Service: Golf 2004 Golf Plus 2005

Service
Workshop Manual
Golf 2004 ➤
Golf Plus 2005 ➤
Running gear, axles, steering
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Service Department. Technical Information
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Repair Group
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00 - Technical data
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40 - Front suspension
42 - Rear suspension
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44 - Wheels, tyres, vehicle geometry
48 - Steering
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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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1 Checklist for evaluating running gear of accident vehicles . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2 General information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
40 - Front suspension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
1 Appraisal of accident vehicles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
2 Repairing front suspension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
2.1 Overview - front axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
2.2 Raising wheel suspension to unladen position, Golf . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
2.3 Raising wheel suspension to unladen position, Golf Plus, CrossGolf . . . . . . . . . . . . . . . . 8
3 Subframe, anti-roll bar, suspension link . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
3.1 Assembly overview: subframe, anti-roll bar, suspension links . . . . . . . . . . . . . . . . . . . . . . 10
3.2 Assembly overview - front left vehicle level sender G78 . . . . . . . . . . . . . . . . . . . . . . . . . . 14
3.3 Removing and installing front left vehicle level sender G78 . . . . . . . . . . . . . . . . . . . . . . . . 15
3.4 Repairing thread in longitudinal member . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
3.5 Fixing position of subframe and brackets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
3.6 Lowering subframe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
3.7 Removing and installing subframe without steering box . . . . . . . . . . . . . . . . . . . . . . . . . . 21
3.8 Removing and installing subframe with steering box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
3.9 Repairing subframe (front-wheel drive) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
3.10 Repairing subframe (four-wheel drive) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
3.11 Checking swivel joint . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
3.12 Removing and installing swivel joint . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
3.13 Removing and installing suspension link with mounting bracket . . . . . . . . . . . . . . . . . . . . 36
3.14 Removing and installing suspension link with mounting bracket (left side for vehicles with
DSG or automatic gearboxes) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
3.15 Removing and installing suspension link with mounting bracket (right side for vehicles with
6-cylinder engines) . . . . .e.n .AG . .. V. o.lk.s.w.ag. e.n.A.G. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
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3.16 Renewing bonded rubber Volksw bush for suspension elink not . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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4 Assemblys overview - wheel bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
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4.1 Removing and installing wheel bearing housing (3-point mounting) . . . . . . . . . . . . . . . . . . 57

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4.2 Removing and installing wheel bearing housing (4-point mounting) . . . . . . . . . . . . . . . . . . 58

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4.3 Removing and installing wheel bearing housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60

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5 Assembly overview: suspension strut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64

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5.1 Removing and installing suspension strut, Golf . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65

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5.2 Removing and installing suspension strut, Golf Plus, CrossGolf . . . . . . . . . . . . . . . . . . . . 70

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5.3 Repairing suspension strut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75

6 Removing and installing drive shafts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
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6.1 Loosening and tightening drive shaft hexagon bolt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77

6.2 Loosening and tightening 12-point flange bolt securing drive shaft . . . . . . . . . . . . . . . . . . 78
6.3 Removing and installing drive shaft with constant velocity joint . . . . . . . . . . . . . . . . . . . . . . 79
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6.4 Removing and installing left drive shaft with (push-on) constant velocity slip joint . . . . . . 81
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6.5 Removing and installing right drive shaft with (push-on) constant velocity slip joint . . . . . . 85
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6.6 Removing and installing drive shafts with triple roller joint AAR2600i . . . . . . . . . . . . . . . . 88
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6.7 Removing and installing drive shafts with triple roller joint AAR3300i . . . . . . . . . . . . . . . . 90
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6.8 Removing and installing intermediate shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92

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7 Repairing drive shaft - overview of drive shafts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94

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7.1 Heat shields for drive shafts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96

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8 Assembly overview - drive shaft with VL90 or VL100 constant velocity joint . . . . . . . . . . . . 97
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8.1 Dismantling and assembling drive shaft with VL90 or VL100 constant velocity joint . . . . . . 99
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8.2 Checking outer constant velocity joint . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103

8.3 Checking inner constant velocity joint . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
9 Assembly overview - drive shaft with VL107 constant velocity joint (bolt-on) . . . . . . . . . . 107
9.1 Dismantling and assembling drive shaft with VL107 constant velocity joint . . . . . . . . . . . . 109
9.2 Repairing intermediate shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114
10 Assembly overview - drive shaft with VL107 constant velocity slip joint (push-on) . . . . . . 116
10.1 Dismantling and assembling drive shaft with VL107 (push-on) constant velocity slip joint
........................................................................ 117
11 Assembly overview - drive shaft with triple roller joint AAR2600i . . . . . .............. . 121
11.1 Dismantling and assembling drive shaft with triple roller joint AAR2600i ............. . 122
12 Assembly overview - drive shaft with triple roller joint AAR3300i . . . . . .............. . 127
12.1 Dismantling and assembling drive shaft with triple roller joint AAR3300i ............. . 129
42 - Rear suspension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134

2 Repairing rear suspension (front-wheel drive) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135
2.1 Overview - rear axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135
2.2 Rear axle in unladen position, Golf . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 136
2.3 Rear axle in unladen position, Golf Plus, CrossGolf . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138
3 Assembly overview: subframe, transverse link, track rod (front-wheel drive) . . . . . . . . . . 140
3.1 Removing and installing rear axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143
3.2 Vehicle level sender for vehicles with automatic headlight range control . . . . . . . . . . . . . . 148
3.3 Renew vehicle level sender in vehicle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 148
3.4 Removing and installing upper transverse link . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149
3.5 Removing and installing lower transverse link . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 151
3.6 Removing and installing track rod . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 152
4 Assembly overview: wheel bearing housing, trailing arm (front-wheel drive) . . . . . . . . . . . . 156
4.1 Removing and installing wheel bearing housing . . . . . . . . . . n. A.G. . .Vo. l.ks.w.a.ge. n.A. . . . . . . . . . . 157
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4.3 Removing and installing wheel bearing/wheel hubiseunit d b . . . . . . . . . . . . . . . . . . . . . . . . . a.ra.n. 164
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4.4 Removing and installing trailing arm with mounting ut
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4.5 Repairing trailing arm . . . . . . . . . . . . . . . . s.s. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 170
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5 Assembly overview: shock absorber, coil spring (front-wheel drive) . . . . . . . . . . . . . . . . . . 173
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5.1 Removing and installing coil spring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 173
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5.2 Removing and installing shock absorbers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 175
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5.3 Repairing shock absorber . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 177
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6 Assembly overview: anti-roll bar (front-wheel drive) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 179

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6.1 Removing and installing anti-roll bar . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 179

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7 Assembly overview - attachment parts for subframe Golf BlueMotion, Golf Plus BlueMotion
(front-wheel drive) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 182
8 Repairing rear suspension (four-wheel drive) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 183
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8.1 Overview of rear axle (aluminium) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 183

8.2 Overview of rear axle (steel) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 185
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8.3 Rear axle in unladen state (aluminium and steel) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 187

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9 Assembly overview - subframe made from aluminium, final drive (four-wheel drive) . . . . 189
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9.2 Repairing subframe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 195

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10 Assembly overview - subframe made from steel, final drive (four-wheel drive) . . . . . . . . 199
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10.2 Repairing subframe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 205

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11 Assembly overview - control arm, track rod (four-wheel drive, subframe made from aluminium . C rig
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and wheel bearing housing made from cast steel) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 212
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11.1 Overview - rear left vehicle level sender G76 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 214
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11.2 Renew vehicle level sender in vehicle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 215

11.3 Removing and installing upper transverse link . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 215
11.4 Removing and installing lower transverse link . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 217
12 Assembly overview - control arm, track rod (four-wheel drive, subframe made from steel and
wheel bearing housing made from aluminium) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 223
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12.1 Overview - rear left vehicle level sender G76 . . .lk.sw . a. g.e.n A
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12.2 Renew vehicle level sender in vehicle . . . . e.d.by. . . . . . . . . . . . . . . . . . . . . . . . .t .gu.a.ra. . . . . .
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12.3 Removing and installing upper transversetholink . . . . . . . . . . . . . . . . . . . . . . . . . . . . . t.ee.o. . .
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13 Assembly overview - wheel bearing housing, trailing link (four-wheel drive, subframe made
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13.1 Changing from wheel housing bearing made from cast steel to wheel bearing housing made
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from aluminium . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 235
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Removing and installing wheel bearing housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 236
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13.3 Renewing bonded rubber bush for wheel bearing housing . . . . . . . . . . . . . . . . . . . . . . . . 240
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13.4 Removing and installing wheel bearing/wheel hub unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . 242
13.5 Removing and installing trailing arm with mounting bracket . . . . . . . . . . . . . . . . . . . . . . . . 243
13.6 Repairing trailing arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 248
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14 Assembly overview - wheel bearing housing, trailing link (four-wheel drive, subframe made
from steel and wheel bearing housing made from aluminium) . . . . . . . . . . . . . . . . . . . . . . 251
14.1 Removing and installing wheel bearing housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 252
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14.2 Renewing bonded rubber bush for wheel bearing housing . . . . . . . . . . . . . . . . . . . . . . . . 255
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14.3 Removing and installing wheel bearing/wheel hub unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . 255
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15 Assembly overview - shock absorber, coil spring (four-wheel drive, subframe made from
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aluminium and wheel bearing housing made from cast steel) . . . . . . . . . . . . . . . . . . . . . . 257
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15.1 Removing and installing coil spring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 257

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15.3 Repairing shock absorber . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . py
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16 Assembly overview - shock absorber, coil spring (four-wheel drive, subframe made from steel
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and wheel bearing housing made from aluminium) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 262
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16.1 Removing and installing coil spring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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16.3 Repairing shock absorber . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 264
17 Assembly overview - anti-roll bar (four-wheel drive, subframe made from aluminium and
wheel bearing housing made from cast steel) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 265
18 Assembly overview - anti-roll bar (four-wheel drive, subframe made from steel and wheel
bearing housing made from aluminium) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 269
19 Assembly overview - drive shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 273
19.1 Loosening and tightening drive shaft hexagon bolt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 274
19.2 Loosening and tightening 12-point bolt for drive shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . 275
19.3 Removing and installing drive shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 276
19.4 Dismantling and assembling drive shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 278
19.6 Checking inner constant velocity joint . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 284
44 - Wheels, tyres, vehicle geometry . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 287

2 Torque settings for wheel bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 288
3 Fitting wheel and tyre . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 289
3.1 General information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 289
4 Removing and fitting tyres (wheels with tyre pressure monitoring) . . . . . . . . . . . . . . . . . . 290
Contents iii
4.1 Notes on safety and conditions for removing and fitting tyres (wheels with tyre pressure
monitoring) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 290
4.2 Wheel change . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 290
4.3 Pressing tyre off wheel rim . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 291
4.4 Removing tyre from wheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 292
4.5 Fitting tyre to wheel rim . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 292
5 Removing and fitting tyres with run-flat capability to wheel rims . . . . . . . . . . . . . . . . . . . . 294
5.1 Notes on safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 294
5.2 Installation conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 294
5.3 Pressing tyre off wheel rim . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 296
5.4 Removing tyre from wheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 296
5.5 Fitting tyre to wheel rim . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 298
6 Tyre monitor display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 300
n AG. Volkswagen A
7 Tyre pressure monitor (TPM) . o.lk.s.w.ag. e. . . . . . . . . . . . . G. d. o.e.s .no. . . . . . . . . . . . . . . . . . . . . . . . 302
V t
7.1 Button behaviour . . . . . . .ed. b.y . . . . . . . . . . . . . . . . . . . . . . . . . g.u.ar.a . . . . . . . . . . . . . . . . . . . 302
ir s nte
7.2 Assembly overview - tyre utho pressure sensor . . . . . . . . . . . . . . . . . . .e.or. . . . . . . . . . . . . . . . 303
7.3 Removing and installing ss
a
tyre pressure sensor . . . . . . . . . . . . . . . . . . .ac. . . . . . . . . . . . . . . 304
ce
e
8 Wheel alignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 305

nl
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8.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 305
y li
erm
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8.2 Test prerequisites . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 307
ility
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8.3 Test preparations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 307
wit
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8.4 Wheel alignment specifications, Golf . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 308
hole
spec
8.5 Wheel alignment specifications, Golf Plus, CrossGolf . . . . . . . . . . . . . . . . . . . . . . . . . . . . 309
es, in part or in w
8.6 Overview - wheel alignment procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 311
t to the co
8.7 Correcting front axle camber . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 312
8.8 Adjusting camber on rear axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 314
rrectness of i
8.9 Adjusting toe at rear axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 315
8.10 Adjusting front axle toe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 316
l purpos
8.11 Basic setting for steering angle sender G85 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 317

8.12 Vehicle data sticker . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 317
nform
ercia
9 Wheels, tyres . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 318

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9.1 Models with breakdown set . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 318
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9.2 Tyre sealant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 318

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9.3 Removing a tyre . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 318

iv
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9.4 Fitting a new tyre . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 319

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9.5 Tyre sealant disposal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 319

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9.6 Alloy wheels with metal valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 319
C
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10 Instructions for changing or fitting wheels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 321
co Vo
by lksw
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10.1 Fitting wheels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 322
agen
Prote AG.
11 Protecting wheel centring seat against corrosion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 323

12 Rough running due to wheels/tyres - causes and rectification . . . . . . . . . . . . . . . . . . . . . . 324
12.1 Causes of rough running . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 324
12.2 Balancing wheels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 324
12.3 Conducting a road test before balancing wheels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 325
12.4 Balancing wheels on stationary wheel balancing machine . . . . . . . . . . . . . . . . . . . . . . . . 325
12.5 Vibration control system VAS 6230 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 327
12.6 Finish balancer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 327
12.7 Radial and lateral runout of wheels and tyres . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 328
12.8 Checking radial and lateral runout on wheels and tyres with tyre gauge V.A.G 1435 . . . . 328
12.9 Checking radial and lateral runout on wheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 329
12.10 Matching . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 330
12.11 Flat spots caused by storage or handling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 331
48 - Steering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 333
iv Contents

2 General repair instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 334

2.1 Steering box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 334
2.2 Gaskets and seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 334
2.3 Nuts and bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 334
2.4 Electrical components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 335
2.5 Guided fault-finding, vehicle self-diagnosis and test instruments . . . . . . . . . . . . . . . . . . . . 335
3 Steering wheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 336
3.1 Removing and installing steering wheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 336
4 Steering column, Golf . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 339
. Volkswag
4.1 Assembly overview: steering column . .k.sw. a. g.e.n .AG . . . . . . . . e.n.A.G. d.o.es. . . . . . . . . . . . . . . . . . . . 339
o l no
4.2 Removing and installing steering column db
yV . . . . . . . . . . . . . . . . . . . . .t .gu.a.r . . . . . . . . . . . . . . 339
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4.3 Basic setting for steering anglethsensor or
is G85 steering angle sender must be nchecked tee
o
after the
following repair work: . . . . .s a. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . r.a.c . . . . . . . . .
u 345
s
4.4 Handling and transporting steering column . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 345
ce
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4.5 Checking steering column for damage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 346
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4.6 Removing and installing mounting bracket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 346
erm
ab
ility
4.7 Removing and installing strut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 348
ot p
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5 Steering column, Golf Plus, CrossGolf . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 351
h re
hole
5.1 Assembly overview: steering column . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 351
spec
5.2 Removing and installing steering column . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 351
es, in part or in w
t to the co
5.3 Basic setting for steering angle sensor G85 steering angle sender must be checked after the
following repair work: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 357
5.4 Handling and transporting steering column . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 357
rrectness of i
5.5 Checking steering column for damage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 358
l purpos
5.6 Removing and installing mounting bracket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 358

5.7 Removing and installing strut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 360
nform
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6 Electromechanical steering box up to model year 2008 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 363

m
6.1 Assembly overview - electromechanical steering box, left-hand drive (1st and 2nd
at
m
io
generations) up to model year 2008 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 363
r co
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6.2 Assembly overview - electromechanical steering box, right-hand drive (2nd generation) up
his
ate
to model year 2008 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 365
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6.3 Removing and installing steering box, left-hand drive (1st and 2nd generations) up to model
or
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year 2008 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 366

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6.4 Removing and installing steering box, right-hand drive (2nd generation) up to model year Co py
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2008 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 374
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7 Electromechanical steering box after model year 2009 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 383
by
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Prote AG.
7.1 Assembly overview - electromechanical steering box, left-hand drive (3rd generation) after
model year 2009 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 383
7.2 Assembly overview - electromechanical steering box, right-hand drive (3rd generation) after
model year 2009 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 384
7.3 Removing and installing steering box, left-hand drive (3rd generation) after model year
2009 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 385
7.4 Removing and installing steering box, right-hand drive (3rd generation) after model year
2009 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 391
8 Distinguishing between steering boxes (1st and 2nd generations), Golf . . . . . . . . . . . . . . 398
9 Differentiating between 2nd and 3rd generation steering boxes . . . . . . . . . . . . . . . . . . . . 399
10 Exchanging 1st generation steering box for 2nd generation steering box, Golf . . . . . . . . . . 400
11 Repairing electromechanical steering box (1st generation), Golf . . . . . . . . . . . . . . . . . . . . 401
11.1 Removing and installing boot . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 401
12 Repairing electromechanical steering box (2nd and 3rd generations) . . . . . . . . . . . . . . . . 406
12.1 Removing and installing boot . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 406
Contents v
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vi Contents

AG. Volkswagen AG d
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1 Checklist for evaluating running gear
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Damage to running gear may go unnoticed during repairs to load-
wit
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bearing and suspension parts of accident vehicles. Under certain
h re
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circumstances, this undiscovered damage could lead to serious
spec
consequential damage during later vehicle operation. Therefore,
the following parts of accident vehicles must be examined in the
t to the co
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‐
rrectness of i
mations of the running gear.
Visual and functional examination of steering system
cial p
♦ Visual examination for deformation and cracks
nform
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♦ Examination for play in track rod joints and steering box
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♦ Visual examination for tears in boots

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♦ Examine electrical and hydraulic lines and hoses for chafing,

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♦ Examine hydraulic lines, threaded connections and steering

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♦ Check steering box and lines for secure seating.
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♦ Check for flawless function from lock to lock by moving the
Prote AG.
steering from stop to stop. In the process, the steering wheel

must turn with a constant force without resistance.
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 1

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.
AG. Volkswagen AG d
agen oes
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Rep. Gr.00 - Technical data
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2 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 .
AG. Volkswagen AG d
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2. General information 3
AG. Volkswagen AG d
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Golf 2004 ➤ , Golf ePlusd by 2005 ➤ gu
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Running gear, axles,
tho steering - Edition 08.2009 eo
au ra
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40 – Front suspension
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1 Appraisal of accident vehicles
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A checklist for evaluating running gear of accident vehicles can
spec
be found under ⇒ page 1 .
es, in part or in w
t to the co
rrectness of i
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Cop py
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rig by
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4 Rep. Gr.40 - Front suspension

n AG. Volkswagen AG do
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Volks Golfs 2004
ot g ➤ , Golf Plus 2005 ➤
by ua
ir se
d Running gear, axles, steering ran - Edition 08.2009
tee
tho
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s
2 Repairing front suspension
ce
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nl
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itte
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erm
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ility
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2.1 Overview - front axle
wit
is n
h re
ole,
spec
Note
t to the co
♦ It is not permitted to weld or straighten load-bearing or wheel-guiding components of the suspension.
rrectness of i
♦ 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‐
cial p
nform
ded connections of components with bonded rubber bushes when the wheel bearing housing is raised to
mer
unladen position, Golf ⇒ page 6 ; Golf Plus, CrossGolf ⇒ page 8 .
atio
m
r co
n in
o
thi
e
I - Assembly overview - sub‐

t
sd
ir va
frame, anti-roll bar, suspen‐
o
p
cum
or
sion links ⇒ page 10

f
en
ng
t.
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II - Assembly overview - wheel Cop py
ht. rig
bearing ⇒ page 56 opy
rig by
Vo
ht
c lksw
III - Assembly overview - sus‐
by
cted agen
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pension strut ⇒ page 64
AG.
2. Repairing front suspension 5

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-
♦ Support -T10149-
AG. Volkswagen AG d
agen oes
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th
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, is n
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hole
spec
es, in part or in w
t to the co
Caution
rrectness of i
All bolts on running gear components with bonded rubber

bushes may be tightened only when the component is in the
l purpos
unladen position (normal position).

Bonded rubber bushes can be twisted only to a limited extent.
n
ercia
for
Axle components with bonded rubber bushes must therefore

mat
m
com
be brought to a position equivalent to the unladen (normal) po‐

ion
sition before being tightened.

in
r
te o
thi
sd
Otherwise, the bonded rubber bush would be subject to torsion

iva
o
r
loading, shortening its service life.

rp
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Cop py
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n AG. Volkswagen AG do Running gear, axles, steering - Edition 08.2009
wage es n
Volks ot g
To simulate by
ed this position on the lifting platform, raise
ran the respec‐
ua
tive wheel oris suspension with the engine and gearbox teejack -V.A.G
th or
1383ss
au
A- and support -T10149- . ac
ce
e
Before the axle on one side is raised, both sides of the vehicle
nl
pt
du
an
must be strapped to the lifting platform arms with tensioning
itte
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straps -T10038- .
erm
ab
ility
ot p
wit
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WARNING
h re
ole,
spec
If the vehicle is not strapped down, there is a danger that the
t to the co
vehicle will slip off the lifting platform!
rrectness of i
– 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
cial p
nform
-a- between the centre of wheel hub and edge of wheel housing
mer
has been attained.
a
m
tion
o
The dimension -a- depends on the ride height of the installed run‐
c
in t
r
ning gear:
o
his
ate
do
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Running gear 1) Ride height -a- in mm

p
cum
or
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ng
Standard running gear (2UA) 382 ± 10 mm

t.
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Cop py
Heavy-duty running gear (2UB) 402 ± 10 mm
ht. rig
rig ht
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Sports running gear except 18" 367 ± 10 mm
co Vo
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wheels (2UC) Prote AG.
Sports running gear with 18" 367 ± 10 mm

wheels (G02/G05/G07/2UC)
Sports running gear GTI (G08) 360 ± 10 mm
Sports running gear R32 (G09) 362 ± 10 mm
Sports running gear GTI; US 382 ± 10 mm
version (G11)
BlueMotion (G04/2UC) 367 ± 10 mm
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 A-
under 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
V.A.G 1383 A-
wage es n
Volks ot g
y ua
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ris tee
tho
u or
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ss
ce
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nl
pt
du
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itte
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erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
m
io
r co
n in t
o
his
ate
d
iv
o
pr
cu
or
m
f
en
ng
t.
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Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
Note
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).

