There
must be a palpable film of grease in the area of the teeth on the
steering rack. If there is no film of grease, the steering box must
be renewed. The steering box must also be renewed if corrosion,
damage or wear to the steering rack is present.
Remove wheel.
Clean outside of steering box in vicinity of boots.
406
rrectness of i
t to the co
nform
spec
a
t
i
h re
o
n in
wit
thi
sd
o
cu
m
en
ole,
cial p
is n
mer
m
ot p
r co
erm
o
e
t
itte
ir va
du
p
or
nl
f
e
g
n
Repairing electromechanical steer

ing box (2nd and 3rd generations)
ility
ab
y li
an
pt
ce
12
ee
or
ac
ho
ut
a
ss

No dirt must enter the steering box through the damaged boot
during this work.
Mark position of nut -3- on steering rack.
Loosen nut -3- while counterholding on head of track rod -2-.
Loosen hose clip -1- from boot using hose clip pliers -V.A.G
Now turn track rod out of track rod head.
Pull boot with spring-type clip off track rod.
Note
If the steering rack shows signs of corrosion, damage, wear or
AG. Volkswagen
AG do
agen
Likewise, if there is no film of grease
sn
lksw on the steering rack, ethe
steering box must
ility
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rm
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d
Caution
ot g
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tee
or
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Installing boot
o
yV
be renewed.
db
ir se
tho
au
s
s
es, in part or in w
l purpos
hole
ercia
, is n
m
ot
com
rrectness of i
t to the co
n
f
o
r
m
spec
atio
h re
n in
wit

Screw in track rod to mark made during removal.
Tighten lock nut -3- to specified torque while counterholding
track rod ball joint -2-.
ht
rig
py
Co
t.
ng
thi
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Push rubber boot -2- onto track rod -1- as shown in figure.
AG.
12. Repairing electromechanical steering box (2nd and 3rd generations)
407

Specified torque for fitting wheels page 288 .
Adapt steering angle sender -G85- using vehicle diagnostic,
testing and information system -VAS 5051B- , guided fault
finding .
Then adapt steering using vehicle diagnostic, testing and
information system -VAS 5051B- , guided fault finding .
Specified torques
Component
Ball joint puller -3287 A Hose clip pliers -V.A.G

1332 Open jaw insert, 38 mm V.A.G 1923 Locking pliers for Phaeton
ht
rig
py
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ht
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do
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50 Nm
rrectness of i
t to the co
nform
spec
a
t
ion
h re
wit
in t
his

equipment required
408
Specified torque
ility
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12.2
ole,
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is n
mer
m
ot p
o
c
r
erm
o
e
t
a
itte
iv
du
pr
r
o
nl
f
e
ng
Track rod ball joint to
es n
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db
ran
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ir s
tee
o
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or
u rod
track
ac
a
ss

Removing track rod
Clean outside of steering box in vicinity of boots.
Loosen nut -3-, counterholding on track rod ball joint -2-.
Remove front wheel.
ly.
joint puller -3287 A- and now remove nut.
Loosen spring-type clamp (item -1- in figure N44-10005
page 409 ) on rubber boot using hose clip pliers -V.A.G
Unscrew track rod from steering rack using open jaw insert,
38 mm -V.A.G 1923- .
ility
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an
pt
ce
ole,
cial p
is n
mer
m
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r co
erm
o
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t
itte
ir va
du
p
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f
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ng
es n
wage
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olks
V
ua
Noted by
ran
ise
tee
r
o
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t
or
ac wear or
au steering rack shows signs of corrosion, damage,
Ifs the
s
Caution

rrectness of i
t to the co
nform
spec
a
t
i
h re
o
n in
wit
thi
s
Installing track rod
do
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rig
ht
.
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12. Repairing electromechanical steering box (2nd and 3rd generations)
409

Screw track rod into track rod ball joint until dimension -a- is
attained.
Dimension -a- = 371 1 mm
Turn track rod into steering rack and tighten to specified tor
que.
Position boot -2- on track rod -1-.


Adapt steering angle sender -G85- using vehicle diagnostic,

testing and information system -VAS 5051B- , guided fault
finding .
rrectness of i
t to the co
nform
spec
a
t
ion
h re
wit
in t
his
ole,
cial p
is n
mer
m
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o
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erm
o
e
t
a
itte
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du
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2004 Golf PDF

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Service

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Service Department. Technical Information

44 - Wheels, tyres, vehicle geometry

Golf 2004 , Golf Plus 2005

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Appraisal of accident vehicles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Golf 2004 , Golf Plus 2005

Checking outer constant velocity joint . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Assembly overview - drive shaft with triple roller joint AAR2600i . . . . .

42 - Rear suspension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134

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Appraisal of accident vehicles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134

Golf 2004 , Golf Plus 2005

Renew vehicle level sender in vehicle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

44 - Wheels, tyres, vehicle geometry . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 287

Appraisal of accident vehicles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 287

Fitting wheel and tyre . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 289

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Golf 2004 , Golf Plus 2005

Removing and fitting tyres with run-flat capability to wheel rims . . . . . . . . . . . . . . . . . . . .

Tyre monitor display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Rough running due to wheels/tyres - causes and rectification . . . . . . . . . . . . . . . . . . . . . .

Appraisal of accident vehicles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 333

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Golf 2004 , Golf Plus 2005

Steering wheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 336

Steering column, Golf . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Differentiating between 2nd and 3rd generation steering boxes . . . . . . . . . . . . . . . . . . . . 399

Repairing electromechanical steering box (1st generation), Golf . . . . . . . . . . . . . . . . . . . .

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Golf 2004 , Golf Plus 2005

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Golf 2004 , Golf Plus 2005

Checklist for evaluating running gear

Check for flawless function from lock to lock by moving the

Check steering box and lines for secure seating.

Examine hydraulic lines, threaded connections and steering

Examine electrical and hydraulic lines and hoses for chafing,

Visual inspection and functional check of running gear

Adhere to the sequence of the following inspection steps!

Exam all components shown in the assembly overviews for

Whenever a safety risk cannot be excluded, the tyre(s) must

1. Checklist for evaluating running gear of accident vehicles

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Golf 2004 , Golf Plus 2005

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Rep. Gr.00 - Technical data

Golf 2004 , Golf Plus 2005

Information concerning wheels, tyres and snow chains can be

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Appraisal of accident vehicles

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Rep. Gr.40 - Front suspension

A checklist for evaluating running gear of accident vehicles can

Overview - front axle

Repairing front suspension

It is not permitted to weld or straighten load-bearing or wheel-guiding components of the suspension.

III - Assembly overview - sus

II - Assembly overview - wheel

I - Assembly overview - sub

2. Repairing front suspension

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