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- .

straps -T10038- .
WARNING
. Volkswagen AG
If the vehicle is not strapped down, there is a dangerksthat
agenthe
AG does
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vehicle will slip off the lifting platform! by
Vo not
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ara
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ris
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– Turn wheel hub until one of the s a holes
wheel sbolt is at the top. c
ce
e
nl
pt
du
an
itte
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erm
Respective nuts and bolts may be tightened only when dimension
ab
ility
-a- between the centre of wheel hub and edge of wheel housing ot p
wit
has been attained.
is n
h re
ole,
spec
ning gear:
t to the co
rrectness of i
wheels (2UC)
cial p
nform
mer
wheels (G02/G07/2UC)
a
m
tion
o
CrossGolf (2UB) 400 ± 10 mm

c
in t
or
his
e
BlueMotion (G06) 373 ± 10 mm

t
iva
do
pr
cum
or

f
en
ng
t.
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op py
C
ht. rig
ht
here ⇒ page 317 .
rig by
copy Vo
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agen
Prote AG.
-V.A.G 1383 A- until dimension -a- is attained.
WARNING


vehicle.
– Detach support -T10149- .

3 Subframe, anti-roll bar, suspension

link
3.1 Assembly overview: subframe, anti-roll bar, suspension links

AG. Volkswagen AG d
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Caution by
Vol
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♦ It is not permitted to weld or straighten load-bearing
auth
or ra
wheel-guiding components of the suspension. ss c
ce
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ility
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spec
1 - Nut
t to the co
❑ 65 Nm
❑ When tightening, coun‐
ter hold on hexagon
rrectness of i
socket of joint stub.
❑ Self-locking
❑ Always renew after re‐
cial p
nform
moving
mer
2 - Coupling rod
a
m
tion
o
❑ Link between anti-roll

c
in t
or
bar and suspension
his
ate
strut
do
priv
cum
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3 - Bracket
f
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py Co
❑ Fixing position . Co py
⇒ page 17
t rig
gh ht
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cop Vo
❑ If bracket is renewed, cted
by lksw
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the wheels must be Prote AG.
aligned ⇒ page 305
4 - Mounting bracket
❑ Fixing position
⇒ page 17
❑ With bonded rubber
bush
5 - Bolt
❑ 50 Nm + 90° further
moving
6 - Bolt
❑ M12 x 1.5 x 90
moving
7 - Bolt
❑ M12 x 1.5 x 90
❑ Always renew after removing

Runningggear, axles,
en AG. V steering
olkswagen AG
d
- Edition 08.2009
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olks not
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8 - Front left vehicle level sender -G78- ed
b ara
nte
ris
❑ Removing and installing ⇒ page 15 utho eo
ra
a c
ss
❑ Can be tested in guided fault finding using ⇒ Vehicle diagnosis, testing and information system VAS 5051
ce
le
un
pt
9 - Bolt
an
d
itte
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❑ 9 Nm
ab
pe
ility
ot
10 - Suspension link
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❑ Different versions of suspension links are possible (cast steel, aluminium).
hole
spec
❑ Allocation ⇒ Electronic parts catalogue “ETKA”
es, in part or in w
t to the co
Note
rrectness of i
❑ If damaged, also renew swivel joint.
l purpos
❑ Removing and installing ⇒ page 36
❑ Renew bush ⇒ page 47
n
ercia
fo
11 - Suspension link
rm
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atio
❑ Different versions of suspension links are possible (welded steel sheet, single-shell steel sheet).
com
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Note
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❑ If damaged, also renew swivel joint. t. Co py
rig
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❑ Renew bush ⇒ page 47
by lksw
cted agen
Prote AG.
12 - Nut
❑ M12 x 1.5
❑ 60 Nm
❑ Self-locking
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
17 - Bolt
18 - Bolt
❑ M12 x 1.5 x 75
3. Subframe, anti-roll bar, suspension link 11

19 - Bolt
❑ M14 x 1.5 x 70
❑ 100 Nm + 90° further n AG. Volkswagen AG do
swage es n
❑ Do not tighten until pendulum
byV
olk
support is bolted to gearbox
ot g
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ed ran
❑ Always renew after
horis removing tee
t or
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20 - Bracket for skid
ss plate
ce
e

nl
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21 - Bolt
erm
ab
ility
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Always observe size and strength class of the bolt. Different torque specifications apply.
wit
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❑ M10 x 75 strength class 8.8: 40 Nm and turn 90° further
ole,
spec
t to the co
Caution
From model year 08,
rrectness of i
HeliCoil inserts are in‐
stalled in the pendulum
support connection in
cial p
the 02Q gearboxes.
nform
Identification ⇒ Rep. Gr.
mer
34
a
m
tion
co
Use a bolt with hardness
in t
or
his
e
class 10.9 for this and all

at
do
riv
other gearboxes.
p
cum
or
f
en
ng
If there is no HeliCoil in‐

i t.
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sert in the 02Q gearbox, Co py
t. rig
use bolts with the
gh ht
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strength class 8.8 and y cop Vo
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cted
the corresponding tor‐
agen
Prote AG.
que setting.

22 - Bolt
Always observe strength class of the bolt. Different torque specifications apply.

Caution
From model year 08,
HeliCoil inserts are in‐
stalled in the pendulum
support connection in
the 02Q gearboxes.
Identification ⇒ Rep. Gr.
34 .
class 10.9 for this and all
other gearboxes.
AG. Volkswagen AG d
If there is no HeliCoil in‐ lksw
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not
sert in the 02Q gearbox, d byV
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ara
use bolts with the orise nte
strength class 8.8 and th eo
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the corresponding tor‐ ss c
que setting.
ce
le
un
pt
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itte
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rm
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ility
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23 - Bracket to pendulum support
, is n
h re
❑ Not an individual part
hole
spec
es, in part or in w
24 - Pendulum support
t to the co
❑ Bolt first to gearbox and then to subframe
❑ Various versions
rrectness of i
l purpos
25 - Lower bonded rubber bush for pendulum support

❑ Pressing out and in for vehicles with front-wheel drive ⇒ page 28
n
ercia
fo
❑ Pressing out and in for vehicles with four-wheel drive ⇒ page 31
rm
m
atio
com
26 - Shield
n in
r
❑ For vehicles with front-wheel drive only

te o
thi
sd
iva
27 - Bolt
o
r
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❑ 6 Nm m
en
ng
i t.
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❑ Self-locking t. Co py
rig
gh ht
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28 - Subframe
by
cop by
Vo
lksw
cted agen
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❑ Removing and installing without steering box ⇒ page 21

❑ Removing and installing with steering box ⇒ page 23
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

31 - Nut
❑ 65 Nm
❑ When tightening, counter hold on hexagon socket of joint stub.
❑ Self-locking
32 - Anti-roll bar
3.2 Assembly overview - front left vehicle level sender -G78-
Note
♦ 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
AG. Volkswagen AG d
❑ M6 x 16 lksw
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❑ 9 Nm db
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3 - Front left vehicle level send‐ auth
ra
er -G78- and front right vehicle ss c
level sender -G289- ce
e
nl
pt
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❑ Complete with attach‐ an

itte
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ments
erm
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ility
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❑ Lever -arrow- must face wit

is n
outwards
h re
ole,
❑ Removing and installing

spec
⇒ page 15
t to the co
❑ Following renewal, ba‐

sic settings for headlight
must be performed.
rrectness of i
Basic setting of headlights ⇒

"Guided fault-finding" function
of vehicle diagnosis, testing
cial p
and information system

nform
VAS 5051
mer
a
m
tion
4 - Suspension link
co
in t
or
his
e
5 - Nut
at
do
riv
❑ 9 Nm
p
cum
or
f
en
ng
❑ Self-locking
t.
yi Co
op
C py
ht. rig
moving rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

3.3 Removing and installing front left vehicle

level sender -G78-
Special tools and workshop equipment required
♦ Torque wrench -V.A.G 1410-
Removing
wage es n
Note Volks ot g
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rise tee
o
To remove front left vehicle level sender -G78-
auth , steering must be or
ac
turned to right lock to ensure clearance between
ss suspension link
and anti-roll bar.
ce
e
nl
pt
du
an
itte
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erm
– Separate connector.
ab
ility
ot p
– Remove bolt and nut.
wit
is n
h re
ole,
– Take out vehicle level sender.
spec
Installing
t to the co
Install in reverse order. Note the following points:
rrectness of i
Note
♦ Lever on vehicle level sender must face towards outside of

cial p
nform
vehicle.
mer
♦ Thread of vehicle level sender must be screwed into front hole a

m
tion
in suspension link. Lug of bracket for vehicle level sender must
co
in t
r
engage in rear hole in order to guarantee correct installation

o
his
e
position.
t
iva
do
pr
cum
for
en
– Perform basic setting of headlights ⇒ "Guided fault-finding"

ng
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function of vehicle diagnostic, testing and information system Co py
VAS 5051
t. rig
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Specified torques Prote AG.
Component Specified torque

Bolt on subframe 9 Nm
Nut 9 Nm
♦ Use new nut

3.4 Repairing thread in longitudinal member

. Volkswagen AG
wa nuts in the longitudinal gen AG d
Repairing the thread in Vcaptive
olks
oes
nomember
t gu is
possible only underecertain
d by conditions ⇒ Body Repairs; Rep.
ara Gr.
nte
50 . tho
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au ra
3.5 Fixing position of subframe and brack‐
ss c
ce
e
nl
pt
ets
du
an
itte
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erm
ab
ility
ot p
wit
♦ Locating pins -T10096-
is n
h re
ole,
spec
t to the co
rrectness of i
cial p
nform
mer
a
m
tion
co
in t
or
♦ Engine and gearbox jack -V.A.G 1383 A-
his
te
iva
do
pr
cum
for
en
ng
i t.
py Co
t. Co py
rig
gh ht
yri by
y cop Vo
lksw
b
cted agen
Prote AG.
Installing locating pins -T10096-

To fix position of subframe with brackets, locating pins -T10096-
must 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.

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
drive (1st and 2nd generations) up toagmodel
n AG. Vyear
olksw2008
agen AG
w e does
⇒ page 369 . y Volks not
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ed ran
Continue with removing handor installing steering box, right-hand
is tee
drive (2nd generation)s aup
ut to model year 2008 ⇒ page 378 . or
ac
s
Continue with removing and installing steering box, left-hand
ce
e
nl
pt
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drive (3rd generation) after model year 2009 ⇒ page 387 .
an
itte
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erm
ab
Continue with removing and installing steering box, right-hand
ility
ot p
drive (3rd generation) after model year 2009 ⇒ page 394 .
wit
is n
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Removing locating pins -T10096-
ole,
spec
Remove in reverse order. Ensure that the locating pins -T10096-

are replaced one after the other with new bolts.
t to the co
Specified torques
rrectness of i
Subframe to body 70 Nm + 90°
cial p
♦ Use new bolts

nform
mer
Bracket to body 70 Nm + 90°

a
m
ti
♦ Use new bolts

o
o
n in
r c
te o
thi
Mounting bracket to body 70 Nm + 90°

s
a
do
ir v
♦ Use new bolts

p
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for
en
ng
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Cop py
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rig ht
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3.6 Lowering subframe
co Vo
by lksw
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Prote AG.


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pt
du
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itte
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erm
ab
ility
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wit
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ole,
spec
t to the co
Removing
– Turn steering wheel to straight-ahead position and remove ig‐
rrectness of i
nition key so that the steering lock engages.
– Remove footwell trim by removing nuts -arrows-.
cial p
nform
mer
atio
m
r co
n in
o
thi
te
sd
ir va
o
p
cum
for
en
ng
t.
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Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
– Remove bolt -1- and pull universal joint -2- off steering box.
– Install lower noise insulation ⇒ General body repairs, exterior;
Rep. Gr. 50 ; Overview - noise insulation .

– Detach exhaust system bracket from subframe -arrows-.
lkswage es n
o ot g
byV ua
ed ran
oris tee
th or
au ac
ss
ce
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nl
pt
du
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itte
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erm
ab
– Disconnect pendulum support from gearbox by removing bolts
ility
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-14-.
wit
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ole,
– Disconnect coupling rods from anti-roll bar.
spec
– Fixing subframe in position ⇒ page 16
t to the co
rrectness of i
cial p
nform
mer
a
m
tio
o
n in
r c
te o
thi
s
a
do
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p
cum
for
en
ng
i t.
py Co
t. Co py
rig
gh ht
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– Position engine and gearbox jack -V.A.G 1383 A- under sub‐ y cop Vo
lksw
frame.
b
cted agen
Prote AG.
– Place, for example, a wooden block -1- between engine and

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

– 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
♦ Use new bolts!
Subframe to bracket 70 Nm + 90°

♦ Use new bolts!
Anti-roll bar to coupling rod 65 Nm

♦ Use new nut.
♦ Counterhold on multi-point socket of joint pin
Universal joint to steering box 30 Nm

♦ Use new bolt
AG. Volkswagen AG d
agen oes
lksw not
Exhaust system bracket to subframe by Vo gu
ara
⇒ Engine; Rep. Gr. 26 orised
nte
h eo
aut ra
ss c
ce
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nl
pt
du
Specified torques for pendulum support to gearbox

an
itte
y li
erm
ab
ility
Caution
ot p
wit
is n
h re
ole,
From model year 08, HeliCoil inserts are installed in the pen‐
spec
dulum support connection in the 02Q gearboxes. Identification

⇒ Rep. Gr. 34 .
t to the co
Use a bolt with hardness class 10.9 for this and all other gear‐
boxes.
rrectness of i
If there is no HeliCoil insert in the 02Q gearbox, use bolts with

the strength class 8.8 and the corresponding torque setting.
cial p
nform
mer
Bolt Specified torque

a
m
tion
M10 x 35 strength class 8.8 40 Nm + 90° further

co
in t
r
♦ Use new bolt

o
his
ate
do
riv

p
cum
or
♦ Use new bolt

f
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
o Vo
20
by c lksw
cted agen
Rep. Gr.40 - Front suspension Prote AG.


♦ Use new bolt
AG. Volkswagen AG d
agen oes
ksw
M10 x 75 strength class 10.9 by
Vol
50not
Nm
gu + 90° further
ara
♦ Use new bolt rised
nte
tho eo
au ra
ss c
ce
e
nl
pt
du
an
3.7 Removing and installing subframe with‐
itte
y li
erm
ab
out steering box
ility
ot p
wit
is n
h re
ole,
spec
t to the co
rrectness of i
cial p
nform
mer
a
m
tio
r co
n in
o
thi
te
sd
ir va
o
p
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or
m
f
en
ng
t.
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Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
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

– Remove bolts -arrows- on heat shield. n AG. Volkswagen AG do

wage es n
olks ot g
– Remove heat shield from subframe. d by V ua
ran
rise tee
Continuation for all vehicles utho
or
a ac
ss
– Remove coupling rods from anti-roll bar.
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
-14-.
rrectness of i
– Fix position of subframe ⇒ page 16 .
– Now unscrew bolts for:
cial p
♦ steering box -3- and -6-
nform
mer
♦ anti-roll bar -11- and -16-
atio
m
r co
n
♦ and subframe -4- and -5-.
in
o
thi
te
sd
ir va
Installing
o
p
cum
or

f
en
ng
t.
yi Co
– Install noise insulation and tighten, specified torque ⇒ General Cop py
ht. rig
body repairs, exterior; Rep. Gr. 50 ; Assembly overview - rig ht
py by
noise insulation . co Vo
by lksw
cted agen
Prote AG.
Specified torques
♦ Use new bolts

♦ Use new bolts
Anti-roll bar to subframe 20 Nm + 90°

♦ Use new bolts

♦ Use new nut
Shield to subframe 6 Nm
♦ Bolt M6 is self-locking
Swivel joint to cast steel suspension link 60 Nm

♦ Use new nuts
Swivel joint to sheet steel or forged aluminium suspension 100 Nm

link
♦ Use new nuts


Steering box to subframe 50 Nm + 90°
♦ Use new bolts
♦ Always renew clamp on 1st and 2nd generation steering
boxes
Exhaust system bracket to subframe

⇒ Engine; Rep. Gr. 26
Caution
AG. Volkswagen
From model year 08, HeliCoillksinserts
wage are installed indthe
n AG o
es npen‐
dulum support connection byin the 02Q gearboxes. Identification
Vo ot g
ua
⇒ Rep. Gr. 34 .
d ran
rise tee
o h
ut or
ss
a class 10.9 for this and all other gear‐ ac
boxes.
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
♦ Use new bolt
rrectness of i
♦ Use new bolt

cial p
♦ Use new bolt

nform
mer

a
m
♦ Use new bolt

ion
co
in t
or
his
te
iva
do
pr
cum
for
3.8 Removing and installing subframe with

en
ng
t.
yi Co
op
steering box
C py
ht. rig
rig ht
py by
o Vo
Special tools and workshop equipment required by c lksw
cted agen
Prote AG.
♦ Ball joint puller -3287 A-

Golf 2004 ➤ , Golf Plus 2005 ➤ agen
AG. Volkswagen AG d
oes
Running gear, axles, steering - Edition 08.2009 olksw not
byV gu
ara
ed
ris nte
♦ Torque wrench -V.A.G 1332- aut
ho eo
ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
Removing
– Remove battery and battery tray ⇒ Electrical system; Rep.
nform
ercia
Gr. 27 ; Battery; Removing and installing battery .
m
at
– Disconnect cable -1- from electrics box.
m
io
r co
n in t
o
his
ate
d
iv
o
pr
cu
or
m
f
en
ng
i t.
py Co
t. Co py
rig
gh ht
yri by
cop by
Vo
lksw
cted agen
Prote AG.
– Disconnect earth cable -2-.

– Separate connection -3-.
– Thread wiring harness out of all retainers along longitudinal

member so that it can be removed together with the steering
harness.

lkswage es n
o ot g
byV ua
ed ran
oris tee
uth or
a ac
ss
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
– Remove front wheels.
rrectness of i
– Separate connector for extended service intervals on oil sump.
cial p
nform
– Detach coupling rods from anti-roll bar.
mer
a
m
tio
o
n in
r c
te o
thi
s
a
do
ir v
p
c
um
for
en
ng
i t.
– Loosen nut on track rod ball joint but do not remove complete‐ py Co
Co py
ly. t. rig
gh ht
yri by
op
Leave nut screwed on a few turns to protect thread on pin.
c Vo
by lksw
cted agen
Prote AG.
– Press track rod ball joint off wheel bearing housing using ball
joint splitter -3287A- and remove nut now.

AG. Volkswagen
Golf 2004 ➤ , Golf Pluslk2005
swa ➤
gen AG do
es n
Vo ot g
d b steering - Edition 08.2009
y ua
ra
e nte
ris
tho eo
– Disconnect pendulum
au support from gearbox by removing bolts ra
c
ss
-14-.
ce
e
nl
pt
du
– Fix position of subframe with brackets. ⇒ page 16
an
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
rrectness of i
cial p
nfo
mer
rmatio
om
n in
or c
thi
te
sd
iva
– Place engine and gearbox jack -V.A.G 1383 A- under sub‐
o
pr
cu
r
frame.
o
m
f
en
ng
i t.
py Co
– Place a wooden block -1- or similar between V.A.G 1383 A . Co py
and subframe.
t rig
gh ht
yri by
cop by
Vo
lksw
cted agen
Prote AG.
– 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.

– Secure subframe to engine and gearbox jack -V.A.G 1383 A-

with the appropriate strap.
Installing
– Install noise insulation and tighten, specified torque ⇒ General
body repairs, exterior; Rep. Gr. 50 ; Assembly overview -
noise insulation .
Specified torques
♦ Use new bolts

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

♦ Use new nut

♦ Use new nuts

link
♦ Use new nuts

♦ Use new bolt
. Volkswagen AG
gen AG does
swa
Exhaust system bracket to y Vsubframe
olk not
gu
⇒ Engine; Rep. Gr. r26 ised b ara
nte
ho eo
aut ra
ss c
ce
le
un
pt

an
d
itte
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rm
ab
pe
Caution
ility
ot
wit
, is n
h re
hole
spec

es, in part or in w
⇒ Rep. Gr. 34 .
t to the co
boxes.
rrectness of i

l purpos

n
ercia
fo

rmat
m
com

ion
♦ Use new bolt

in
r
te o
thi
sd
iva

o
r
rp
cu
fo
♦ Use new bolt

m
en
ng
i t.
py Co
t. Co py
rig
gh ht
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cop Vo
27
by lksw
cted agen
Prote 3. Subframe, anti-roll bar, suspension link
AG.

Bolt AG. Volkswagen AG d

Specified torque
agen oes
M10 x 75 strength class 8.8 olksw 40 Nm
not + 90° further
yV gu
♦ Use new bolt ir se
db ara
nte
tho eo
u ra
M10 x 75 strength class 10.9 ss
a
50 Nm + 90° furtherc
♦ Use new bolt
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
3.9 Repairing subframe (front-wheel drive) is n
h re
ole,
spec
t to the co
equipment required
♦ Removal tool -3372-
rrectness of i
♦ Assembly tool -T10214-
cial p
nform
mer
a
m
tio
r co
n in
o
thi
te
s
a
do
ir v
p
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
Pressing out bonded rubber bush

– Remove subframe ⇒ page 21 .
– Attach assembly tool -T10244- to subframe.

– 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
♦ Tube -T10244/3- has a larger and a smaller internallkdiameter.
swa
gen oes
not
The subframe must lie against the large internal db
y diameter
Vo of gu
ara
tube -T10244/3-. ir se nte
tho eo
s au ra
c
Pressing in bonded rubber bush s
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
– Bolt bonded rubber bushes together using original bolt, mak‐
es, in part or in w
t to the co
ing sure that both notches -arrows- line up precisely.
rrectness of i
l purpos
nform
mercia
at
m
io
r co
n in t
o
his
ate
d
iv
o
pr
cu
or
m
f
– Insert assembled bonded rubber bushes with bolt head down‐
en
ng
t.
yi
wards into tube -T10214/2- .
Co
Cop py
ht. rig
1- Thrust piece -T10214/3-
rig ht
py by
co Vo
by lksw
2- Bonded rubber bush
cted agen
Prote AG.
3- Tube -T10214/2-
4- Tube -T10214/1-
5- Thrust plate -VW 401-

– 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.

– Detach assembly tool -T10244- from subframe and check
pressed-in bonded rubber bushes forn Aproper
G. Volksseating.
wagen AG
age does
ksw not
y Vol gu
b ara
ed nte
ris
tho eo
au ra
c
ss
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le
un
pt
an
d
itte
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rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
• 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
n
ercia
area of the opening for the pendulum support.

orm
m
atio
• The notches in the bonded rubber bushes must be centred in

com
n in
the subframe opening.

r
te o
thi
• A gap -arrow- between the bonded rubber bushes is accept‐

sd
iva
able.
r
rp
cu
fo
m
en
ng
– Install subframe ⇒ page 22 .

t.
yi Co
Cop py
ht. rig
ht
rig by
copy Vo
by lksw
cted agen
Prote AG.

3.10 Repairing subframe (four-wheel drive)

AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
th
au ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
rrectness of i
cial p
nform
mer
a
m
tion
co
in t
or
his
te
iva
do
pr
cum
for
en
ng
Pressing out bonded rubber bush i t.

py Co
Co py
– Remove subframe ⇒ page 21 .
t. rig
gh ht
yri by
cop Vo
– Press out both bonded rubber bushes at the same time as by lksw
cted agen
illustrated.
Prote AG.
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-.
Pressing in bonded rubber bush

– 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- .
3- Tube -T10214/2-
4- Tube -T10214/1-
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
h o eo
ut
– Press in bonded rubber bushes -1- until dimension -a-
ss a is ob‐ ra
c
tained.
ce
e
nl
pt
du
an
Dimension -a- = 2 - 3 mm.
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
rrectness of i
– Align tube -T10214/2- with pressed-in bonded rubber bushes

on subframe. Corners of inner core should be parallel to edge
cial p
nform
of assembly tool -T10244- .

mer
atio
The distance -a- must be identical on the right and left to ensure
m
r co
parallel installation.
n in
o
thi
e
– Position subframe against smaller internal diameter of tube

t
sd
ir va
-T10244/3-.
o
p
cum
for
en
ng
i t.
py Co
t. Co py
rig
gh ht
yri by
y cop Vo
lksw
b
cted agen
Prote AG.

– 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.
wage es n
Volks ot g
d by ua
ran
ir se tee
tho
or
s au ac
s
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
rrectness of i
• The notches in the bonded rubber bushes must be centred in
the subframe opening.
cial p
nform
• A gap -arrow- between the bonded rubber bushes is accept‐
mer
able.
a
m
tio
– Install subframe ⇒ page 22 .
r co
n in
o
thi
te
s
ir va
do
p
cum
for
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
3.11 Checking swivel joint

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

– 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-
♦ Torque wrench -V.A.G
1332- AG. Volkswagen AG d
agen oes
olksw not
yV gu
♦ Engine and gearbox jack - ised b ara
nte
V.A.G 1383 A- hor eo
aut ra
s c
♦ Torque/angle wrench - s
ce
e
V.A.G 1756-
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
rrectness of i
cial p
nform
mer
a
m
tio
r co
n in
o
thi
te
s
ir va
do
p
cum
for
en
ng
i t.
py Co
t. Co py
rig
gh ht
yri by
y cop Vo
lksw
b
cted agen
Prote AG.
Removing
– Loosen drive shaft bolt at wheel hub:
♦ Hexagon bolt ⇒ page 77
♦ Twelve-point bolt ⇒ page 78

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.
AG. Volkswagen AG d
agen oes
lksw not
Note by
Vo gu
ara
ed
ris nte
ho eo
♦ Place engine and gearbox jack -V.A.G 1383 A-s aoru similar un‐
t ra
c
derneath (danger of accident through falling parts when swivel
s
ce
e
joint is pressed out).

nl
pt
du
an
itte
♦ Leave nut screwed on a few turns to protect thread on swivel
y li
erm
ab
joint.
ility
ot p
wit
is n
h re
Installing
ole,
spec
– Fit swivel joint in wheel bearing housing.
t to the co
– Fit drive shaft in wheel hub.
– Screw on new self-locking nut and counterhold with -T40- Torx
rrectness of i
key.
cial p
nform
mer
a
m
tion
co
in t
or
his
te
iva
do
pr
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

– 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
♦ Use new nuts

link
♦ Use new nuts
. Volkswagen AG
gen AG does
swa
Swivel joint to wheel bearing housingby Volk not
gu
ara
60 Nm
♦ Use new nut ris
ed nte
tho eo
au ra
Drive shaft to wheel hub “hexagon
ss bolt” 200c Nm +180°
♦ Use new bolt
ce
e
nl
pt
du
an
itte
y li
Drive shaft to wheel hub “12-point bolt” 70 Nm + 90°

erm
ab
♦ Use new bolt

ility
ot p
wit
is n
h re
ole,
spec
3.13 Removing and installing suspension link

t to the co
with mounting bracket

rrectness of i

cial p
nform
mer
atio
m
r co
n in
o
thi
te
sd
ir va
o
p
cum
for
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

wage es n
Volks ot g
by ua
d ran
rise tee
tho
u or
a ac
ss
ce
le
un
pt
an
d
itte
y li
erm
Removing
ab
ility
ot p
– Remove wheel.
wit
is n
h re
ole,
– Remove lower noise insulation ⇒ Rep. Gr. 50 ; Assembly
spec
overview - noise insulation .
t to the co
– Pull swivel joint out of suspension link.
rrectness of i
– Fixing position of mounting bracket ⇒ page 17 .
cial p
nform
mer
a
m
tio
r co
n in
o
thi
te
sd
iva
o
pr
cu
r
fo
m
en
ng
i t.
– Replace bolt for left side -1- and for right side -8- with locating
py Co
Co py
pins -T10096- and tighten locating pins to 20 Nm. ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
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.
– Now remove bolt -10- for left side and bolt -17- for right side.

AG. Volkswagen AG d
agen oes
o lksw not
V
Golf 2004 ➤ , Golf Plus 2005 ed by ➤ gu
ara
s nte
tho
ri
- Edition 08.2009 eo
au ra
ss c
– Remove bolts -1-.
ce
e
nl
pt
du
an
– Remove suspension link with mounting bracket.
itte
y li
erm
ab
Installing
ility
ot p
wit
is n
– Insert suspension link with mounting bracket into subframe.
h re
ole,
spec
t to the co
rrectness of i
– Start bolts -10- and -17-, but do not yet tighten.
cial p
nfo
mer
rmatio
om
n in
or c
thi
te
sd
iva
o
pr
cu
or
m
f
en
ng
i t.
py Co
t. Co py
rig
gh ht
yri by
cop by
Vo
lksw
cted agen
Prote AG.
– Start bolt -1- and tighten.

– Now replace locating pin -T10096- with a new bolt and tighten
to specified torque.
– Bolt suspension link to swivel joint and tighten -arrows-.

– 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 .
wage es n
Volks ot g
y ua
edb ran
ir s tee
tho
u or
a ac
Specified torques ss
ce
e
nl
pt
du
an
itte
y li
erm
ab
Mounting bracket to bracket 50 Nm + 90°
ility
ot p
♦ Use new bolts
wit
is n
h re
ole,
spec
♦ Use new bolts
t to the co
♦ Use new nuts
rrectness of i
link
♦ Use new nuts
cial p
Suspension link to bracket 70 Nm +180° nform

mer
a
♦ Use new bolt
m
tion
co
in t
♦ Tighten bolt in unladen state

or
his
ate
do
priv
cum
or
f
en
ng
t.
yi Co
3.14 Removing and installing suspension link Cop py
ht. rig
ht
with mounting bracket (left side for ve‐
rig by
copy Vo
by lksw
hicles with DSG or automatic gearbox‐
cted agen
Prote AG.
es)

wage es n
Volks ot g
y ua
edb ran
ris tee
tho
u or
a ac
ss
ce
Removing
le
un
pt
an
d
itte
– Remove left front wheel.
y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
– Remove bolts -arrows- on heat shield.
rrectness of i
– Remove heat shield from subframe.
l purpos
Continuation for all vehicles n

ercia
form
m
atio
com
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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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– Loosen bolt -17-.
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– Position engine and gearbox jack -V.A.G 1383 A- under sub‐

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.
♦ Ensure boot is not damaged or twisted. AG. Volkswagen AG d
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– Install lower noise insulation ⇒ Generald by body repairs, exterior; ara
ise nte
Rep. Gr. 50 ; Assembly overview tho
r - noise insulation . eo
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Specified torques
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♦ Use new bolts

spec
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♦ Use new bolts
rrectness of i

♦ Use new bolts
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Mounting bracket to bracket 50 Nm + 90°

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♦ Use new bolts

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♦ Use new bolts



♦ Use new bolts
boxes

Caution
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From model yearV08, olks HeliCoil inserts are installed
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34 . nte
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Use a bolt
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3.15 Removing and installing suspension link

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– Remove wheel. d by V ua
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– Remove lower noise insulation auth ⇒ Rep. Gr. 50 ; Assembly or
ac
overview - noise insulationss.
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pt

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– Pull swivel joint out of suspension link.

erm
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– Loosen bolt -10-.

– Remove coupling rods from anti-roll bar.
♦ and subframe -4- and -5-.
– Lower subframe until bolt -10- can be unscrewed completely.
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– Unscrew bolts -1- and remove suspension link with bracket. ss
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n
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– Raise subframe back to its original position.
format
m
– Now replace locating pins -T10096- at positions -1-, -8-, -9-

com
ion
and -18- with new bolts and tighten them to specified torque.
in
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– Screw in bolts -4- and -5- and tighten.

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– Tighten bolts -7-.

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Running gear, axles, AG. Volksw- aEdition
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– Bolt suspension ris link to
e swivel joint and tighten -arrows-. nte
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spec
t to the co
rrectness of i
– Bolt suspension link to bracket in unladen state -10-.
– Bolt coupling rods to anti-roll bar.
cial p
– Attach lower noise insulation ⇒ Rep. Gr. 50 ; Assembly over‐
nform
mer
a
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Specified torques
♦ Use new bolts

♦ Use new bolts

♦ Use new bolts

♦ Use new bolts

♦ Use new nuts

link
♦ Use new nuts
Anti-roll bar to coupling rod 20 Nm + 90°

♦ Use new nut


Suspension link to bracket 70 Nm +180°
♦ Use new bolt

♦ Use new bolts
boxes

AG. Volkswagen AG d
agen
3.16 Renewing bonded Vrubber bush for suspension link
w s no oe
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Special tools and workshop au ac
ss
equipment required
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♦ Tube -T10219/1-
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♦ Drift -T10219/2-
pe
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♦ Thrust plate -VW 402-
h re
hole
spec
♦ Press tool -VW 411-
es, in part or in w
t to the co
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– Press out bonded rubber bush as illustrated.
1- Press tool -VW 411-
2- Tube -T10219/1-
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-
AG. Volkswagen AG d
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– Press in bonded rubber bush until core of bush -1- and hole in
t to the co
suspension link -2- are flush.

rrectness of i
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– Press bush back slightly in the suspension link.

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

equipment required
♦ Guide -VW 439-
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♦ Tube -VW 418 A-
Pressing mounting bracket with bush

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The bonded rubber bush by is available as a replacement part
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2- Guide -VW 439-
3- Thrust plate -VW 402- rrectness of i
Pressing in mounting bracket with bush onto suspension link

– Moisten hexagon flats of suspension link with assembly lubri‐
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nform
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atio
– Carefully press bush onto suspension link to stop.

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3.18 Removing and installing anti-roll bar

equipment required
1332-
V.A.G 1383 A- n AG. Volkswagen AG do
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♦ Ball joint puller -3287 A- ed by V ua
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Removing

– Detach coupling rods from anti-roll bar.

– Loosen nut on track rod ball joint on each side but do not re‐
move completely.
AG. Volkswagen AG d
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– Press track rod ball joint off wheel bearingd bhousing
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– Fixing position of subframe with bracket
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a ⇒ page 16 . c
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pt
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– Unbolt anti-roll bar from subframe -11 and 16-

rrectness of i
.
-14-.
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– Place engine and gearbox jack -V.A.G 1383 A- under sub‐

frame.

AG. Volkswagen AG d
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Installing
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♦ Coat seal on steering box with suitable lubricant, e.g. soft Cop py
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soap, before installing steering box.
rig
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♦ After fitting the steering box to the jointed shaft, ensure that
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the seal is not kinked when lying against the assembly plate
AG.
and that the opening to the footwell is correctly sealed. Oth‐

erwise, this can result in water leaks and/or noise.
♦ Ensure sealing surfaces are clean.
– Install lower noise insulation ⇒ Rep. Gr. 50 ; Assembly over‐

– Install front wheels and tighten ⇒ page 288 .
Specified torques
♦ Use new bolts


♦ Use new bolts

♦ Use new bolts

♦ Use new bolts

♦ Use new nuts

link
♦ Use new nuts
AG. Volkswagen AG d
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Anti-roll bar to coupling rod Volksw 65 Nm not
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♦ Use new nut sed by ara
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♦ Counterhold on multi-point socket of joint pin auth
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♦ Use new bolts
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Suspension link to bracket 70 Nm +180°
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is n
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♦ Use new bolts
rrectness of i
boxes

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♦ Use new bolt
nform
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co
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ate
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Caution
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by lksw
⇒ Rep. Gr. 34 . cted agen
Prote AG.
boxes.

♦ Use new bolt

♦ Use new bolt

♦ Use new bolt


♦ Use new bolt
– After installing, perform basic settings for steering angle send‐

er -G85- ⇒ Vehicle diagnosis, testing and information system
VAS 5051.
AG. Volkswagen AG d
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mer
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rig
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AG. Volkswagen AG d
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Golf 2004 ➤ , Golf Plus by V 2005 ➤
ol not
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d ara
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4 Assembly overview - wheel bearing
ce
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nl
pt
du
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itte
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erm
ab
ility
1 - Wheel bearing housing (3-
ot p
wit
point mounting) - FS III brakes
, is n
h re
hole
spec
⇒ page 60
es, in part or in w
t to the co
❑ With integrated brake
carrier.
❑ If wheel bearing housing
rrectness of i
is renewed, wheels
must be aligned
l purpos
⇒ page 305 .
❑ Allocation ⇒ Electronic
nform
ercia
parts catalogue “ETKA”

m
at
2 - Wheel hub with wheel bear‐
m
io
r co
n
ing (3-point mounting) - FS III
in t
o
brakes
his
ate
d
v

i
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pr
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or
⇒ page 57
m
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❑ The ABS sensor ring is py Co
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hub
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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
❑ 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 .

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
AG. Vbe
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14 - Bolt by
V ua
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❑ Torque setting ⇒ Brake systems;oris Rep. Gr. 46 ; Repairing front brake .tee o
th
au ra
c
15 - Wheel hub with wheel bearing
ss
(4-point mounting)
ce
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nl
pt
du
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itte
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❑ The ABS sensor ring is installed in the wheel hub
erm
ab
ility
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spec
16 - Wheel bearing housing (4-point mounting) - FN3 brakes
t to the co
❑ With bolted-on brake carrier.
❑ If wheel bearing housing is renewed, wheels must be aligned ⇒ page 305 .
rrectness of i
cial p
❑ M12 x 1.5 x 45
nform
mer
atio
m

r co
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o
18 - Drive shaft
thi
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19 - Nut
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❑ Self-locking
agen
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4.1 Removing and installing wheel bearing

housing (3-point mounting)
4. Assembly overview - wheel bearing 57

Removing
Note
AG. Volkswagen AG d
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During this step, vehicle must dnot by be standing on its wheels or
Vo gu
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wheel bearing will be damaged.orise nte
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– Remove wheel.
ce
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nl
pt
du
an
– Remove brake caliper and hang from body using wire ⇒ Brake
itte
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system; Rep. Gr. 46 ; Repairing front brake .
erm
ab
ility
ot p
– Remove ABS speed sensor ⇒ Brake systems; Rep. Gr. 46 ;
wit
is n
Repairing front brake.
h re
ole,
spec
– Remove brake disc.
t to the co
– Press drive shaft as far as possible out of wheel hub (towards
gearbox).
– Remove bolts -arrows-.
rrectness of i
– Take wheel bearing unit out of wheel bearing housing.
Installing
cial p
nform
mer
a
m
– Install brake caliper ⇒ Brake systems; Rep. Gr. 46 ; Repairing
tio
r co
n in
front brake .
o
thi
te

a
do
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p
cum
or

f
en
ng
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♦ Twelve-point bolt ⇒ page 78 t. Co py
rig
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cop by
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cted
Note
agen
Prote AG.

– Install ABS speed sensor ⇒ Brake systems; Rep. Gr. 46 ;

Repairing front brake .
Specified torques
Drive shaft to hub 70 Nm + 90°
♦ Use new bolt
Wheel hub with wheel bearing to wheel bearing housing 70 Nm + 90°

♦ Use new bolts

housing (4-point mounting)

♦ Torque wrench -V.A.G 1332- n AG. Volkswagen AG do

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pt
du
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erm
ab
ility
ot p
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t to the co
Removing
rrectness of i
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nform
mer
a
m
t
Note
ion
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or
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at
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t.
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– Remove wheel.
Co
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system; Rep. Gr. 46 ; Repairing front brake . by c lksw
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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 .

Specified torques
Drive shaft to wheel hub “hexagon bolt” agen
AG. Volkswagen AG d 200 Nm +180°
oes
♦ Use new bolt olksw not
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Drive shaft to wheel hub “12-point bolt” ut ho
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♦ Use new bolt ss
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nl
pt
du
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itte
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♦ Use new bolts
erm
ab
ility
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spec
4.3 Removing and installing wheel bearing housing
t to the co
equipment required
rrectness of i
♦ Ball joint puller -3287A-
cial p
1332-
nform
mer
a
m
tion
V.A.G 1383 A-
co
in t
or
♦ Torque/angle wrench -
his
ate
V.A.G 1756-
do
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pr
cum
or
f
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ng
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t. Co py
rig
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cop by
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Prote AG.

AG. VolkGolf
swage2004
n AG d ➤ , Golf Plus 2005 ➤
agen
VRunning
olksw gear, axles, steering
oes
no-t Edition 08.2009
by gu
ara
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ris
♦ Spreader -3424- tho eo
au ra
c
ss
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un
pt
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d
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rm
ab
pe
ility
ot
wit
, is n
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hole
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es, in part or in w
t to the co
rrectness of i
l purpos
Removing
n
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fo
rm
m
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n in
r
te o
thi
sd
iva
Note
o
r
rp
cu
fo
m
en
ng
t.
yi
Co
op py
wheel bearing will be damaged. t. C rig
gh ht
pyri by
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by
– Remove wheel. cted agen
Prote AG.
system; Rep. Gr. 46 ; Repairing front brake .
– Now remove backplate from wheel bearing housing.
– Loosen nut on track rod ball joint but do not remove complete‐
ly.
joint splitter -3287A- and remove nut now.
gearbox).

AG. Volkswagen AG d
agen oes
olksw not
V
Golf 2004 ➤ , Golf Plus d 2005 ➤
b y gu
ara
ir se nte
Running gear, axles,th steering - Edition 08.2009
o eo
au ra
ss c
– Remove threaded connection between wheel bearing housing
ce
e
nl
pt
and suspension strut -arrow-.
du
an
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
rrectness of i
– Insert spreader -3424- into slot of wheel bearing housing.
cial p
nform
– Turn ratchet handle through 90° and detach from spreader
mer
-3424- .
atio
m
r co
n in
o
thi
te
sd
ir va
o
p
cum
for
en
ng
t.
yi Co
Cop py
ht. rig
ht
rig by
copy Vo
by lksw
cted agen
Prote AG.
– Loosen nuts -arrows-.

– 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 .

Specified torques
Suspension strut to wheel bearing housing 70 Nm + 90°
♦ Use new nut

♦ Use new nuts

link
♦ Use new nuts

♦ Use new nut
Drive shaft to wheel hub “hexagon bolt” 200 Nm +180°

♦ Use new bolt

♦ Use new bolt
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
se nte
ori eo
th
au ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
rrectness of i
cial p
nform
mer
a
m
tion
co
in t
or
his
ate
do
priv
cum
or
f
en
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t.
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Cop py
t. rig
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pyri by
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by
cted agen
Prote AG.

5 Assembly overview: suspension strut

AG. Volkswagen AG d
agen
1 - Shock absorber Volksw
oes
not
gu
by ara
❑ Can be renewed sepa‐ rised
nte
rately utho eo
ra
a c
❑ Allocation ⇒ Electronic ss
ce
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nl
pt
du
an
itte
y li
2 - Bump stop
erm
ab
ility
ot p
3 - Protective sleeve
wit
is n
h re
4 - Coil spring
ole,
spec
⇒ page 76
t to the co
❑ Observe colour coding
rrectness of i
Spring allocation via PR No.
cial p
These numbers are located on
nform
the vehicle data sticker.
mer
a
m
t
❑ Surface of coil must not
ion
co
be damaged.
in t
or
his
ate
5 - Deep groove ball thrust
do
priv
c
bearing
um
or
f
en
ng
t.
6 - Suspension strut mounting
yi Co
Cop py
❑ Note correct installation
t. rig
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position ⇒ page 67
p by
co Vo
by lksw
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7 - Nut
Prote AG.
❑ M14 x 1.5
❑ 60 Nm
❑ Self-locking
moving
8 - Suspension strut turret
9 - Bolt
10 - Protective cap

5.1 Removing and installing suspension strut, Golf

equipment required
1332-
♦ Spreader -3424-
AG. Volkswagen AG d
♦ Engine and gearbox jack - agen oes
olksw not
V
V.A.G 1383 A- ed by gu
ara
ris nte
o
♦ Support -T10149- auth eo
ra
ss c
ce
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nl
pt
du
an
itte
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erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
m
tio
r co
n in
o
thi
te
sd
iva
o
pr
cu
or
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f
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ng
i t.
py Co
t. Co py
rig
gh ht
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cop by
Vo
lksw
cted agen
Prote AG.
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.
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ir se nte
tho eo
au ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
– Pull wheel bearing housing with swivel joint out of suspension
es, in part or in w
link.
t to the co
– Pull outer joint of drive shaft out of wheel hub.
– Secure drive shaft to body with wire.
rrectness of i
l purpos
Caution
nform
ercia
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‐
m
at
m
aged.
io
r co
n in t
o
his
ate
d
v
– Bolt swivel joint to suspension link again.

i
o
pr
cu
or
m
f
en
ng
t.
yi
– Bolt engine and gearbox jack -V.A.G 1383 A- with support
Co
Cop py
-T10149- to wheel hub using a wheel bolt. ht. rig
rig ht
py by
co Vo
by lksw
cted agen
WARNING Prote 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.
– Separate threaded connection between wheel bearing hous‐

ing and suspension strut -arrow-.


-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 A-
until 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
– Remove hexagonobolts
lksw -arrows- for upper shock
agen G do
es n absorber
ot g
mounting anddremove
by
V suspension strut. ua
r e an
ris tee
Installing tho or
au ac
ss
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
Installation position of spring plate

rrectness of i
– Insert suspension strut with one of the two markings

-arrows- pointing forwards.
cial p
nform
mer
a
m
tio
o
n in
r c
te o
thi
s
a
do
ir v
p
cum
for
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

AG. Volk-sw
Edition
agen A 08.2009
agen G do
es n
ksw
Vol ot g
Tighten hexagon bolts ed -arrows- for
by upper shock absorber uamount‐
ran
ing. ho
ris tee
t or
au ac
– Install plenum
ss chamber cover.
ce
e
nl
pt
– Install wiper arms ⇒ Rep. Gr. 92 ; Wiper system; Removing
du
an
itte
and installing wiper arms .
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
rrectness of i
-T10149- to wheel hub using a wheel bolt.
cial p
WARNING
nform
mer
a
m
tion
co
in t
or
his
te
iva
do
pr
cum
for
en
ng
i t.
py Co
t. Co py
rig
gh
– Position suspension strut on wheel bearing housing.
ht
yri by
cop by
Vo
lksw
– Remove wire from wheel bearing housing.
cted agen
Prote 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 -arrow-
WARNING


lkswage es n Golf 2004 ➤ , Golf Plus 2005 ➤
o ot g
d byV Running gear, axles,
ua
ran
steering - Edition 08.2009
e
oris tee
h
– Remove nuts -arrows-.s aut or
ac
s
– Fit drive shaft in wheel hub.
ce
le
un
pt
an
d
itte
– Fit wheel bearing housing with swivel joint in suspension link.
y li
rm
ab
pe
ility
– Bolt swivel joint to suspension link.
ot
wit
, is n
h re
hole
spec
Note
es, in part or in w
t to the co
rrectness of i
l purpos

n
ercia
form
m
atio
Note
com
n in
r
te o
thi
sd
iva
o
r
rp
cu
fo
m
en
ng
i t.
Continue installation in reverse order. py Co
t. Co py
rig
gh ht
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y cop Vo
lksw
b
cted agen
Prote
Specified torques
AG.

♦ Use new nut
Suspension strut to body (suspension turret) 15 Nm + 90°

♦ Use new bolts

♦ Use new nuts

link
♦ Use new nuts
Coupling rod to suspension strut 65 Nm

♦ Use new nut

♦ Use new bolt

♦ Use new bolt

5.2 Removing and installing suspension strut, Golf Plus, CrossGolf

equipment required
1332-
♦ Spreader -3424-
V.A.G 1383 A-
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
r
tho eo
au ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
m
io
r co
n in t
o
his
ate
d
iv
o
pr
cu
or
m
f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
Removing pyri by
Vo
co lksw
by
cted agen
– Loosen drive shaft bolt at wheel hub: Prote AG.

Note

– Remove wheel.

– 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.
wage
Caution Volks
es n
ot g
d by ua
ran
ir se tee
Do not allow the drive shaft to hang
utho down under its own weight, or
for this would allow the innerss ajoint to bend too far and be dam‐ ac
aged.
ce
e
nl
pt
du
an
itte
y li
erm
ab
– Bolt swivel joint to suspension link again.
ility
ot p
wit
is n
h re
ole,
spec
t to the co
WARNING
rrectness of i
cial p

nform

mer
atio
m
r co
n in
o
thi
e
– Separate threaded connection between wheel bearing hous‐

t
sd
ir va
ing and suspension strut -arrow-.

p
cum
for
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.


-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 A-
until 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.
wage es n
Volks ot g
y ua
edb ran
ir s tee
tho
or
s au ac
s
ce
e
nl
pt
du
an
itte
y li
erm
ab
– Remove hexagon bolts -arrows- for upper shock absorber
ility
ot p
mounting and remove suspension strut.

wit
, is n
h re
Installing
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
m
io
r co
n in t
o
his
ate
d
iv
o
pr
cu
or
m
f
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
72
co Vo
by lksw
Rep. Gr.40 - Front suspension Prote
cted AG.
agen

Installation position of spring plate

– Insert suspension strut with one of the two markings
-arrows- pointing forwards. olks
wage es n
o
yV t gu
db ara
rise nte
tho eo
au ra
c
ss
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
Tighten hexagon bolts -arrows- for upper shock absorber mount‐
t to the co
ing.
– Install windscreen wiper motor ⇒ Rep. Gr. 92 ; Windscreen
wash/wipe system; Removing and installing windscreen wiper
rrectness of i
system .
– Install centre section of bulkhead ⇒ Rep. Gr. 50 ; Assembly
overview - plenum chamber bulkhead .
cial p
nform
mer
a
m
tion
co
in t
or
his
te
iva
do
pr
cum
or

f
en
ng
t.
i
py Co
t. Co py
rig
gh ht
yri by
WARNING cop Vo
by lksw
cted agen
Prote AG.
– 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- .

AG. Volkswagen AG d
agen oes
Golf 2004 ➤ , Golf Plus 2005 ➤ Vol
ksw not
gu
by
Running gear, axles, steering -risEdition
ed 08.2009 ara
nte
ho eo
aut ra
– Tighten threaded connection between
ss wheel bearing housing c
and suspension strut -arrow-
ce
e
nl
pt
du
an
itte
y li
erm
ab
WARNING
ility
ot p
wit
is n
h re
ole,
spec
t to the co
rrectness of i
cial p
– Fit drive shaft into wheel bearing.
nform
mer
– Fit wheel bearing housing with swivel joint in suspension link.
a
m
tio
r co
n in
– Bolt swivel joint to suspension link.
o
thi
te
sd
ir va
o
p
cu
Note
or
m
f
en
ng
t.
yi Co
op
Ensure boot is not damaged or twisted. C py
t. rig
gh ht
pyri by
Vo
co
by lksw
cted agen
Prote AG.
Note


Specified torques
♦ Use new nut
Suspension strut to body (suspension turret) 15 Nm + 90°

♦ Use new bolts

♦ Use new nuts

link
♦ Use new nuts
Coupling rod to suspension strut 65 Nm

♦ Use new nut
Drive shaft to wheel hub “hexagon bolt” 200 Nm + 180°

♦ Use new bolt


♦ Use new bolt
5.3 Repairing suspension strut

equipment required
1332-
♦ Spring compressor -V.A.Gwagen AG. Volkswagen AG doe
1752/1- yV
olks s no
t gu
b ara
ed nte
♦ Spring retainertho-V.A.G
ris e or
1752/4- sa
u ac
s
ce
e
♦ Shock absorber set -

nl
pt
du
T10001-
an
itte
y li
erm
ab
♦ Commercially available
ility
ot p
ratchet handle
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
m
io
r co
n in t
o
his
ate
d
iv
o
pr
cu
or
m
f
en
ng
i t.
py Co
t. Co py
rig
gh ht
yri by
cop by
Vo
lksw
cted agen
Prote AG.
– Remove suspension strut ⇒ page 70 or ⇒ page 65 .

AG. Volkswagen AG d
agen08.2009
Running gear, axles, steering - oEdition oes
lksw no t gu
yV
db ara
Removing coil spring ir se nte
tho eo
au ra
– Compress coil spring withssspring compressor -V.A.G 1752/1- c
until deep groove ball thrust bearing is free at top.
ce
e
nl
pt
du
an
itte
1- Spring compressor -V.A.G 1752/1-
y li
erm
ab
ility
2- Torque wrench -V.A.G 1332-
ot p
wit
, is n
3- Tool insert -T10001/8-
h re
hole
spec
4- Ratchet handle -T10001/11-
es, in part or in w
t to the co
5- Tool insert -T10001/5-
6- Spring retainer -V.A.G 1752/4-
rrectness of i
WARNING
l purpos
First compress spring far enough to ensure that upper spring
nform
ercia
plate is free.
m
at
m
io
r co
n in t
o
his
ate
d
iv
o
pr
cu
– Ensure that coil spring is seated correctly in spring retainer -
or
m
f
V.A.G 1752/4- -arrow-.
en
ng
t.
yi Co
op py
– Unscrew hexagon nut from piston rod.
. C rig
ht ht
rig by
py
– Remove individual components of suspension strut and coil
co Vo
by lksw
cted
spring with spring compressor -V.A.G 1752/1- .
agen
Prote 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
Suspension strut mounting to shock absorber 60 Nm
♦ Use new nut

6 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
Removing and installing intermediate shaft ⇒ page
swa
92
gen AG
.
. does
k not
Vol gu
by ara
ed nte
WARNING oris eo
th
au ra
c
ss
When removing and installing drive shafts, do not allow them
ce
le
un
pt
to hang free and stop against joints due to over bending.
an
d
itte
y li
rm
ab
pe
ility
6.1 Loosening and tightening drive shaft
ot
wit
, is n
h re
hexagon bolt
hole
spec
es, in part or in w
t to the co
♦ Torque/angle wrench -V.A.G 1756-
rrectness of i
l purpos
n
ercia
form
m
atio
com
n in
r
te o
thi
sd
iva
o
r
rp
cu
fo
m
en
ng
i t.
py Co
Co py
Wheel bearings must not be subjected to load after bolt securing
t. rig
gh ht
yri by
drive shaft to wheel hub has been loosened. by cop Vo
lksw
cted agen
Prote
If wheel bearings are loaded with weight of vehicle, bearing will
AG.
be damaged. This reduces the service life of the wheel bearing.

It is therefore important to note the following:
♦ 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

Running gear, axles, steering - Edition 08.2009 AG. Volkswagen AG d
agen oes
olksw not
– Remove hexagon bolt -arrow-. ed byV gu
ara
ris nte
Tightening hexagon bolt aut
ho eo
ra
ss c
– Renew hexagon bolt.
ce
e
nl
pt
du
an
itte
y li
erm
ab
Note
ility
ot p
wit
is n
The wheels must not be in contact with the ground when the drive
h re
ole,
shaft bolt is tightened; otherwise, the wheel bearing will be dam‐
spec
aged.
t to the co
– Tighten hexagon bolt to 200 Nm.
rrectness of i
– Lower vehicle onto its wheels.
– Turn hexagon bolt 180° further.
cial p
nform
mer
6.2 Loosening and tightening 12-point
a
m
tio
o
flange bolt securing drive shaft
n in
r c
te o
thi
s
a
do
ir v
p
cum
or
♦ Socket, 24 mm -T10361-
f
en
ng
i t.
py Co
t. Co py
rig
gh ht
yri by
cop by
Vo
lksw
cted agen
Prote AG.
Wheel bearings must not be subjected to load after bolt securing

drive shaft to wheel hub has been loosened.
♦ Procedure for loosening 12-point flange bolt.


Loosening 12-point bolt
wage e
– To avoid damage to wheel bearing, yV
olksdo not loosen 12-point bolt
s no
t gu
using 24 mm socket -T10361- ir se
d bfurther than 90° with vehicle still ara
nte
standing on its wheels. utho eo
ra
sa c
– Raise vehicle so that swheels are off the ground.
ce
le
un
pt
an
d
itte
y li
rm
ab
– Remove 12-point bolt -arrow-.
pe
ility
ot
wit
Fitting 12-point bolt
, is n
h re
hole
– Renew 12-point bolt.
spec
es, in part or in w
t to the co
Note
rrectness of i
l purpos
aged.
n
ercia
format
m
– Tighten 12-point bolt to 70 Nm.

com
ion
in
r

te o
thi
sd
iva
– Turn 12-point bolt 90° further.
o
r
rp
cu
fo
m
en
ng
t.
yi
6.3 Removing and installing drive shaft with
Co
Cop py
ht. rig
constant velocity joint rig ht
py by
co Vo
by lksw
cted
agen
Prote AG.

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
Installing agen oes
olksw not
byV gu
ar
Remove any paint ris residue and/or corrosion on thread and asplines
e d
nte
of outer joint.autho eo
ra
ss c
– Insert drive shaft.
ce
e
nl
pt
du
an
– Guide outer joint into wheel hub splines as far as possible.

itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
rrectness of i
cial p
nform
mer
a
m
tion
co
in t
or
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ate
do
iv
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or
f
en
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i t.
py Co
t. Co py
rig
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Prote AG.

– 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
During this step,olvehicle
ksw
a
must not be standing
oes
not on its wheels or
yV
wheel bearing
sed b will be damaged. gu
ara
n
ri tee
ho
ut or
– Install
ss
a
wheel and tighten ⇒ page 288 . ac
ce
e
nl
pt
du
an
Specified torques
itte
y li
erm
ab

ility
ot p
wit
is n

h re
ole,
♦ Use new nuts

spec

t to the co
link
♦ Use new nuts
rrectness of i

♦ Use new bolt
cial p

nform
♦ Use new bolt

mer
a
m
tion
o
Drive shaft to flange shaft on gearbox “M8 multi-point sock‐ 40 Nm

c
in t
r
et” ♦ Initially tighten diagonally to 10 Nm.

o
his
te
♦ Use new bolts

a
do
priv
cum
r
♦ Use new backing plates

fo
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ng
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py Co
Co py
Drive shaft to flange shaft on gearbox “M10 multi-point
gh
t. rig
ht 70 Nm
socket” yri
♦ Initially tighten diagonally to 10 Nm.
by
cop Vo
♦ Use new bolts by lksw
cted agen
Prote AG.
6.4 Removing and installing left drive shaft

with (push-on) constant velocity slip joint

♦ Multi-purpose tool -VW 771-
♦ Drive shaft puller -T10382-
wage es n
Volks ot g
y ua
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ris tee
tho
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ss
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nl
pt
du
an
itte
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erm
ab
ility
ot p
wit
is n
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ole,
spec
t to the co
rrectness of i
cial p
nform
mer
Removing
atio
m
r co
n
– Loosen drive shaft bolt at wheel hub ⇒ page 78 .
in
o
thi
te
sd
ir va
o
p
Caution
cum
for
en
ng
t.
yi Co
During this step, vehicle must not be standing on its wheels. Cop py
ht. rig
rig ht
The wheel bearing can be damaged by the weight of the vehi‐ py by
co Vo
by lksw
cted agen
Prote AG.

– Remove wheel.


link. wage
es ks not
Vol gu
– Push drive shaft outer joint out ofedwheel
by hub by hand. ara
nte
is
or eo
– Secure drive shaft to preventauthit from falling. ra
ss c
ce
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nl
pt
du
an
itte
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erm
ab
ility
ot p
wit
is n
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spec
– Position puller -T10382/1- behind constant velocity slip joint
-1-.
t to the co
Cut-out -arrow- of puller -T10382/1- must face constant velocity
slip joint -1-.
rrectness of i
cial p
nform
mer
atio
m
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n in
o
thi
te
sd
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cum
for
en
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i t.
py Co
t. Co py
rig
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cop by
Vo
lksw
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Prote AG.

– 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
AG. Volkswaggrease
en AG -G
060 735 A2- agen does
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Vol y gu
db ara
– Mesh outer and inner splines
ris
e of gearbox and constant velocity nte
slip joint. utho eo
ra
a c
ss
– Slide drive shaft into constant velocity joint to stop by hand.
ce
e
nl
pt
du
an
– Now push constant velocity joint onto stub shaft of gearbox
itte
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with a “sudden, hard push”.
erm
ab
ility
ot p
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Note
ole,
spec
Never use a hammer or other striking tool!
t to the co
– Check that constant velocity slip joint is seated securely by
rrectness of i
pulling on constant velocity joint against resistance of retaining
ring.
cial p
Caution nform
mer
For this check, pull only on constant velocity slip joint, not on
a
m
tion
drive shaft.
co
in t
or
his
ate
do
riv
– Detach tensioning strap -T10038- .

p
cum
or
f
en
ng

t.
yi Co
Cop py
ht. rig
ht
rig
– Bolt swivel joint to suspension link -arrows-. py by
co Vo
by lksw
cted agen
Prote AG.
Note

– Tighten drive shaft bolt at wheel hub ⇒ page 78 .
Note


Running
n AG. Volkswaggear,
en AG axles, steering - Edition 08.2009
lkswage does
not
Vo gu
y
Specified torques ised b ara
nte
or eo
h
ut
Component ss a Specified
ra
c torque
ce
le
un
pt
♦ Use new nuts
an
d
itte
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rm
ab
pe
ility
ot
link
wit
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♦ Use new nuts
hole
spec
es, in part or in w
Drive shaft to wheel hub “12-point bolt” 70 Nm + 90° further
t to the co
♦ Use new bolt
rrectness of i
l purpos
6.5 Removing and installing right drive shaft with (push-on) constant velocity
slip joint
n
ercia
format
m
com
ion
equipment required
in
r
te o
thi
sd
iva
♦ Multi-purpose tool -VW
o
r
rp
cu
771-
fo
m
en
ng
i t.
♦ Tensioning strap -T10038- py Co
t. Co py
rig
♦ Drive shaft puller -T10382-
gh ht
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lksw
b
♦ Torque wrench -V.A.G cted agen
Prote AG.
1332-
♦ Torque/angle wrench -
V.A.G 1756-
Removing
– Loosen drive shaft bolt at wheel hub ⇒ page 78 .

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


– 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.
lkswage es n
o ot g
byV ua
ed ran
ris
– Set up drive shaft puller -T10382- . utho tee
or
a ac
For the constant velocity slip joint -1-, notch -arrow- in the puller ss
ce
le
plate -T10382/1- must face the spindles -T10382/2- .

un
pt
an
d
itte
y li
– Assemble drive shaft puller -T10382- complete with multi-pur‐
rm
ab
pose tool -VW 771- .
pe
ility
ot
wit
, is n
h re
hole
Note
spec
es, in part or in w
t to the co
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.
rrectness of i
l purpos
n
ercia
form
m
atio
com
n in
r
te o
thi
– Using tensioning strap -T10038- e.g. on lifting platform arm,

sd
iva
pull suspension strut with attachments back until the drive

r
rp
cu
fo
shaft puller -T10382- can be applied parallel to drive shaft.

en
ng
i t.
py Co
t. Co py
rig
gh ht
yri by
y cop Vo
lksw
b
cted agen
Prote AG.

– 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.
wage es n
Volks ot g
– Detach tensioning strap -T10038- ed.b
y ua
ran
ir s tee
ho
– Guide outer joint into wheel ahub
ut splines as far as possible. or
ac
ss
ce
e
nl

pt
du
an
itte
y li
erm
ab
ility
ot p
Note
wit
is n
h re
ole,

spec
t to the co

– Tighten drive shaft bolt at wheel hub ⇒ page 78 .
rrectness of i
Note
cial p
nform

mer

m
tion
co
in t
or

his
te
iva
do
pr
cum
or
Specified torques
f
en
ng
t.
yi Co
op
C py
ht. rig
rig ht
py by
co Vo
by lksw
♦ Use new nuts cted agen
Prote AG.


link
♦ Use new nuts
Drive shaft to wheel hub “12-point bolt” 70 Nm + 90° further

♦ Use new bolt
6.6 Removing and installing drive shafts

with triple roller joint AAR2600i
wage es n
Volks ot g
by ua
d ran
rise tee
tho
u or
a ac
ss
ce
le
un
pt
an
d
itte
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rm
ab
pe
ility
ot
wit
, is n
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hole
spec
es, in part or in w
t to the co
♦ Wedge -T10161-
rrectness of i
l purpos
n
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form
m
atio
com
n in
r
te o
thi
sd
iva
o
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rp
cu
fo
m
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i t.
py Co
. Co py
rig
Removing
t
gh ht
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cop Vo
by lksw
cted agen
Prote AG.
Note

– Remove wheel.


link.
– Pull drive shaft out of wheel hub and tie up to body.
AG. Volkswagen AG d
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– Insert wedge -T10161- dbetween
by gearbox housing and tripleuaran
ir se
roller joint. tho tee
or
au ac
– Press inner joints out of gearbox by striking wedge -T10161-
s
ce
le
with a hammer.
un
pt
an
d
itte
– Remove drive shaft.
y li
rm
ab
pe
ility
Installing
ot
wit
, is n
– Fit new retaining ring into groove of joint pin.
h re
hole
spec
– Mesh outer and inner splines of joint body and gearbox.
es, in part or in w
t to the co
– Slide drive shaft into joint body to stop by hand.
– Now “suddenly” push joint body into gearbox.
rrectness of i
The joint travel can be used for the “sudden push”. Do not, how‐
l purpos
ever, pull the drive shaft too far out of the joint body.
n
ercia
fo
Note
rm
m
atio
com

n in
r
te o
thi
sd
iva
– Check that drive shaft is seated securely in gearbox by pulling

o
r
rp
cu
on joint body against resistance of retaining ring.

fo
m
en
ng
t.
yi
For this check, pull only on joint body and not on drive shaft.
Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

Note

Note
olkswagen AG
During this step, vehicle must not be standing on its wheels or kswagen AG. V does
wheel bearing will be damaged. by
Vol
not
gu
ara
ed nte
ris
ho eo
– Install wheel and tighten ⇒ page 288 . au
t ra
c
ss
ce
e
nl
pt
Specified torques
du
an
itte
y li
erm
ab
ility
ot p
wit
is n
♦ Use new nuts
h re
ole,
spec
t to the co
link
♦ Use new nuts
rrectness of i
♦ Use new bolt

cial p
nform
♦ Use new bolt
mer
a
m
tion
co
in t
or
his
te
6.7 Removing and installing drive shafts

iva
do
pr
c
with triple roller joint AAR3300i
um
for
en
ng
t.
yi Co
op
Special tools and workshop equipment required C py
ht. rig
rig ht
by
♦ Torque wrench -V.A.G 1332- copy Vo
by lksw
cted agen
Prote AG.
Removing

– 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. AG. Volkswagen AG d
agen oes
lksw not
– Tighten multi-point socket-head bolts diagonally to the speci‐ db
y Vo gu
ara
fied torque. o
ir se nte
eo
th
u ra
– Install lower noise insulation. ⇒ Rep. Gr. 50 ; Assembly
ss
a over‐ c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
Note
t to the co
rrectness of i

cial p
nform
Specified torques
mer
a
m

ion
co
in t
or

his
ate
♦ Use new nuts

do
iv
pr
cum
or
f
en
Swivel joint to sheet steel or forged aluminium suspension

ng
yi 100 Nm t.
Co
link ht.
Cop py
♦ Use new nuts
rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
♦ Use new bolt

♦ Use new bolt

AG. Volkswagen AG d
agen oes
olksw not
V
Golf 2004 ➤ , Golf Plused2005
by ➤ gu
ara
s nte
Running gear, axles,thosteering - Edition 08.2009
ri
eo
au ra
ss c
ce
e
nl
pt
du
an
Drive shaft to flange shaft on gearbox “M8 multi-point sock‐ 40 Nm
itte
y li
erm
et” ♦ Initially tighten diagonally to 10 Nm.
ab
ility
♦ Use new bolts
ot p
wit
is n
h re
Drive shaft to flange shaft on gearbox “M10 multi-point 70 Nm
ole,
spec
socket” ♦ Initially tighten diagonally to 10 Nm.
♦ Use new bolts
t to the co
rrectness of i
6.8 Removing and installing intermediate
shaft
cial p
nform
mer
a
m
tio
r co
n in
o
thi
te
s
ir va
do
p
cum
for
en
ng
i t.
py Co
t. Co py
rig
gh ht
yri by
cop by
Vo
lksw
cted agen
Prote AG.
Removing
– Remove drive shaft on right side ⇒ page 80 .
– Loosen all bolts on bearing bracket -arrows-.
– Pull intermediate shaft off gearbox.
Repairing intermediate shaft ⇒ page 114 .
Installing
– First renew seal -1- on gearbox.

– Now push intermediate shaft onto stub shaft of gearbox until

AG. Volkswagen AG d
bearing -2- contacts bearing kswbracket
agen -1- without “gap”
oes
not
l
-arrow-. by
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a
ed ran
ris tee
tho or
au ac
ss
ce
e
nl
pt
du
an
itte
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erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
– Tighten bolts -arrows- to prescribed torque.
– Install drive shaft ⇒ page 80 .
rrectness of i
l purpos
nform
mercia
at
m
io
r co
n in t
o
his
ate
d
iv
o
pr
cu
or
m
f
en
ng
t.
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Specified torques ht. Cop py
rig
rig ht
py by
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by lksw
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Intermediate shaft bearing to bearing bracket 20 Nm
Prote AG.

Running gear, axles, steering - Edition 08.2009 agen
AG. Volkswagen AG d
oes
olksw not
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7 Repairing drive shaft - overview of drive shafts
ri
tho eo
au ra
ss c
ce
le
un
pt
I - Assembly overview - drive
an
d
itte
y li
shaft with VL90 or VL100 con‐
rm
ab
stant velocity joint
pe
ility
⇒ page 97
ot
wit
, is n
h re
II - Assembly overview - drive
hole
spec
shaft with VL107 constant ve‐
es, in part or in w
locity joint (bolt-on)
t to the co
⇒ page 107
III - Assembly overview - drive
rrectness of i
shaft with VL107 constant ve‐
locity slip joint (push-on)
l purpos
⇒ page 116
n
ercia
form
m
atio
com
n in
r
te o
thi
sd
iva
o
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rp
cu
fo
m
en
ng
i t.
py Co
t. Co py
rig
gh ht
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cop by
Vo
lksw
cted agen
Prote AG.

IV - Assembly overview - drive

shaft with triple roller joint
AAR2600i ⇒ page 121
V - Assembly overview - drive
shaft with triple roller joint
AAR3300i ⇒ page 127
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
th
au ra
ss c
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nl
pt
du
an
itte
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erm
ab
ility
ot p
Distinguishing between drive shafts when installed

wit
is n
h re
ole,
VL90 VL100 VL107 (bolt- VL 107 (push- AAR2600i AAR3300i

spec
on) on)
t to the co
Diameter of 90 100 107 - - -

inner joint in
mm
rrectness of i
Cover be‐ - - X - - -
tween inner
joint and drive
cial p
flange
nform
mer
With bearing - - X - - X
a
bracket on
m
tio
r co
n in
right side
o
thi
e
Inner joint fit‐ - - - - X -

t
sd
ir va
ted in gearbox
o
p
cu
or
m
f
Inner joint - - - x - -
en
ng
i t.
pushed onto
py Co
Co py
stub shaft
t. rig
gh ht
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cop by
Vo
lksw
cted agen
Prote AG.
7. Repairing drive shaft - overview of drive shafts 95

7.1 Heat shields for drive shafts

Front-wheel drive
Hexagon bolt -1- 25 Nm
Four-wheel drive:
Nuts -1- 20 Nm
♦ Initially tighten all nuts to n AG. Volkswagen AG
10 Nm olkswage does
no
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un
pt
an
d
itte
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erm
ab
ility
ot p
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Four-wheel drive:
is n
h re
ole,
spec
t to the co
Nuts -1- 20 Nm
♦ Initially tighten all nuts to
10 Nm
rrectness of i
cial p
nform
mer
a
m
tio
r co
n in
o
thi
te
sd
iva
o
pr
cu
r
fo
m
en
ng
i t.
py Co
t. Co py
rig
gh ht
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cop by
Vo
lksw
cted agen
Prote AG.

8 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
swage es n
2 - Bolt yV
olk ot g
ua
d b ran
❑ M16 x 1.5 x 80oris
e
tee
th or
❑ Hexagonssbolt,
au
200 Nm ac
and turn +180° further
ce
e
nl
pt
du
❑ 12-point bolt, 70 Nm +
an
itte
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90° further
erm
ab
ility
ot p
moving
wit
, is n
h re
hole
When bolt is loosened or tight‐
spec
ened, vehicle must not be
es, in part or in w
standing on its wheels
t to the co
3 - Right drive shaft
rrectness of i
4 - Hose clip
l purpos

moving
❑ Tightening ⇒ page 103
nform
mercia
5 - Boot
a
m
tio
r co
❑ Check for splits and

n in
o
chafing
thi
te
sd
va
❑ Material: Hytrel (poly‐

i
o
pr
cu
ester elastomer)
or
m
f
en
ng
i t.
py Co
6 - Hose clip t. Co py
rig
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op
moving
c Vo
by lksw
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Prote
AG.
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
12 - Left drive shaft
13 - Locking plate
❑ Renew each time after removing wage
es n
Volks ot g
14 - Multi-point socket head bolt d by ua
ran
ir se tee
❑ Initially tighten diagonally to 10 Nm and then
th tighten diagonally to specified torque.
o
or
s au ac
s
M8 bolt: 40 Nm
ce
le
un
pt
an
d
M10 bolt: 70 Nm
itte
y li
erm
ab
❑ Always renew bolts after removing
ility
ot p
wit
is n
15 - Retaining ring
h re
ole,
❑ Remove and install with -VW 161- A.
spec
16 - Seal
t to the co
❑ Adhesive surface on constant velocity joint must be free of oil and grease!
17 - Inner constant velocity joint
rrectness of i
❑ Renew only as complete unit
❑ Pressing off ⇒ page 102
cial p
❑ Pressing on ⇒ page 102
nform
mer
a
m
tio
18 - Dished spring
r co
n in
o
thi
te
sd
iva
o
pr
cu
r
fo
m
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

8.1 Dismantling and assembling drive shaft with VL90 or VL100 constant ve‐
locity joint

equipment required
♦ Press tool -VW 408 A-
♦ Tube -VW 416 B-
♦ Thrust plate -VW 447 H-
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ir se nte
tho eo
au ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
rrectness of i
cial p
nform
mer
atio
m
r co
n in
o
thi
te
sd
ir va
o
p
cum
for
en
ng
t.
yi Co
Cop py
ht. rig
ht
rig by
copy Vo
by lksw
cted agen
Prote AG.
♦ Circlip pliers -VW 161 A-

1331-
1332-
♦ Special pliers -V.A.G 1682- AG. Volkswagen AG d
agen oes
olksw not
♦ Assembly tool -T10065- d by
V gu
ara
ir se nte
tho eo
au ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
is n
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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 -T10382-
and multi-purpose tool -VW 771- .
1- Puller plate -T10382/1-
2- Spindles -T10382/2-
Driving on outer constant velocity joint AG. Volkswagen AG d
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Installation position of dished spring 1 and thrust washer 2 on

outer joint
1- Dished spring
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2- Thrust washer
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– Install new retaining ring.

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– If necessary, push new joint boot onto drive shaft.

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– Drive onto shaft with plastic head hammer until retaining ring
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Pressing off inner constant velocity joint utho eo
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Assembling
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Installation position of dished spring at inner joint
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Pressing on inner constant velocity joint
Note
Chamfer on internal circumference of ball hub (splines) must face

contact shoulder on drive shaft.

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
AG. Volkswagen AG d
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♦ Make sure thread of spindle -A- on pliers moves freely. Lubri‐
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h re
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spec
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es, in part or in w
force for the clip will not be attained although the correct torque
t to the co
is applied.
rrectness of i
Tightening hose clip on small diameter
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8.2 Checking outer constant velocity joint
cted agen
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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.
– 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. wage
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– Press in opposing balls one after the other; ethe d b original position
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– Fit new retaining ring into hub. ss
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an
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8.3 Checking inner constant velocity joint
ility
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Removing
hole
spec
es, in part or in w
soiled, and to check the running surfaces and the balls for wear
t to the co
and damage.
rrectness of i
– Press out joint body in direction of arrow.

l purpos
– Press balls out of cage.

n
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Note
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in
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The ball hub and joint body are paired. Do not interchange them.
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– 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.
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– Also make sure that chamfer onVinner olks circumference of ball s not g
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hub is visible after swinging eitd binto
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– Swing ball hub into place by swinging hub out of cage as

t to the co
shown in figure -arrows-.

rrectness of i
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– Swivel in hub with balls by applying firm pressure to cage

-arrow-.
Checking function of constant velocity joint
The constant velocity joint is correctly assembled if the ball
gen AGhub
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9 Assembly overview - drive shaft with VL107 constant velocity joint

(bolt-on)

plete unit
❑ Removing ⇒ page 110 .
❑ Installing: drive onto agen AG. Volkswagen AG do
shaft to stop using olksa
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❑ Checking aut ⇒ page 103
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2 - Bolt
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❑ M16 x 1.5 x 80
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❑ Hexagon bolt, 200 Nm
rm
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90° further
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3 - Hose clip
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4 - Boot
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5 - Hose clip cop Vo
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❑ Always renew after re‐ Prote AG.
moving
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
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 A-
16 - Seal
❑ Checking ⇒ page 104 wage es n
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18 - Cap orise
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❑ Drive off carefully withssdrift
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❑ Adhesive surface must be free of oil and grease!

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19 - Locking plate
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is n
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spec
❑ Initially tighten diagonally to 10 Nm and then tighten diagonally to specified torque.

t to the co
M8 bolt: 40 Nm
rrectness of i
M10 bolt: 70 Nm
21 - Hose clip
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22 - Bolt
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23 - Countersunk head bolt
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❑ Qty. 3
24 - Bearing bracket
❑ 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
♦ Support sleeve -VW 522-
♦ Tensioner -40 - 204 A-
♦ Special pliers -V.A.G 1682-
AG. Volkswagen AG d
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AG. Volkswagen AG d
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♦ Puller -T10382-
an
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– Fold back boot.
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– Assemble puller -T10382- complete with multi-purpose tool - Cop py
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– Pull constant velocity joint from drive shaft with puller -T10382- Prote
cted AG.
agen
Driving on outer constant velocity joint

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 n AG. Volkswagen AG do

lkswage es n
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– Remove retaining ring. ed b ua
ran
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– Remove both hose clips and slide bootatowards outer joint.
uth or
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– Use drift to drive off boot.
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Pressing off inner constant velocity joint
rrectness of i
Assembling
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1- Dished spring Prote AG.

– Press joint on to stop.
– Install retaining ring.
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– Coat sealing surface of cover with -D 454 300 A2- .
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– Apply continuous bead of sealant (2...3 mm Ø) past inner edge
erm
ab
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of holes -arrow- to clean surface of cover.
ot p
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– Using bolts -arrows-, align new cover in relation to bolt holes.
mer
The alignment must be very accurate, because no further align‐
a
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ment is possible once the part has been hammered on.
r co
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– Drive on cover using a plastic hammer.
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– Wipe off surplus sealant.
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-arrows B-.
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– Tighten hose clip by turning spindleolkwith
swa a torque wrench (do
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Note
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♦ Because a stainless steel hose clip is required due to the hard
itte
y li
erm
material of the joint boot (compared to rubber), it is possible to
ab
ility
tighten the hose clip only with special pliers -V.A.G 1682- .
ot p
wit
is n
h re
ole,
spec
♦ Use torque wrench -C- with adjustment range 5 … 50 Nm, (e.g.
t to the co
rrectness of i
is applied.
cial p
nform
mer
atio
m
r co
n i
Checking outer constant velocity joint ⇒ page 103
n
o
thi
te
sd
ir va
Checking inner constant velocity joint ⇒ page 104
o
p
cum
for
Checking function of constant velocity joint ⇒ page 106
en
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9.2 Repairing intermediate shaft

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Special tools and workshop ot g
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equipment required
ris
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tee
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♦ Thrust plate
s a -VW 401-
u ac
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nl
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♦ Thrust piece -T10032-
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ab
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♦ Thrust piece -3118-
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♦ Separating device Kukko
h re
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-15-2-
spec
t to the co
rrectness of i
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Prote AG.
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
4- Separating device Kukko -15-2-
Note
Hold shaft when pressing out.

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-
6- Separating device Kukko -15-2-
7- Thrust plate -VW
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Shoulder -arrow-
ed
by of press tool -3118- must be facing
ua
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10 Assembly overview - drive shaft with VL107 constant velocity slip joint
(push-on)

❑ Renew only complete
plastic mallet
2 - Bolt
moving
AG. Volkswagen AG d
When bolt is loosened or tight‐ wage
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ened, vehicle must not be db
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3 - Circlip ss c
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4 - Thrust washer
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❑ Installation position
spec
⇒ page 118
t to the co
5 - Dished spring
❑ Installation position
⇒ page 118
rrectness of i
6 - Clamp
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7 - Boot
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8 - Clamp . Cop py
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❑ Always renew after removing rig ht
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9 - Drive shaft
10 - Clamp
11 - Boot for constant velocity slip joint
12 - Circlip

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rise Running gear, axles, steering - Edition nte 08.2009
ho eo
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13 - Clamp
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14 - Constant velocity slip joint
ot
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❑ Renew only complete
hole
spec
es, in part or in w
t to the co
❑ Installing: drive onto shaft to stop using a plastic mallet
rrectness of i
10.1 Dismantling and assembling drive shaft
l purpos
with VL107 (push-on) constant velocity
slip joint
n
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format
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com
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Cop py
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♦ Puller -T10382-

– Fold back boot.
VW 771- .
10. Assembly overview - drive shaft with VL107 constant velocity slip joint (push-on) 117

outer joint
AG. Volkswagen AG d
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1- Dished spring Volksw
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2- Thrust washeror ise nte
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– Install new retaining
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Removing inner constant velocity slip joint

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t to the co

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VW 771- .
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tion
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ate
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Driving on inner constant velocity slip joint

pr
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– If necessary, push new joint boot onto drive shaft. ht. rig
rig ht
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– Knock onto shaft with plastic hammer until circlip engages. by c lksw
cted agen
Prote AG.


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- .
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is applied. swa
gen AG does
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Tightening hose clip on small diameter ho eo
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The joint is to be dismantled to renew the grease if it is heavily n

ercia
format
damage.
m
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ion
Removing
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– Swing ball hub and ball cage. i t.

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Prote AG.
10. Assembly overview - drive shaft with VL107 constant velocity slip joint (push-on) 119
joint body.
– 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
AG. Volkswagen AG d
becomes noticeable during lksw load change jolts; in esuch
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Installing ss a ac
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– Fit cage with hub into joint body.
rm
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ot
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of the hub relative to the cage and joint body must be restored.
h re
hole
spec
– Fit new retaining ring into hub.

es, in part or in w
t to the co

rrectness of i
l purpos
n
ercia
form
m
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by
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11 Assembly overview - drive shaft with triple roller joint AAR2600i

plete unit
❑ Removing ⇒ page 124 . n AG. Volkswagen AG do
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3 - Right drive shaft
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4 - Left drive shaft
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5 - Hose clip
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chafing
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7 - Hose clip
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 1275-
12 - Boot for triple roller joint
11. Assembly overview - drive shaft with triple roller joint AAR2600i 121
13 - Hose clip
14 - 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 Dismantling and assembling drive shaft with triple roller joint AAR2600i

equipment required
♦ Thrust plate -VW 402- olks
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♦ Press tool -VW 408 A- rised ran
tee
tho
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♦ Press tool -VW 411-ss au ac
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♦ Tube -VW 416 B-

nl
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♦ Thrust washer -VW 447 H- y li

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♦ Hose clip pliers -V.A.G

1275-
AG. Volkswagen AG d
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♦ Assembly tool -T10065- erm
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y ua
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♦ Puller -T10382-
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– Pull constant velocity joint from drive shaft with puller -T10382- co Vo
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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.

AG. Volkswagen AG d
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ss Running gear, axles, steering - Edition 08.2009
ce
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– Remove retaining ring.
itte
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1 - Pliers (commercially available)
ility
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- or -VW 161 A-
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spec
– Set drive shaft into press.
t to the co
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– Press triple roller spider off drive shaft.
mer
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– Pull boot off shaft.
ion
co
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his
ate
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Assembling
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– Push small hose clip for boot onto shaft.
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– Push joint body onto shaft.
by lksw
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Fitting triple roller spider
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)

roller joint.
– Tighten both hose clips with hose clip pliers -V.A.G 1275- .
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Running gear, oaxles,
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12 Assembly overview - drive shaft with triple roller joint AAR3300i
ara
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plete unit
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shaft with plastic mallet
spec
until compressed retain‐
t to the co
ing ring seats.
rrectness of i
2 - Bolt
❑ M16 x 1.5 x 80
cial p
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a
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m
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❑ Always renew after re‐ Prote AG.
moving
4 - Boot for constant velocity
joint
chafing
ester elastomer)
5 - Hose clip
moving
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
12 - Boot for triple roller joint
13 - Hose clip
14 - 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
M8 bolt: 40 Nm wage es n
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12.1 Dismantling and assembling drive shaft with triple roller joint AAR3300i

equipment required
♦ Press tool -VW 408 A- wage
es n
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♦ Press tool -VW 411- byV ua
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♦ Tube -VW 416 B- auth or
ac
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1275-
1331-
♦ Torque wrench -
V.A.G 1332-
AG. Volkswagen AG d
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du
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t to the co
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♦ Puller -T10382- agen

AG. Volkswagen AG d
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n
VW 771- .
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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.
– Remove retaining ring.

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.
AG. Volkswagen AG d
agen oes
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se nte
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As of 08.2004, a different grease is used in the triple roller joints. t to the co

This grease cannot be mixed with the previous one. The triple
roller joint must therefore be cleaned before greasing during re‐
pair work.
rrectness of i

cial p
nform
mer
roller joint.
a
m
tion
co

in t
or
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ate

do
priv
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or
Drive shaft (cylindrical version)

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

wage es n
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Note o
ir se
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th or
au ac
To make it easier to insert the multi-point socket-head bolts when ss
ce
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installing the drive shaft, position ear -arrow A- of hose clip be‐
nl
pt
du
an
tween mounting flanges -arrows B- of joint body.
itte
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– Tighten hose clip using hose clip pliers -V.A.G 1275-.

rrectness of i
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mer
a
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tion
co
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or
his
ate
do
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pr
cum
or
f
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t.
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– Tighten small hose clip using hose clip pliers -V.A.G 1275-. ht. Cop py
rig
rig ht
py by
co Vo
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42 – Rear suspension
AG. Volkswagen AG d
agen oes
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th
au ra
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nl
pt
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ab
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t to the co
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co
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ate
do
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t.
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134 Rep. Gr.42 - Rear suspension

2 Repairing rear suspension (front-

wheel 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 (front-
wheel drive) ⇒ page 173
IV - Assembly overview: anti-
roll bar (front-wheel drive)
⇒ page 179
AG. Volkswagen AG d
agen oes
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d by ara
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au ra
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Note
rrectness of i
♦ It is not permitted to weld or straighten load-bearing or wheel-

guiding components of the suspension.
cial p

nform
mer

atio
m
r co
♦ Bonded rubber bushes can be twisted only to a limited extent.

n in
Therefore, you should only tighten the threaded connections

o
thi
te
sd
of components with bonded rubber bushes when the wheel

ir va
bearing housing is raised to unladen position, Golf

p
cum
or
⇒ page 136 ; Golf Plus, CrossGolf ⇒ page 138 .

f
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ng
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py Co
t. Co py
rig
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cop by
Vo
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135
Prote AG.
2. Repairing rear suspension (front-wheel drive)

2.2 Rear axle in unladen position, Golf

AG. Volkswagen AG d
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Special tools and workshop ed by gu
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equipment required ho
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♦ Engine and gearbox jack - ss c
V.A.G 1383 A-
ce
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nl
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t to the co
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o
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t.
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Cop py
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pyri by
Vo
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cted agen
Prote AG.
Note


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- .

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 -a-

ning gear:

olkswagen AG
Standard running gear (2UA) 380 ± 10 mm swagen AG. V does
k not
Vol
Heavy-duty running gear (2UB) 400 ± 10 ed mm
by gu
ara
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Sports running gear except 18" 365ut±
ho 10 mm eo
ra
wheels (2UC) ss
a c
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le

un
pt
an
wheels (G02/G05/G07/2UC)
d
itte
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spec
version (G11)
es, in part or in w
t to the co
BlueMotion (G04/2UC) 365 ± 10 mm
rrectness of i
l purpos
here ⇒ page 317 .

n
ercia
until dimension -a- is attained. form

m
atio
com
WARNING
n in
r
te o
thi
sd
iva

o
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rp
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fo
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i t.
♦ Do not leave the engine and gearbox jack under the ve‐
py Co
Co py
hicle for longer than necessary.
t. rig
gh ht
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cted agen
Prote AG.
– Pull engine and gearbox jack out from underneath vehicle.
– Remove support -T10149- .
2. Repairing rear suspension (front-wheel drive) 137

2.3 Rear axle in unladen position, Golf Plus, CrossGolf

equipment required
V.A.G 1383 A-
AG. Volkswagen AG d
agen oes
olksw not
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ara
ed
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aut ra
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itte
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spec
t to the co
rrectness of i
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a
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Note
n in
o
thi
te
s
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do
p

um
for
en

ng
i t.
py Co
t. Co py
rig
gh
ht
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lksw
b
cted agen
Prote AG.
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- .

straps -T10038- .
WARNING


ning gear:

wheels (2UC)
wheels (G02/G07/2UC)
CrossGolf (2UB) 395 ± 10 mm
BlueMotion (G06) 370 ± 10 mm
vehicle data sticker. The running gear is identified by the PR n AG. Volkswagen AG do
number. Which PR. No. refers to which running gear can be found wage es n
Volks ot g
here ⇒ page 317 . ed
by ua
ra
is nte
or eo
– Raise wheel bearing housing using engine and gearbox
au
th jack ra
until dimension -a- is attained. ss c
ce
e
nl
pt
du
an
itte
WARNING
y li
erm
ab
ility
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h re
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spec

t to the co

rrectness of i

– Pull engine and gearbox jack out from underneath vehicle.
cial p
nform

mer
a
m
tion
co
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or
his
ate
do
priv
cum
or
f
en
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t.
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Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote
139
AG.
2. Repairing rear suspension (front-wheel drive)

AG. Volkswagen AG d
agen oes
olksw not
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d by ara
Golf 2004 ➤ , Golf Plus 2005 ➤ ho
ir se nte
eo
t
au ra
c
ss
ce
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nl
pt
du
an
3 Assembly overview: subframe, transverse link, track rod (front-wheel
itte
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drive)
ility
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1 - Eccentric bolt
spec
❑ For camber adjustment
t to the co
❑ Check wheel alignment
whenever this compo‐
rrectness of i
nent is loosened
⇒ page 305 .
2 - Nut
cial p
❑ M12 x 1.5
nform
❑ 95 Nm mer
a
m
tion
❑ Self-locking
co
in t
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his
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a
do
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❑ Always tighten threaded
um
or
f
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connections in unladen
t.
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position: Cop py
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Golf ⇒ page 136 p by
co Vo
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Golf Plus, CrossGolf
AG.
⇒ page 138
3 - Eccentric washer
❑ Inner hole with lug
4 - Eccentric bolt
❑ For track adjustment
nent is loosened
⇒ page 305 .
6 - Nut
❑ 95 Nm
Note
❑ M12 x 1.5
❑ Self-locking
Golf ⇒ page 136
7 - Subframe
8 - Bolt
❑ M12 x 1.5 x 90
9 - Lower transverse link

10 - Nut
❑ M12 x 1.5 x 75
❑ 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
❑ Self-locking
Golf ⇒ page 136
olkswagen AG
en AG. V
17 - Bolt olks
wag does
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❑ Always renew after removing ise
d b ara
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❑ Always tighten threaded connections in
au
thunladen position: eo
ra
ss c
Golf ⇒ page 136
ce
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nl
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18 - Upper transverse link

wit
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spec
19 - Washer
t to the co
20 - Nut
❑ M14 x 1.5
rrectness of i

❑ Self-locking
cial p

nform
mer
Golf ⇒ page 136

a
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21 - Wheel bearing housing

p
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141
cted agen
Prote AG.
3. Assembly overview: subframe, transverse link, track rod (front-wheel drive)

22 - Washer
23 - Bolt
Golf ⇒ page 136 n AG. Volkswagen AG do
wage es n
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Golf Plus, CrossGolf ⇒ page 138 d by
V ua
ran
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24 - Track rod au
th or
ac
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♦ Forwards closed (left and right track rods differ)
itte
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♦ Downwards open (left and right track rods identical)
ility
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❑ It is permitted to install mixed types.
wit
is n
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t to the co
25 - Bolt
rrectness of i
26 - Nut
❑ M12 x 1.5
cial p
nform
❑ Self-locking
mer
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c

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Golf ⇒ page 136
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3.1 Removing and installing rear axle

equipment required
1332-
♦ Engine/gearbox jack -
V.A.G 1383/A -
AG. Volkswagen AG d
agen oes
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Removing subframe with attachments

hole
spec
es, in part or in w
– Remove wheels.
t to the co
– Removing coil springs ⇒ page 174

– Remove front and rear silencers of exhaust system ⇒ Engine
rrectness of i
⇒ Rep. Gr. 26
l purpos
– On vehicles with automatic headlight range control, separate

wiring connection -1-.
n
ercia
fo
– Remove ABS speed sensor out of wheel bearing housing.

rm
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atio
com
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3. Assembly overview: subframe, transverse link, track rod (front-wheel drive) 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 -2-

from brake cable bracket.
wage es n
Volks ot g
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nl
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spec
Vehicles with retainer for handbrake cable

t to the co
– Remove retainer -1- by pushing out inner pin of rivet -arrow-.
Continuation for all vehicles
rrectness of i
cial p
nform
mer
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– 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.

wage es n
Volks ot g
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rise tee
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ss
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nl
– Now secure vehicle to hoist using tensioning straps -T10038

pt
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-.
itte
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WARNING
wit
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hole

spec
es, in part or in w
vehicle will slip off the lifting platform/hoist.

t to the co
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l purpos
nform
mercia
at
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o
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ate
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Cop py
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Prote AG.

AG. Volkswagen AG d
agen oes
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Golf 2004 ➤ , hGolf
orise
Plus 2005 ➤ nte
eo
t
Running gear,a axles, steering - Edition 08.2009
u ra
c
ss
ce
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nl
pt
du
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itte
frame using universal gearbox mounting -V.A.G 1359/2- and
y li
erm
ab
secure with tensioning strap.
ility
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wit
is n
h re
ole,
spec
t to the co
rrectness of i
cial p
nform
– Unscrew bolt -1- or -2- on both sides.
mer
a
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o
n in
Note
r c
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s
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Only the left vehicle side is shown to improve clarity.

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– Secure position of subframe using 2 locking devices -T10096-

and tighten to 20 Nm.
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

n AG. Volkswagen AG o
Running
olksgear,
wage axles, steering - dEdition
es n
o
08.2009
yV t gu
db ara
Specified torques ir se nte
tho eo
au ra
c
Component ss Specified torque
ce
e
nl
pt
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♦ Use new bolts
y li
erm
ab
ility
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Shock absorber to wheel bearing housing 180 Nm
wit
, is n
h re
hole
spec
♦ Use new bolts
es, in part or in w
t to the co
Handbrake cable to trailing arm
⇒ Brake systems; Rep. Gr. 46
rrectness of i
l purpos
nform
mercia
at
m
io
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n in t
o
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ate
d
iv
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t.
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Cop py
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rig ht
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by lksw
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Prote AG.
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- .
wage es n
Volks ot g
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1 - Subframe tho tee
or
s au ac
2 - Lower transverse link s
ce
le
un
pt
3 - Bolt
an
d
itte
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❑ 5 Nm
rm
ab
pe
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ot
4 - Rear left vehicle level send‐
wit
, is n
er -G76-
h re
hole
spec
❑ Complete with attach‐
es, in part or in w
ments
t to the co
❑ Lever -arrow- must face
outwards
rrectness of i
❑ Renewing in vehicle
⇒ page 148
l purpos
n
ercia
f
ormat
m
com
ion
must be performed.
in
r
te o
thi
Perform basic settings of
sd
iva
headlights using ⇒ Vehicle di‐

o
r
rp
agnosis, testing and informa‐ cu

fo
m
en
ng
tion system VAS 5051.

t.
yi Co
Cop py
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3.3 Renew vehicle level sender in vehicle


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
The lever of rear left vehicle level sender -G76- must face
ksw outside
agen oes
not
of vehicle. y Vol gu
db e
ara
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– After completing installation, carry out basic
utho setting of head‐ eo
ra
lights ⇒ "Guided fault-finding" function
ss of vehicle diagnosis,
a c
testing and information system VAS 5051 .
ce
e
nl
pt
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itte
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Specified torques
erm
ab
ility
ot p
wit
is n
h re
Rear left vehicle level sender -G76- to lower transverse link 5 Nm
ole,
spec
and subframe
t to the co
3.4 Removing and installing upper trans‐
rrectness of i
verse link
cial p
nform

mer
a
m
tion
co
in t
or
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ate
do
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or
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rig
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Prote AG.
Removing
– Remove wheel.
– Remove coil spring ⇒ page 173 .
– Unhook speed sensor line -arrow A- from upper transverse

link.
– Remove bolt -1-.
wage es n
Volks ot g
by ua
d ran
rise tee
tho
u or
a ac
– Mark position of eccentric bolt -arrow- relative to subframe us‐ ss
ce
ing e.g. a felt tip pen. e
nl
pt
du
an
itte
– Remove bolt -arrow-.
y li
erm
ab
ility
– Remove upper transverse link.
ot p
wit
is n
Installing
h re
ole,
spec
– Install upper transverse link on vehicle and tighten bolts hand
tight.
t to the co
The transverse link may be bolted only when dimension “a” has
been attained.
rrectness of i
Golf ⇒ page 137
cial p
nform
– Bolt upper transverse link to subframe and tighten new nut to
mer
specified torque.
a
m
tion
co
– Observe mark made for position of eccentric bolt -arrow- rel‐
in t
or
his
e
ative to subframe.
at
do
priv
cum
or
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t.
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Cop py
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rig ht
py by
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by lksw
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Prote AG.
– Tighten bolt -1- for upper transverse link.
Note
The washer -2- must be installed so that there is a gap

-arrow B- between the washer and the backplate -3-.
– Attach speed sensor line -arrow A- from upper transverse link.

– Install coil spring ⇒ page 173 .
– Perform wheel alignment ⇒ page 305 .

Specified torques
Upper transverse link to wheel bearing housing 130 Nm + 90°
♦ Use new nuts and bolts
♦ Tighten threaded connections only when vehicle is in
the normal running position.
Upper transverse link to subframe 95 Nm

♦ Use new nut ♦ To tighten nuts, set torque wrench -V.A.G
1332- to 80 Nm.
the normal running position. ♦ Applies only in conjunction with insert tool,
18 mm -T10179-
3.5 Removing and installing lower trans‐

verse link
AG. Volkswagen AG d
agen oes
Removing Volksw not
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– Remove wheel. orise nte
eo
th
u ra
– Remove coil spring. ⇒ page 173 . ss
a c ce
le
un
– Remove bolt -arrow- for lower transverse link -1-.

pt
an
d
itte
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Vehicles with dynamic headlight range control

rm
ab
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ility
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wit
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hole
spec
es, in part or in w
t to the co
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n
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Golf 2004 ➤ , Golf Plus 2005 n➤
AG. Volkswagen AG d
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Running gear, axles, Vsteering
olks - Edition 08.2009 es not g
by ua
ed ran
ris tee
– Remove bolts -1- from
th lower
o transverse link. or
au ac
ss
ce
e
nl
pt
du
– Mark position of eccentric bolt -arrow- relative to subframe us‐
an
itte
y li
ing e.g. a felt tip pen.
erm
ab
ility
ot p
– Disconnect and lower rear part of exhaust system.
wit
is n
h re
ole,
spec
– Remove lower transverse link.
t to the co
Installing
– Install lower transverse link on vehicle and tighten bolts hand
rrectness of i
tight.
The transverse link may be bolted only when dimension “a” has
been attained ⇒ page 137 .
cial p
nform
mer
– Bolt upper transverse link to subframe and tighten new nut
a
-arrow- only to specified torque.
m
tio
o
n in
r c

te o
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ative to subframe.
s
a
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p
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or
– Reinstall rear section of exhaust system.

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Vehicles with dynamic headlight range control ht. Cop py
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– Install bolts -1- in lower transverse link. py by
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Continuation for all vehicles Prote AG.
– Tighten bolt -arrow- for lower transverse link -1-.

Specified torques
Lower transverse link to wheel bearing housing 90 Nm + 90°
Lower transverse link to subframe 95 Nm

♦ Use new nut
the normal running position
3.6 Removing and installing track rod


AG. Volkswagen AG d
agen oes
olksw not
V gu
by ara
Removing rised
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– Remove wheel.
ss
au ra
c
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e

nl
pt
du
an
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– Remove nut -1- and pull coupling rod -2- out of anti-roll bar.
erm
ab
ility
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– Remove bolt -arrow- for track rod -3-.

wit
is n
h re
ole,
spec
t to the co
rrectness of i
cial p
nform
mer
– Remove bolts -arrows- for anti-roll bar clamp.

a
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tion
co
in t
or
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te
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t. Co py
rig
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Prote AG.
– 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 .
– Bolt track rod to subframe andgetighten

AG. Volnew
kswagnut
en Ato
G dspecified
a n
torque. Vol
ksw
oes
not
by gu
ara
ed nte
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th
au ra
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nl
pt
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ab
ility
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wit
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spec
es, in part or in w
– Tighten bolts -arrows- for anti-roll bar clamp. t to the co

rrectness of i
l purpos
nform
mercia
at
m
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n in t
o
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ate
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– Tighten bolt -arrow- for track rod -3-. Co py
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– Connect coupling rod -2- to anti-roll bar and tighten nut -1-. op
c Vo
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AG.


AG. Volkswagen AG d Golf 2004 ➤ , Golf Plus 2005 ➤
agen Runningnot gear, axles, steering - Edition 08.2009
oes
olksw
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ise nte
Specified torques hor eo
aut ra
ss c
ce
e
nl
pt
du
Track rod to wheel bearing housing 130 Nm + 90°
an
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
Track rod to subframe 90 Nm + 90°
t to the co
Anti-roll bar to subframe 25 Nm +45°
♦ Use new bolts
rrectness of i
cial p
nform
mer
♦ Use new nut
a
m
tion
co
in t
or
his
ate
do
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cum
or
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t. Co py
rig
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Prote AG.
4 Assembly overview: wheel bearing housing, trailing arm (front-wheel

drive)
1 - Bolt
moving
3 - Bolt
❑ M12 x 1.5 x 80
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 anti-
roll bar.
A mixed installation is not per‐
missible.
❑ Connects anti-roll bar to
trailing arm and wheel
bearing housing n AG. Volkswagen AG do
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5 - Bolt Volks ot g
y ua
edb ran
❑ 90 Nm +45° further ho
ir s tee
t or
❑ Observe tightening se‐ s au ac
s
quence ⇒ page 168
ce
le
un
pt

an
d
itte
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moving
rm
ab
pe
ility
6 - Trailing arm
ot
wit
, is n

h re
hole
spec

es, in part or in w
t to the co
7 - Bolt
❑ 8 Nm
rrectness of i
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
l purpos
❑ Before inserting sensor, clean inner surface of bore and coat with lubricating paste -G 000 650-
n
ercia

format
m

com
ion
10 - Bonded rubber bush

in
r
te o
thi
❑ Renewing ⇒ page 161

sd
iva
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rp
cu
11 - Nut
fo
m
en
ng
t.
yi
❑ 45 Nm
Co
Cop py
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156
AG.
Rep. Gr.42 - Rear suspension

12 - Bolt lkswage es n
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❑ 4 Nm ris
ed b ran
tee
tho
or
13 - Brake disc au ac
ss
ce
e
14 - Grease cap
nl
pt
du
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itte
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erm
ab
❑ Pressing off and driving in ⇒ page 164
ility
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wit
A proper seal can be achieved only by installing a new grease cap.
is n
h re
ole,
spec
15 - Bolt
❑ M16 x 1.5 x 70
t to the co
❑ Loosen and tighten with bit XZN 18 -T10162-
rrectness of i
cial p
❑ ABS sensor ring is installed in wheel bearing.
nform
mer
a
m
tio
The wheel bearing and wheel hub are assembled one housing.
o
n in
r c
te o
thi
This wheel bearing/wheel hub unit is maintenance-free and has zero play. Adjustments and repairs are not
s
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possible!
p
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17 - Bolt py Co
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❑ 12 Nm
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18 - Backplate
by lksw
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Prote AG.

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
wage es n
Volks ot g
by ua
d ran
rise tee
tho
u or
a ac
ss
ce
e
nl
pt
du
an
itte
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erm
ab
ility
– Install bolts for track rod -1-, upper transverse link -2- and low‐
ot p
er transverse link -3-.

wit
is n
h re
ole,
– Attach coupling rod -arrow- to wheel bearing housing hand

spec
tight.
t to the co
rrectness of i
cial p
nform
mer
a
m
tio
o
n in
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thi
s
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Cop py
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Prote AG.

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
when dimension “a”swhas AG. Volkswagen AG
agenbeen obtained ⇒dopage
es 137 .
olk not
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ho eo
aut ra
ss c
ce
e
nl
pt
du
an
itte
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erm
ab
ility
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– Tighten bolt for track rod -1-.

wit
is n
h re
– Tighten bolt for lower transverse link -3-.

ole,
spec
t to the co
rrectness of i
cial p
nform
mer
a
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tion
co
in t
or
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ate
do
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pr
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or
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t.
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Cop py
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pyri by
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co lksw
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Prote AG.
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
AG. Volkswagen AG d
♦ Tighten threaded connections only when wavehicle
gen is in oes
olks not
the normal running position. d byV gu
ara
e nte
ris
ho eo
Wheel bearing housing to lowerut suspension link 90
r a Nm + 90°
sa c
♦ Use new nuts and bolts s
ce
le
un
pt

an
d
itte
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rm
ab
pe
ility
ot
Wheel bearing housing to track rod 130 Nm + 90°

wit
, is n

h re
hole
spec

es, in part or in w

t to the co
Trailing arm to wheel bearing housing 90 Nm +45°

♦ Use new bolts
rrectness of i
l purpos
Coupling rod to wheel bearing housing 45 Nm

♦ Use new nut
n
ercia
fo
Splash plate to wheel bearing housing 12 Nm

rm
m
atio
ABS speed sensor to wheel bearing housing 8 Nm

com
n in
Shock absorber to wheel bearing housing

r
180 Nm
te o
thi
sd
iva
Brake disc to wheel bearing housing. 4 Nm

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ng
t.
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Cop py
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Prote AG.

4.2 Renewing bonded rubber bush for wheel bearing housing

equipment required
♦ Press tool -30 - 506 B-
♦ Drift sleeve -41-501-
♦ Sleeve -3160-
♦ Assembly tool -3301-
AG. Volkswagen AG d
agen oes
olksw not
V gu
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ise nte
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th
au ra
ss c
ce
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nl
pt
du
an
itte
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erm
ab
ility
ot p
wit
is n

h re
ole,
spec
t to the co
rrectness of i
cial p
nform
mer
a
m
tion
co
in t
or
his
te
Removing
iva
do
pr
cum
– Remove wheel.
for
en
ng
i t.
py Co
– Remove coil spring ⇒ page 173 . t. Co py
rig
gh ht
– Remove wheel bearing/wheel hub unit ⇒ page 164 . yri by
cop by
Vo
lksw
cted agen
Prote AG.
– Attach tools as shown in figure.

1- Nut -3346/3-
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
lkswage es n
– Attach tools as shown in figure. d byV
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1- Nut -3346/3- utho
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– Pull in bonded rubber bush by turning spindle.

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♦ Install bonded rubber bush carefully so that it does not cant.

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– Install backplate.
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– Tighten bolt -arrow- for lower transverse link -1-. agen

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– Install brake disc. aut
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Specified torques
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Wheel bearing housing to lower suspension link 90 Nm + 90°
♦ Use new nuts and bolts cial p
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4.3 Removing and installing wheel bearing/wheel hub unit

equipment required
♦ Hub grease cap puller -VW
637/2-
♦ Fitting sleeve -3241-
1332-
1410-
♦ Tool insert -T10162-
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Removing
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– Raise vehicle.
– Remove wheel.
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Loosen grease cap from seat by tapping lightly on the claw of hub
grease cap puller -VW 637/2-.
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Hang brake caliper from body. t to the co
– Remove cross-head screw for brake disc and remove brake

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– Remove multi-point socket head bolt using socket insert -

T10162- .
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– Pull wheel hub/wheel bearing unit off stub axle.

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Installing
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– Carefully push wheel bearing/wheel hub unit onto stub axle.

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Ensure that the wheel bearing/wheel hub unit does not cant!
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♦ 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.
– 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
♦ Use new bolt
4.4 Removing and installing trailing arm with

mounting bracket
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Removing
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– Remove wheel.
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– Remove coil spring ⇒ page 173 . C py
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– Remove bolt -arrow- securing handbrake cable -1- to trailing

arm -2-.
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– Unbolt coupling rod -1- from trailing arm.
in
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– Mark installation position of mounting bracket on body.

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t. Co py
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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
Dimension -a- is 34 ± 1 mm.

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Position: threaded connection between trailing arm and wheel
bearing housing
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yet.
– Raise wheel suspension using engine and gearbox jack -
V.A.G 1383 A- and support -T10149- until mounting bracket
contacts body.
– 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.

– 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.
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– Bolt handbrake cable -1- to trailing arm -2- -arrow-. an

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– Attach retainer -1- by pushing in inner pin of rivet -arrow-.

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Specified torques
Trailing arm to wheel bearing housing 90 Nm +45°
♦ Use new bolts
Trailing arm to mounting bracket 90 Nm + 90°

♦ Use new bolt

Mounting bracket to body 50 Nm +45°
♦ Use new bolts
Coupling rod to trailing arm. 45 Nm

♦ Use new nut

AG. Volkswagen AG d
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4.5 Repairing trailing arm
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– Remove trailing arm ⇒ page 166 .

– Set up tools as shown in figure.

1- Tube -T10230/3-
3- Removal tool -3372-
– Press out bonded rubber bush.
– Place trailing arm on a flat surface.
olkswagen AG
en AG. V
– Mark a vertical
olks line on trailing arm bush.
wag does
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Dimension -A- = 114 mm
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There are two different types of bonded rubber bushes. On both

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o
types, the marked line must be between the projections -1- after
c
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– Attach mounting bracket to trailing arm ⇒ page 167 .
– Install trailing arm ⇒ page 168 .
rrectness of i
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5 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
moving
6 - Shock absorber
⇒ page 175
❑ Note different versions
of running gear
⇒ page 317 , vehicle
AG. Volkswagen AG d
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❑ Removing and installing tho eo
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⇒ page 151 ss c
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⇒ page 157
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5.1 Removing and installing coil spring

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♦ Suspension strut clamp -V.A.G 1752-

cial p
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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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♦ Adapter -V.A.G 1752/9- , not illustrated
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– Remove wheel.
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– Insert spring compressor -3-.
WARNING
rrectness of i
Ensure that coil spring is correctly seated in spring retainers -
V.A.G 1752/4- -2- (accident risk).
cial p
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a
– Use a spanner or a reversible ratchet handle to compress
m
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spring compressor.
c
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2- Adapter -V.A.G 1752/9-
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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.

– 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 ge G do
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– Install wheel
by
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5.2 Removing and installing shock absorb‐
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Removing . Cop py
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– Remove wheel. py by
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– Remove wheel housing liner ⇒ General body repairs, exterior;
agen
Prote AG.
Rep. Gr. 66 .


– 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 .
rrectness of i
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a
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Specified torques
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Shock absorber to body 50 Nm +45°
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n AG. VolkswageGolf
n AG d2004 ➤ , Golf Plus 2005 ➤
wage oes
Volks Running gear, axles, steering
not
gu - Edition 08.2009
by ara
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5.3 Repairing shock absorber ho eo
aut ra
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un
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an
1 - Shock absorber
d
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ab
pe
ility
⇒ page 175
ot
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of running gear
spec
es, in part or in w
data plate
t to the co
2 - Protective cap
rrectness of i
3 - Protective tube
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4 - Support ring
n
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m
5 - Bump stop
atio
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❑ For shock absorbers
n in
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with support ring
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⇒ Item 4 (page 177)
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7 - Nut
❑ M10 x 1.0
❑ 25 Nm
moving
❑ Loosening and tighten‐
ing ⇒ page 178
8 - Cover
9 - Shock absorber mounting
❑ For shock absorbers without support ring ⇒ Item 4 (page 177)
10 - Bump stop

♦ Shock absorber set -T10001-
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Dismantling and assembling
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Loosening and tightening threaded connection for shock absorb‐
spec
er mounting
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1- Commercially available ratchet handle
2- Socket -T10001/9-
rrectness of i
3- Ratchet handle -T10001/11-
4- Socket -T10001/1-
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Specified torque cted agen
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Shock absorber mounting to shock absorber 25 Nm
♦ Use new nut

6 Assembly overview: anti-roll bar (front-wheel drive)
1 - Anti-roll bar
of running gear
data plate
⇒ page 179
2 - Bush
❑ Always renew bushes
on both sides of the ve‐
hicle.
3 - Clamp
4 - Bolt
❑ Tighten evenly.
moving
position:
Golf ⇒ page 136 n AG. Volkswagen AG do
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6 - Nut
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❑ 45 Nm
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❑ Self-locking
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7 - Coupling rod
t to the co
❑ Modified coupling rod
for model year 2004
rrectness of i
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.
cial p
A mixed installation is not permissible.

nform
mer
❑ Connects anti-roll bar to trailing arm and wheel bearing housing

a
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tion
o
8 - Shield
c
in t
or
❑ Only in vehicles having two ball joints in coupling rod. For vehicles with new coupling rod (one ball joint
his
ate
do
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and one bonded rubber bush), no shield is installed. See also ⇒ Item 7 (page 179) .
pr
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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-.
AG. Volkswagen AG d
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– Removes abolts -arrows- for anti-roll bar clamp.
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– Remove anti-roll bar.

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– Install anti-roll bar in vehicle.

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– Evenly tighten bolts -arrows- for anti-roll bar clamp.

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Running
en AG. Vgear,
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wag does
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– Connect coupling rod -2- to anti-roll bar and ed tighten nut
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Specified torques
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♦ Use new bolts
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6. Assembly overview: anti-roll bar (front-wheel drive) 181

7 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
-arrow-
– Pivot shield in
-direction of arrow- onto
rivet screws and tighten
nuts
9 - Angle piece
❑ With rivet screw
AG. Volkswagen AG d
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182
AG.

8 Repairing rear suspension (four-

wheel 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 overviewby Vo - sub‐ gu
ara
frame, final rdrive
ised
(four-wheel nte
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drive, aluminium)
auth ⇒ page 189 eo
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II - Assembly overview - control
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⇒ page 212
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spec
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rrectness of i
cial p
nform
mer
atio
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r co
n in
o
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t.
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Cop py
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rig ht
py by
co Vo
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Prote AG.
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
. Volkswagen AG
gen AG does
V - Anti-roll bar (four-wheel Volkswa not
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drive, subframe made from ed
by ara
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aluminium and wheel tbearing
ho
ris eo
housing made from scastau steel) ra
c
⇒ page 265 s
ce
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nl
pt
du
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erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
rrectness of i
cial p
nform
mer
a
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rig
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Prote AG.

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
drive, steel) ⇒ page 199 y Volks s no
t gu
b ara
ed
II - Assembly overviewho - control
ris nte
e
aut
arm, track rod (four-wheel or
ac
s
drive, subframes made from
ce
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steel and wheel bearing hous‐

nl
pt
du
an
ing made from aluminium)
itte
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⇒ page 223
erm
ab
ility
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wit
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hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
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n in
o
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pr
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t. Co py
rig
gh ht
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lksw
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cted agen
Prote AG.

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
drive, subframe made from
steel and wheel bearing hous‐
ing made from aluminium)
⇒ page 269
AG. Volkswagen AG d
agen oes
olksw not
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d by ara
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au ra
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ce
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nl
pt
du
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itte
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erm
ab
ility
ot p
wit
is n
h re
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spec
t to the co
rrectness of i
cial p
nform
mer
atio
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n in
o
thi
te
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p
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for
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t.
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Cop py
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ht
rig by
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Prote AG.

8.3 Rear axle in unladen state (aluminium and steel)

equipment required
V.A.G 1383 A-
AG. Volkswagen AG d
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olksw not
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th
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ce
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nl
pt
du
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ab
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ot p
wit
is n
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spec
t to the co
Note
rrectness of i
cial p
nform
mer

a
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o

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or

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f
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rig
To simulate this position on the lifting platform, raise the axle on gh ht
yri by
one side using the engine and gearbox jack -V.A.G 1383 A- and cop Vo
by lksw
support -T10149- .
cted agen
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straps -T10038- .
WARNING


ning gear:

AG. Volkswagen AG d
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Sports running gear except 18" 365 ± 10 mm Volksw
oes
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Sports running gear with 18" 365 ± 10uthmm
o eo
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wheels (G02/G05/G07/2UC) ss
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le

un
pt
an
d
itte
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rm
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pe
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version (G11)
wit
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hole
spec
es, in part or in w
t to the co
here ⇒ page 317 .
rrectness of i
until dimension -a- is attained.
l purpos
WARNING
n
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form

m
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com

n in
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te o
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– Tighten affected nuts and bolts. Cop py
t. rig
gh ht
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– Lower wheel bearing housing. p by
co Vo
by lksw
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– Pull engine and gearbox jack out from underneath vehicle. Prote AG.

9 Assembly overview - subframe made from aluminium, final drive (four-

wheel drive)
-Arrow- indicates direction of travel.
1 - Subframe
Note
2 - Nut
moving
AG. Volkswagen AG d
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3 - Rear bonded rubber bush olks
w not
byV gu
ara
❑ Renewing ⇒ page ris 195
ed nte
ho eo
ut
4 - Front bonded rubber
ss
a bush ra
c
ce
e
nl
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du
an
itte
5 - Cross member
y li
erm
ab
ility
6 - Bolt
ot p
wit
, is n
7 - Final drive
h re
hole
spec
es, in part or in w
⇒ Rep. Gr. 39 ; Remov‐
t to the co
ing and installing rear fi‐
nal drive
rrectness of i
8 - Bolt
❑ M12 x 1.5 x 85
l purpos
nform
ercia
9 - Washer
m
10 - Bracket
at
m
io
r co
11 - Bolt
in t
o
his
te
❑ M12 x 1.5 x 85
a
d
iv
o
pr
cu
or
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f
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i t.
py Co
t. Co py
rig
gh ht
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cop by
Vo
lksw
cted agen
Prote AG.
9. Assembly overview - subframe made from aluminium, final drive (four-wheel drive) 189
AG. Volkswagen AG d
agen oes
olksw not
Golf 2004 ➤ , Golf Plus 2005 ➤ d byV gu
ara
e nte
Running gear, axles, steering - Edition 08.2009 horis
eo
aut ra
ss c
ce
e
nl
pt
du
an
itte
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erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
rrectness of i
cial p
Removing subframe with attachments
nform
mer
atio
m
Note
r co
n in
o
thi
e
Please note that subsequent assembly work for which the hexa‐
t
sd
ir va
o
gon or twelve-point bolt of the drive shaft has to be loosened
p
cum
or
requires that the vehicle is stood on its wheels. Loosen hexagon
f
en
ng
t.
bolt ⇒ page 274 or loosen twelve-point bolt of drive shaft
i
py Co
Co py
⇒ page 275 . gh
t. rig
ht
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cop by
Vo
lksw
– Remove wheels. cted agen
Prote AG.
– Remove coil springs ⇒ page 257 .

– 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-.

– Unscrew hexagon bolt -1- and detach handbrake cable -2-

from brake cable bracket.

wage es n
olks ot g
– Unclip speed sensor wire from retainer -1-d-arrows-.
by
V ua
ran
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th or
au ac
ss
ce
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nl
pt
du
an
itte
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erm
ab
ility
ot p
wit
is n
h re
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spec
– Disconnect brake pipes, items-1- and -2-. t to the co

rrectness of i
cial p
nform
mer
a
m
tion
co
in t
or
his
ate
do
priv
cum
or
f
en
ng
t.
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Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

– 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-.
AG. Volkswagen AG d
agen oes
ksw
– Unbolt rear propshaft
byV
ol tube with flexible couplingnoand
t gu vibration
damper fromrisrear
ed final drive -arrows-. ara
nte
ho eo
aut ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
– Unscrew centre bearing bolts -arrows- two turns.

rrectness of i
l purpos
nform
mercia
at
m
io
r co
n in t
o
his
ate
d
iv
o
pr
cu
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f
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py Co
t. Co py
rig
gh ht
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Prote AG.

– 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

the vehicle will slip off the lifting platform!
sw agen AG
. Volkswagen AG
does
olk not
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edb ara
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ho eo
aut ra
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ce
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nl
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du
an
itte
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erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
– Unscrew one hexagon bolt -1- or -2- on each side.

m
tio
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n in
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thi
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Note
iv
o
pr
cu
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Only the left side of vehicle is shown to improve clarity.

n
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t. Co py
rig
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Prote AG.

– 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
agen
Installing subframe with attachments olksw
oes
not
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Install in reverse order. In the process, note the oris following:
e nte
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th
u ra
Attach propshaft to rear final drive ⇒ Final
ss drive 02D; Rep. Gr.
a c
39 ; Removing and installing propshaft .
ce
le
un
pt
an
d
– Bleed brake system ⇒ Rep. Gr. 47 ; Bleeding brake system

itte
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⇒ Rep. Gr. 47 .
ab
ility
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is n
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Note
t to the co
If an aluminium subframe is to be replaced by one made of steel,
then please proceed with the following work sequence
rrectness of i
⇒ page 204 .
Specified torques
cial p
nform
mer
a
m
tio
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♦ Use new bolts
o
thi
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p
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i t.
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♦ Use new bolts Co py
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cop
Vo
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agen
Prote AG.

9.2 Repairing subframe

equipment required
♦ Hydraulic press -VAS
6178-
V.A.G 1383 A-
♦ Foot pump -VAS 6179-
AG. Volkswagen AG d
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olksw not
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nl
pt
du
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ot p
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is n
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t to the co
Pulling out front or rear bonded rubber bushes

– Remove rear wheels.
rrectness of i
– Remove coil springs ⇒ page 257 .

– Remove front and rear exhaust system silencer ⇒ Rep. Gr.
26 ; Exhaust system; Removing and installing parts of the ex‐
cial p
haust system .
nform
mer

atio
m
body.
r co
n in
o
thi
– Remove anti-roll bar ⇒ page 265 .

te
sd
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– Remove track rods.

p
cum
for
en
ng
t.
– Remove brake line bracket from front mountings of subframe.
i
py Co
t. Co py
rig
gh ht
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cop by
Vo
lksw
cted agen
Prote AG.
– Now secure vehicle to lifting platform on both sides using ten‐

sioning straps -T10038-.
WARNING lkswage es n
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byV ua
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If the vehicle is not strapped down, thoristhere is a great danger that tee
or
the vehicle will slip off the lifting au platform! ac
ss
ce
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nl
pt
du
an
itte
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erm
ab
ility
ot p
wit
is n
h re
ole,
spec
– Position engine and gearbox jack -V.A.G 1383 A- with univer‐
sal gearbox support -V.A.G 1359/2- beneath subframe and
t to the co
secure with strap.
rrectness of i
cial p
nform
mer
a
m
tio
r co
n in
o
thi
te
s
a
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– Unscrew one hexagon bolt -1- or -2- on each side.

p
cum
for
en
ng
i t.
py Co
Co py
Note
t. rig
gh ht
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lksw
b
Only the left side of vehicle is shown to improve clarity. cted agen
Prote AG.

– 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.

– Set up special tools as shown in figure.

1 - Nut -T10263/5-
2 - Washer (commercial type)
3 - Subframe
4 - Tube -T10263/1-
5 - Hydraulic press -VAS 6178-
7 - Nut -T10263/5-
8 - 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
en AG. V
– Set up special tools witholkbonded
swa
g
rubber bush ondosubframe
es n
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shown. ed
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WARNING
ss c
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nl
pt
du
Thrust piece -T10263/3- must be positioned so that lugs on

an
itte
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bonded rubber bush align with free aperture on thrust piece -

erm
ab
T10263/3- .
ility
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1 - Nut -T10263/5-
spec
t to the co

3 - Thrust piece -T10263/3-
rrectness of i
4 - Subframe
cial p

nform
mer
7 - Hydraulic press -VAS 6178-

a
m
tion

co
in t
or
his
e
9 - Nut -T10263/5-
at
do
priv
10 - Spindle -T10263/4-
um
or
f
en
ng
t.
– Take up play in special tools and bonded rubber bush.
i
py Co
t. Co py
rig
– Operate pump to carefully pull bonded rubber bush in until
gh ht
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op
collar lies “flush” on subframe.
c Vo
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Prote AG.
. Volkswagen AG
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Golf 2004 ➤ , Golf Plus 2005 ➤ olks
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Specified torques ss
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♦ Use new bolts
ot
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es, in part or in w
t to the co
rrectness of i
l purpos
n
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format
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cop by
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AG. VolkswagGolf
en AG2004 ➤ , Golf Plus 2005 ➤
agen
kswRunning gear, axles, steering - Edition 08.2009
does
ol not
byV gu
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10 Assembly overview - subframe made from steel, final drive (four-wheel ss
aut ra
c
drive)
ce
le
un
pt
an
d
itte
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rm
ab
pe
ility
ot
wit
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1 - Subframe
h re
hole
spec
2 - Rear bonded rubber bush
es, in part or in w
t to the co
3 - Front bonded rubber bush
rrectness of i
l purpos
4 - Final drive
⇒ Rep. Gr. 39 ; Remov‐
n
ercia
fo
ing and installing rear fi‐
rm
m
nal drive .
atio
com
n in
5 - Bolt
r
te o
thi
❑ M12 x 105
sd
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o
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rp
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m
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❑ Renew each time after

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rig
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6 - Washer cop Vo
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❑ Installed between final Prote AG.
drive and subframe.
7 - Washer
❑ Washer must be placed
with holes on lugs of
bonded rubber bush.
8 - Bolt
❑ M12 x 105
removing

10. Assembly overview - subframe made from steel, final drive (four-wheel drive) 199
Running gear, axles, steering - Edition 08.2009 n AG. Volkswagen AG do
wage es n
Volks ot g
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♦ Engine/gearbox jack -V.A.G 1383 A- edb ua
ran
ris tee
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nl
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du
an
itte
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erm
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ility
ot p
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is n
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t to the co
rrectness of i
Removing subframe with attachments cial p
Note
nform
mer
Please note that subsequent assembly work for which the hexa‐
a
m
tion
gon or twelve-point bolt of the drive shaft has to be loosened
co
in t
requires that the vehicle is stood on its wheels. Loosen hexagon
or
his
e
bolt ⇒ page 274 or loosen twelve-point bolt of drive shaft

at
do
iv
⇒ page 275 .
pr
cum
or
f
en
ng
t.
yi Co
– Remove wheels. . Cop py
rig
ht ht
– Removing coil spring ⇒ page 257 .
rig by
copy Vo
by lksw
cted
– Remove rear exhaust system silencer ⇒ Rep. Gr. 26 ; Ex‐
agen
Prote AG.
haust system; Removing and installing parts of the exhaust
system .
body.
– Remove clip -1-.
Note
Do not open brake line.

AG. Volkswagen AG d
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olksw not
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d by ara
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– Markauinstallation position of mounting bracket on body.
t ra
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ss
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nl
pt
du
an
itte
– Disconnect connector for rear left vehicle level sender -G76- .
y li
erm
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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
cial p
present, mark the position of the flexible coupling and the final
nform
drive flange to one another -arrows-.

mer
atio
– Disconnect connectors for rear right speed sensor -G44- and

m
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rear left speed sensor -G46- .

in
o
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o
p
cum
for
en
ng
t.
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Cop py
ht. rig
ht
rig by
copy Vo
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cted agen
Prote AG.
– Unbolt rear propshaft tube with flexible coupling and vibration
damper from rear final drive -arrows-.
– Unscrew centre bearing bolts -arrows- two turns.
AG. Volkswagen AG d
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th
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– Support propshaft -A- on tunnel support -1- using a wooden
ce
le
un
pt
block.
an
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rm
– Push rear propshaft tube towards gearbox as far as possible.
ab
pe
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ot
– Disconnect Haldex coupling connector above final drive.
wit
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hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
– Now strap vehicle to the lifting platform arms on both sides of
n
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the vehicle using tensioning straps -T10038- .

form
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WARNING
n in
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If the vehicle is not strapped down there is a great danger that

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To secure the subframe in place, ensure that at positions -1- and
d
itte
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-2- the locating pins -T10096- are screwed in one after the other
rm
ab
pe
on both sides of vehicle.
ility
ot
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– Unscrew one hexagon bolt -1- or -2- on both sides.
h re
hole
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es, in part or in w
Note
t to the co
rrectness of i
l purpos
n
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fo
rm
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– Replace the subframe securing bolts on both sides one after
agen
Prote AG.
the other with locating pins -T10096- and tighten to 20 Nm.
The position of the subframe is now fixed.
– Carefully lower subframe with attachments about 2 cm.
– Unclip brake lines on both sides -arrow-.
Note
The clips will be destroyed and must be renewed.
– Unclip brake line from clips -arrows- above drive shaft flange
on gearbox -1-.
Note
The clips will be destroyed and must be renewed.
– Carefully lower subframe with attachments.
Note
When lowering, ensure sufficient clearance between brake lines,

electrical cables and centring pin and the propshaft.
Installing subframe with attachments

Install in reverse order. Note the following points:agen AG. Volkswagen AG d
oes
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Note ris
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ra
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ss
♦ Make sure that the plate between wheel bearing housing and
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must also be installed ⇒ Braking systems; Rep. Gr. 47 ; Brake
h re
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line repair and ⇒ Electronic parts catalogue“ETKA” .
spec
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Attach propshaft to rear final drive ⇒ Final drive 02D/0AV; Rep.
Gr. 39 ; Removing and installing propshaft .
rrectness of i
Specified torques
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♦ Hydraulic press -VAS
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T10205/13-
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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
system .
body.
– Remove anti-roll bar ⇒ page 265 .
– Remove track rods ⇒ page 231 .
Note
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3 - Tube -T10263/6-
4 - Hydraulic press -VAS 6178- and thrust piece -T10205/13-
5 - Nut -T10263/5-
6 - 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
Running gear, axles, steering - Edition 08.2009 wage es n
Volks ot g
by ua
d ran
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Distinguishing features of bonded rubber bushes tho ri tee
or
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I - Front bonded rubber bush ss
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– Insert bonded rubber bush -1- in subframe so that the nose
and the plate -arrows- face perpendicular to direction of travel.
cial p
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nform
face perpendicular to direction of travel.
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– Insert special tools with bonded rubber bush into subframe as
Prote AG.
shown.
1 - Nut -T10263/5-
6 - Nut -T10263/5-
7 - 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
system .

Note

WARNING


secure with strap.
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10. Assembly overview - subframe made from steel, final drive (four-wheel drive)
AG.

– 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 -T10263/5-
2 - Washer , from -T10263-
3 - Tube -T10263/6-
5 - Nut -T10263/5-
6 - Spindle -T10263/4- AG. Volkswagen AG d
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Pulling in rear bonded rubber bush

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wit
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shown.
1 - Nut -T10263/5-
6 - Nut -T10263/5-
7 - 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
Subframe to body 90 Nm + 90° further
♦ Use new bolts!
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
nent is loosened
⇒ page 305 .
❑ Do not turn more than
90° in either direction
(i.e. from minimum to
maximum adjustment
position).
2 - Nut
❑ M12 x 1.5
❑ 95 Nm
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17 - Bolt
19 - Washer
20 - Nut
❑ M14 x 1.5
❑ 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
❑ Self-locking
11.1 Overview - rear left vehicle level sender -G76-
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Removing
– Remove bolts -2- and -3-.
– Take out sender.
Installing
Lever on sender must face outwards.
– Perform basic setting of headlights following replacement.
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– Remove wheel.
cast steel) 215


link.
– Remove bolt -1-.
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Installing
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ing:
The threaded connections of the wishbone may only be tightened
rrectness of i
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 .
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Specified torques

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Component utho Specified torque
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Upper transverse link to subframe ss 95 Nm
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♦ Use new nut ♦ To tighten nuts, set torque wrench -V.A.G
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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. n AG. Volkswagen AG do
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38
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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 .
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Installing
The track rod may only be bolted when dimension “a” has been

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prescribed torque.
– Tighten bolts -arrows- for anti-roll bar clamp.

– Remove tensioning strap -T10038- .
– Tighten bolt -arrow- for track rod -3-.
Note
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♦ Use new nut
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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
nent is loosened
⇒ page 305 .
maximum adjustment
position).
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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12. Assembly overview - control arm, track rod (four-wheel drive, subframe made from steel and wheel bearing housing made from
aluminium) 223
AG. Volkswagen AG d
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Golf 2004 ➤ , Golf Plus 2005d➤ by
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ara
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horis
- Edition 08.2009 eo
aut ra
ss c
7 - Subframe
ce
le
un
pt
an
d
8 - Bolt
itte
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rm
ab
❑ M12 x 1.5 x 125
pe
ility
ot
wit
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hole
spec
es, in part or in w
t to the co
10 - Nut
rrectness of i
l purpos
❑ Self-locking
n
ercia
format
m
11 - Bolt
com
ion
❑ M12 x 1.5 x 75
in
r
te o
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12 - Threaded rivet
fo
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❑ M6 py Co
t. Co py
rig
gh
13 - Spreader rivet
ht
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Prote AG.
15 - Hexagon bolt
❑ M6 x 12
❑ 8 Nm
16 - Nut
❑ Self-locking
17 - Washer
18 - Bolt
❑ M14 x 1.5 x 115
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

26 - Track rod
♦ 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
28 - Bolt
❑ M12 x 1.5 x 95
❑ Renew each time after removing wagen AG. Volkswagen AG does
olks not
❑ Always tighten threaded connections
db
yV in unladen position ⇒ page gu187
ar
e an
ris tee
29 - Nut tho or
au ac
❑ 90 Nm + 90° further ss
ce
e
nl
❑ Self-locking
pt
du
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erm
ab
ility
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spec
t to the co
rrectness of i
cial p
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a
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cted agen
Prote AG.
aluminium) 225
12.1 Overview - rear left vehicle level sender -G76-
Note
♦ The vehicle level sender is available as a replacement part only complete with coupling rod and upper and
lower retaining plates.
♦ Control unit for headlight range control -J431-
1 - Subframe
3 - Bolt lkswage es n
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yV ua
❑ M5 x 20 ed b ran
oris tee
❑ 5 Nm auth or
ac
ss
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pt
er -G76-
an
d
itte
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ab
ments
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ility
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, is n
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outwards
hole
spec
es, in part or in w
⇒ page 226
t to the co
rrectness of i
must be performed.
l purpos

n
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f
ormat
VAS 5051
m
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in
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Removing
– Remove bolts -arrows- from subframe.
– Remove rear left vehicle level sender -G76- .
Installing n AG. Volkswagen AG do
wage es n
Volks ot g
Install in reverse order. Note the following points: d by ua
ran
ir se tee
ho
The lever of rear left vehicle level sender -G76-
au
t must face outside or
ac
of vehicle. ss
ce
e
nl
pt
du
– Following renewal, carry out basic setting of headlights ⇒
an
itte
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"Guided fault-finding" function of vehicle diagnosis, testing and
erm
ab
information system VAS 5051 .
ility
ot p
wit
is n
h re
Specified torques
ole,
spec
t to the co
and subframe
rrectness of i
cial p
verse link
nform
mer
atio
m
r co
n i

n
o
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te
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for
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t.
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Cop py
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Removing
– Remove wheel.
aluminium) 227

link. AG. Volkswagen n AG do
wage es n
– Remove bolt -1-. olks ot g
byV ua
ed ran
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tho or
au ac
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nl
pt
du
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itte
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erm
ab
ility
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spec
t to the co
rrectness of i
– Remove upper transverse link -1-.
Installing
cial p
nform
– Install upper transverse link on vehicle and tighten bolts hand
mer
tight.
a
m
tion
o
The transverse link may only be bolted when dimension“a” has

c
in t
r

o
his
ate
do
iv
pr
cum
or
f
en
ng
– Bolt upper transverse link -1- to subframe and tighten new nut
t.
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-arrow-. Cop py
ht. rig
ht
rig
py by
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by lksw
ative to subframe. Prote
cted AG.
agen
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
Upper transverse link to wheel bearing housing 130 Nm + 90° further


Upper transverse link to subframe 95 Nm
♦ Use new nut. ♦ To tighten nuts, set torque wrench -V.A.G
1332- to 80 Nm.
olks
wage es n
o ♦ Applies only in conjunction with insert tool,
db
yV t gu
ara 18 mm -T10179-
ir se nte
tho eo
s au ra
c
s
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nl
pt
du
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itte
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verse link
erm
ab
ility
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is n
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spec
t to the co
rrectness of i
cial p
nform
mer
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Removing
p
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for
en
ng
t.
– Remove wheel.
yi Co
Cop py
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– Remove coil spring ⇒ page 257 . rig ht
py by
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by lksw
– Remove bolt -arrow- for lower transverse link -1-. Prote
cted AG.
agen
aluminium) 229

Installing
– Install lower transverse link on vehicle and tighten bolts hand
tight.
The transverse link may only be bolted when dimension“a” has

ative to subframe.
– Reinstall rear section of exhaust system.
– Install bolts -1- in lower transverse link.

AG. Volkswagen AG d
– Check and adjust wheel alignment ⇒ page 305olk.swagen oes
not
V gu
by ara
ed nte
oris eo
th
au ra
c
ss
ce
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nl
pt
du
an
itte
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erm
ab
ility
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wit
is n
Specified torques
h re
ole,
spec

t to the co
Lower transverse link to wheel bearing housing 90 Nm + 90° further

rrectness of i


cial p
♦ Use new nut.

nform
mer

a
m
tion

co
in t
or
his
ate
do
priv
cum
or
f
en
ng
t.
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Cop py
ht. rig
ht
rig by
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cted
230
agen
Prote AG.


wage es n
olks ot g
♦ Torque wrench -V.A.G 1332- d by
V ua
ran
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tho
or
s au ac
s
ce
le
un
pt
an
d
itte
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rm
ab
pe
ility
ot
wit
, is n
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hole
spec
es, in part or in w
t to the co
rrectness of i
Removing
l purpos
– Remove wheel.
n
ercia
for
m
m
atio
com
– Remove bolt -arrow- for track rod -3-. n in

r
te o
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rig ht
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by lksw
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Prote AG.

aluminium) 231

WARNING


AG. Volkswagen AG d
agen oes
olksw not
y V gu
db ara
ir se nte
tho eo
au ra
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ce
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nl
pt
du
– Remove track rod -1-.

an
itte
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erm
ab
Installing
ility
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wit

is n
h re
ole,
spec
Note
t to the co
Note different versions of track rods: downwards open or forwards

closed.
rrectness of i
The track rod may only be bolted when dimension “a” has been
cial p
nfo
mer
– Bolt track rod -1- to subframe and tighten new nut -arrow- to
matio
prescribed torque.
om
n in
or c
thi
te
sd
iva
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pr
cu
or
m
f
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ng
t.
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Cop py
ht. rig
ht
rig by
copy Vo
by lksw
cted agen
Prote AG.

– Tighten bolts -arrows- for anti-roll bar clamp.

– Tighten bolt -arrow- for track rod -3-.
Note
Ensure that a washer is installed between the nut and the wheel
bearing housing.
– Connect coupling rod -2- to anti-roll bar and tighten nut -1-.
– Check and adjust wheelwaalignment
gen AG
. Volk⇒
swpage
agen A305
G do .
e
ks s no
Vol t gu
d by ara
Specified torques ris
e nte
utho eo
ra
a
Componentss c Specified torque
ce
e
nl
Track rod to wheel bearing housing 130 Nm + 90° further

pt
du
an

itte
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erm
ab

ility
ot p

wit
is n
h re
ole,
Track rod to subframe 90 Nm + 90° further

spec

t to the co
Anti-roll bar to subframe 25 Nm + 45° further

♦ Use new bolts!
rrectness of i

cial p

nform
♦ Use new nut.

mer
a
m
tio
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n in
o
thi
te
s
a
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p
cum
for
en
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t.
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Cop py
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ht
rig by
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cted agen
Prote AG.
aluminium) 233
13 Assembly overview - wheel bearing housing, trailing link (four-wheel

drive, subframe made from aluminium and wheel bearing housing
made from cast steel)
1 - Bolt
moving
3 - Bolt
❑ M12 x 1.5 x 80
moving
4 - Coupling rod
5 - Bolt
moving
❑ Only wheel bearing
housings made from
aluminium are available
as replacement parts. agen
AG. Volkswagen AG d
oes
Therefore, certain parts olksw not
V gu
have to be exchanged d by ara
ir se nte
and/or installed in addi‐ utho eo
tion when replacing ss
a ra
c
⇒ page 235 ce
e
nl
pt
du
6 - Trailing arm an
itte
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erm
ab
❑ Removing and installing ility
ot p
⇒ page 243
wit
is n

h re
ole,
spec
7 - Drive shaft
t to the co
❑ Assembly overview
⇒ page 273 .
rrectness of i
⇒ page 276
8 - Bolt
❑ M12 x 1.5 x 45
cial p
nform
mer

m
tion
co
in t

or
his
te
iva

do
pr
cum
❑ Installing with wheel bearing housings made from aluminium is permissible ⇒ Electronic parts catalogue
for
en
ng
“ETKA”
t.
yi Co
op py
C
ht. rig
ht
rig
tain parts have to be exchanged and/or installed in addition when replacing ⇒ page 235 py by
co Vo
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cted
10 - Rear speed sensor -G44/G46-
agen
Prote AG.
11 - Bolt
❑ 9 Nm


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

The wheel bearing and wheel hub are assembled one housing.
This wheel bearing/wheel hub unit is maintenance free and has no play. Adjustments and repairs are not
possible!
18 - Bolt
❑ 10 Nm
❑ Only wheel bearing housings made from aluminium are wage
olksavailable as replacements nparts. Therefore, cer‐
e
V ot g
tain parts have to be exchanged and/or installed ein
d b addition when replacing ⇒ page 235
y ua
ran
is tee
or
19 - Splash plate au
th or
ac
ss
ce
e
nl
pt
du
an
itte
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erm
ab
ility
ot p
13.1 Changing from wheel housing bearing

wit
, is n
made from cast steel to wheel bearing h re

hole
spec
housing made from aluminium
es, in part or in w
t to the co
A wheel housing bearing made from cast steel has been changed
to a wheel bearing housing made from aluminium. Only wheel
rrectness of i
bearing housings made from aluminium are available as replace‐

ment parts. Therefore, certain parts have to be exchanged and/
l purpos
or installed in addition when replacing ⇒ Electronic parts cata‐

logue “ETKA” .
nform
ercia
The following parts have to be renewed and/or installed in addi‐

tion:
m
at
m
io
r co
♦ Brake carrier
in t
o
his
te
♦ Bolts (qty. 2) for backing plate

a
d
iv
o
pr
cu
or
♦ Bolt, nut and washer for top control arm to wheel bearing
m
f
en
ng
housing
t.
yi Co
Cop py
ht.
♦ Bolt, nut and washer for track rod to wheel bearing housing
rig
rig ht
py by
co Vo
by lksw
cted agen
Prote
13. Assembly overview - wheel bearing housing, trailing link (four-wheel drive, subframe made from aluminium and wheel bearing housing
AG.
made from cast steel) 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
catalogue“ETKA”.

housing
wage es n
Volks ot g
d by ua
ran
ir se tee
tho
or
s au ac
s
ce
e
nl
pt
du
an
itte
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erm
ab
ility
ot p
wit
is n
h re
ole,
Removing
spec
t to the co
– Loosen outer threaded connection for drive shaft
⇒ page 274 .
rrectness of i
– Remove wheel.
– Remove brake carrier with brake caliper and tie to body with
cial p
wire ⇒ Rep. Gr. 46 .

nform
mer
a
m
tion
Note
co
in t
or
his
e
Hang brake caliper from body.

at
do
priv
cum
or
f
en

ng
t.
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disc. ht. Cop py
rig
rig ht
– Remove ABS speed sensor from wheel bearing housing. py by
co Vo
by lksw
cted agen
Prote AG.

– Unbolt coupling rod from wheel bearing housing -arrow-.
– Hold wheel bearing housing and unscrew

wage
n AG.bolts
Volksw-arrows-.
agen AG
doe
ks s no
Vol t gu
– Remove coupling rod -1- from
ed
by trailing arm. ara
is nte
or eo
– Take out wheel bearing
au housing.
th ra
ss c
Installing
ce
le
un
pt
an
d

itte
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rm
ing:
ab
pe
ility
ot

wit
, is n

h re
hole

spec

es, in part or in w
t to the co

rrectness of i
l purpos

bearing housing
n
ercia

orm
operations.
m
atio
com
n in
r
te o
thi
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r
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cu
fo
m
en
ng
t.
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Cop py
ht. rig
ht
rig by
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by lksw
cted agen
Prote AG.

olkswagen AG
en AG. V
Golf 2004 ➤ , Golf Plus 2005 ➤ olkswag does
not
V
Running gear, axles, steering -edEdition
by 08.2009 gu
ara
ris nte
ho eo
ut
– Position trailing arm on wheelssbearing
a housing using bolts ra
c
-2- but do not tighten yet.
ce
le
un
pt
an
d
itte
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yet.
rm
ab
pe
ility
ot
wit
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h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos

n
ercia
form
m
atio
com
n in
r
te o
thi
sd
iva
o
r
rp
cu
fo
m
en
ng
t.
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Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
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


Wheel bearing housing to lower suspension link 90 Nm + 90°
n AG. Volkswagen AG
age does
ksw not
Vol
Wheel bearingedhousing
by to track rod gu
ara 130 Nm + 90°
♦ Use new thornuts
is and bolts nte
eo
au ra
♦ Tighten
ss threaded connections only when vehicle is in c
ce
le
un
pt
an
d
itte
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Trailing arm to wheel bearing housing 90 Nm + 90°
rm
ab
pe
♦ Use new bolts
ility
ot
wit
, is n
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hole
♦ Use new nut
spec
es, in part or in w
t to the co
rrectness of i
l purpos

♦ Use new bolt
n
ercia
form
m
atio
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♦ Use new bolt
r
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py Co
t. Co py
rig
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lksw
cted agen
Prote AG.

13.3 Renewing bonded rubber bush for wheel bearing housing

equipment required
♦ Press tool -30 - 506 B-
♦ Drift sleeve -41 - 501-
♦ Sleeve -3160-
♦ Assembly tool -3350- n AG. Volkswagen AG do
wage es n
Volks ot g
y ua
edb ran
ir s tee
tho
u or
a ac
ss
ce
e
nl
pt
du
an
itte
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erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
rrectness of i
cial p
nform
mer
atio
m
r co
n in
o
thi
te
sd
ir va
o
p
cum
for
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
♦ Torque wrench -V.A.G 1332- cted agen
Prote AG.
Removing
– Remove wheel.

Note
Hang brake caliper from body.

disc.
wage es n
Volks ot g
y ua
edb ran
ris tee
tho
u or
a ac
ss
ce
e
nl
pt
du
an
1 - -3346/3-
itte
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erm
ab
2 - -3301-
ility
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wit
is n
3 - -3301/3-
h re
ole,
spec
4 - -41-501-
t to the co
5 - -3350/1-
6 - -3346/2-
rrectness of i
– Pull out bonded rubber bush by tightening spindle.
Pulling in bonded rubber bush
cial p
nform
mer
a
m
tio
o
n in
r c
te o
thi
s
a
do
ir v
p
cum
for
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.


1 - -3346/3-
2 - -3301-
3 - -30-506 B-
5 - -3160-
6 - -3350/2-
7 - -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:
AG. Volkswagen AG d
started has been attained ⇒ page 188 . lkswagen oes
n o ot g
yV ua
edb ran
Specified torques ho
ris tee
aut or
ac
ce
le
un
Wheel bearing housing to lower suspension link 90 Nm + 90° pt

an
d
itte
♦ Use new nuts and bolts y li

rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec

es, in part or in w
t to the co

rrectness of i
13.4 Removing and installing wheel bearing/

l purpos
wheel hub unit

n
ercia

format
m

com
ion
in
r
te o
thi
sd
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o
r
rp
cu
fo
m
en
ng
i t.
py Co
t. Co py
rig
gh ht
yri by
cop by
Vo
lksw
cted agen
Prote AG.

Removing
– Remove drive shaft ⇒ page 276 .
Note
Do not suspend the brake caliper from the brake hose.

disc.
– Pull wheel hub/wheel bearing unit out from wheel bearing
housing.
Installing n AG. Volkswagen AG do
wage es n
olks ot g
Carry out installation in the reverse sequence, noting theedfollow‐
by
V ua
ran
ing: horis tee
t or
au ac
– Use a new hexagon bolt and tighten ⇒ page 274 s .
s
ce
e
nl
pt
du
an
itte
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erm
ab
ility
ot p
wit
, is n
Specified torques
h re
hole
spec
es, in part or in w
t to the co
♦ Use new bolt
rrectness of i

l purpos
nform
ercia
13.5 Removing and installing trailing arm with

m
mounting bracket
at
m
io
r co
n in t

o
his
ate
d
iv
o
pr
cu
or
m
f
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

Removing
– Remove wheel.
– Remove bolt -arrow- securing handbrake cable -1- to trailing
arm -2-.
wage es n
Volks ot g
d by ua
ran
ir se tee
tho
or
au ac
Vehicles with retainer for handbrake cable ss
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
rrectness of i
– Unbolt coupling rod -1- from trailing arm.
cial p
nform
mer

a
m
tion
co
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

wage es n
y Volks Golf 2004 ➤ , Golf otPlus
gu 2005 ➤
b ar
iseRunning gear, axles, steering - Editiona08.2009
d
r nte
ho eo
aut ra
– Remove bolts -arrows-. ss c
ce
e
nl
pt
– Remove trailing arm with mounting bracket.
du
an
itte
y li
erm
If the trailing arm is to be renewed, the mounting bracket must be
ab
ility
removed from the longitudinal member.
ot p
wit
is n
The position of the mounting bracket must then be adjusted in
h re
ole,
relation to the trailing arm.
spec
t to the co
rrectness of i
Determining position of mounting bracket in relation to trailing arm
cial p
nform
Dimension -a- is 34 mm.
mer
a
m
tion
co
2 - Trailing arm
in t
or
his
ate
– Tighten bolt when dimension -a- is set.
do
priv
cum
or
Installing
f
en
ng
t.
yi Co
op
C py
ht. rig
ing: rig ht
py by
co Vo
by lksw
Threaded connection for trailing arm and wheel bearing housing cted agen
Prote AG.

bearing housing
operations.
– Position trailing arm and mounting bracket on wheel bearing

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

– Tighten bolts -arrows- on position of old imprint.


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Volks ot g
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u or
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ss
ce
e
nl
pt
du
an
itte
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erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
rrectness of i
cial p
nform
mer
atio
m
– Bolt handbrake cable -1- to trailing arm -2- -arrow-.

r co
n in
o
thi
te
sd
ir va
o
p
cum
for
en
ng
i t.
py Co
t. Co py
rig
gh ht
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y cop Vo
lksw
b
cted agen
Prote AG.

Vehicles with retainer for handbrake cable wage es n
Volks ot g
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db
– Attach retainer -1- by pushing in inner pin of rivet -arrow-.
ir se ran
tee
tho
u or
Continuation for all vehicles ss
a ac
ce
e
After installation, toe setting must be checked on wheel alignment
nl
pt
du
an
unit.
itte
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erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
Specified torques
rrectness of i
l purpos
Trailing arm to wheel bearing housing 90 Nm + 90°
♦ Use new bolts
nform
ercia
Trailing arm to mounting bracket 90 Nm + 90°

m
at
m
♦ Use new bolt
io
r co
n in t
o
his
e

at
d
v
♦ Use new bolts

i
o
pr
cu
or
m
f
en
ng
t.
Coupling rod to trailing arm. 45 Nm
yi Co
op
♦ Use new nut
C py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote
AG.

13.6 Repairing trailing arm

equipment required
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
ss c
ce
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nl
pt
du
an

itte
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erm
ab
– Remove trailing arm ⇒ page 243 .

ility
ot p
wit
is n
h re
ole,
spec
t to the co
rrectness of i
cial p
nform
mer
atio
m
r co
n in
o
thi
te
sd
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o
p
cum
for
en
ng
i t.
py Co
t. Co py
rig
gh ht
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cop Vo
248
by lksw
cted agen
Rep. Gr.42 - Rear suspension Prote AG.


1- Tube -T10230/3-
– Press out bonded rubber bush.
– Place trailing arm on a flat surface.
– Mark a vertical line on trailing arm bush.
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
th
au ra
ss c
Dimension -A- = 114 mm
ce
e
nl
pt
du
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itte
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erm
ab
ility
ot p
wit
is n
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ole,
spec
t to the co
There are two different types of bonded rubber bushes. On both rrectness of i
cial p
types, the marked line must be between the projections -1- after
nform
being pressed in.

mer
a
m
tion
co
in t
or
his
ate
do
priv
cum
or
f
en
ng
i t.
py Co
t. Co py
rig
gh ht
yri by
cop by
Vo
lksw
cted agen
Prote AG.


1- Tube -T10230/5-
2- Thrust plate -T10230/12- (chamfer must face bonded rubber
bush)
– Press bonded rubber bush in flush.
– Attach mounting bracket to trailing arm ⇒ page 245 .
– Install trailing arm ⇒ page 243 .
wage es n
Volks ot g
y ua
edb ran
ir s tee
tho
or
s au ac
s
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
rrectness of i
cial p
nform
mer
a
m
tion
co
in t
or
his
ate
do
priv
cum
or
f
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote
250
AG.

AG. Volkswagen AG d
agen oes
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byV gu
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ed
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ho
Golf 2004 ➤ , Golf Plus 2005 ➤ e or a
sRunning
s gear, axles, steering - Edition 08.2009 c
ce
e
nl
pt
du
an
itte
y li
14 Assembly overview - wheel bearing housing, trailing link (four-wheel
erm
ab
ility
ot p
drive, subframe made from steel and wheel bearing housing made
wit
is n
from aluminium)
h re
ole,
spec
t to the co
rrectness of i
2 - Cover
3 - Bolt
cial p
❑ M12 x 1.5 x 80
nform
mer
atio
m
r co
n
removing
in
o
thi
te
sd
ir va
4 - Coupling rod
o
p
cum
or
en
g
n
i t.
py Co
bearing housing Co py
t. rig
gh ht
yri by
5 - Bolt cop Vo
by lksw
cted agen
❑ 90 Nm + 45° further Prote AG.
❑ Observe tightening se‐

quence ⇒ page 254
removing
6 - Trailing arm
⇒ page 243
7 - Drive shaft
❑ Assembly overview
⇒ page 273
⇒ page 276
❑ M14 x 1.5 x 45
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


13 - Nut
❑ M12 x 25
❑ 45 Nm
❑ Self-locking
14 - Bolt
❑ M10 x 35
15 - Bolt n AG. Volkswagen AG do
wage es n
❑ 4 Nm Volks ot g
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16 - Brake disc utho tee
or
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17 - Bolt ss
ce
e
nl
pt
du
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itte
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❑ Loosening and tightening hexagon bolt for drive shaft ⇒ page 274
erm
ab
ility
ot p
wit
is n
❑ Loosening and tightening twelve-point bolt for drive shaft ⇒ page 275
h re
ole,
spec
t to the co
Note
rrectness of i
cial p
The wheel bearing and wheel hub are assembled one housing. nform
mer
This wheel bearing/hub unit is maintenance and adjustment free. Adjustments and repairs are not possible!
m
tion
co
in t
or
19 - Bolt
his
te
iva
do
❑ M6 x 12
pr
cum
for
❑ 12 Nm
en
ng
t.
yi Co
op
20 - Backplate
C py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
housing

Removing
– Remove coil spring ⇒ page 257 . wage es n
Volks ot g
y ua
db
– Loosen the outer drive shaft threaded connectionir se ran
tee
⇒ page 274 . autho
or
ac
ss
– Remove wheel.
ce
e
nl
pt
du
an
itte
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erm
ab
ility
ot p
– Remove ABS speed sensor from wheel bearing housing.
wit
is n
h re
ole,
spec
t to the co
rrectness of i
cial p
nform
mer
atio
m
r co
n in
o
thi
te
sd
ir va
– Unscrew bolts -arrows- and remove splash plate -1-.
o
p
cum
for
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
– 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
gen AG a oes
lksw n
It is important to keep db
yto
Vothe specified sequence for the following
ot g
ua
operations. o
ir se
ran
te
th eo
au ra
c
ss
– Fit trailing arm to wheel bearing housing with bolts -arrows-
ce
e
nl
pt
du
but do not tighten yet.

an
itte
y li
erm
ab
ility
yet.
ot p
wit
is n

h re
ole,

spec
– Tighten trailing arm bolts -arrows- to specified torque, ensur‐

t to the co
ing that components are positioned as required ⇒ page 254 .

rrectness of i

tightened only when the dimension between the centre of wheel
hub and lower edge of wheel housing has been attained
cial p
⇒ page 188 .
nform
mer

a
m
Gr. 46 .
ion
co
in t
or

his
te
iva
do
pr
cum
or
Specified torques
f
en
ng
t.
yi Co
op
C py
ht. rig
ht
rig
Upper transverse link to wheel bearing housing 130 Nm + 90° further
py by
co Vo
by lksw
♦ Use new nuts and bolts Prote
cted AG.
agen



Wheel bearing housing to lower suspension link 90 Nm + 90° further
Wheel bearing housing to track rod 130 Nm + 90° further

Trailing arm to wheel bearing housing 90 Nm + 45° further

♦ Use new bolts!

♦ Use new nut.

Brake disc to wheel bearing wage
olks housing. 4 Nm
es n
V ot g
by ua
Drive shaft to wheel
ir se hub “hexagon bolt”
d ran
tee 180 Nm +180° further
♦ Use new boltutho
or
a ac
ss
Drive shaft to wheel hub “12-point bolt” ce 70 Nm + 90° further
e
nl
pt
du
♦ Use new bolt an

itte
y li
erm
ab
ility
ot p
wit
is n
h re
14.2 Renewing bonded rubber bush for

ole,
spec
wheel bearing housing

t to the co
⇒ page 240
14.3 Removing and installing wheel bearing/

rrectness of i
wheel hub unit

cial p
nform

mer
a
m
tion
co
in t
or
his
ate
do
priv
cum
or
f
en
ng
t.
yi Co
Cop py
ht. rig
ht
rig by
copy Vo
by lksw
cted agen
Prote AG.
from aluminium) 255

Removing
– Remove drive shaft ⇒ page 276 .
wage es n
– Remove brake carrier with brake caliper and tie to bodyy Vwith
olks ot g
ua
wire ⇒ Rep. Gr. 46 . ise
d b ran
tee
r
tho or
s au ac
s
Note
ce
le
un
pt
an
d
itte
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Do not suspend the brake caliper from the brake hose.
erm
ab
ility
ot p
wit
– Remove bolt for brake disc and remove brake disc.
is n
h re
ole,
spec
– Pull wheel hub/wheel bearing unit out from wheel bearing
t to the co
housing.
Installing
rrectness of i
ing:
cial p
– Use a new hexagon bolt and tighten ⇒ page 274 .
nform
mer
a
m
tio
r co
n in
o
thi
te
sd
va
Specified torques
i
o
pr
cu
r
fo
m
en
ng

t.
yi Co
Cop py
Wheel hub with wheel bearing to wheel bearing housing 70 Nm + 90° further
ht. rig
rig ht
♦ Use new bolt py by
co Vo
by lksw
cted agen
Prote AG.

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 AG. Volkswagen AG d
agen oes
lksw not
3 - Lower spring seat by Vo gu
ara
ed
❑ End of coil spring horisturned nte
eo
to stop s aut ra
c
s
4 - Bolt
ce
e
nl
pt
du
an
❑ M14 x 1.5 x 70
itte
y li
erm
ab
❑ 180 Nm
ility
ot p
wit
5 - Bolt
is n
h re
ole,
spec
6 - Shock absorber
t to the co
⇒ page 259
rrectness of i
of running gear
cial p
nform
data plate
mer

m
tion
co

in t
or
⇒ page 217
his
te
iva
do
pr

um
for
en
ng

t.
yi Co
op
⇒ page 236 C py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

♦ 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

♦ Spring retainer -V.A.G 1752/4-
♦ Adapter -V.A.G 1752/9- , not illustrated

Removing
– Remove wheel.
– Insert spring compressor -3-.
WARNING
Make sure coil spring is properly seated in spring retainer
olks
wage - es n
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V.A.G 1752/4- (risk of accident). d byV ua
ran
e
ris tee
tho or
s au ac
– Use a spanner or a reversible ratchet handle
s to compress
ce
e
spring compressor.
nl
pt
du
an
itte
y li
– Compress coil spring until it can be removed.
erm
ab
ility
ot p
– Remove spring.
wit
is n
h re
1- Adapter -V.A.G 1752/9-
ole,
spec
t to the co
Installing
rrectness of i
ing:
cial p
nform
End of spring -arrow- must lie against stop on bottom spring seat.
mer
– Install spring together with spring seat.

a
m
tion
co
– The bottom spring seat has a pin.

in t
or
his
ate
do
iv
pr
cum
or
f
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

– 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.

ers gen AG. Volkswagen AG d
a oes
lksw
ot g n
Special toolsd band
y V workshop equipment required
o
ua
r
e an
ris tee
♦ Torque
ut
ho wrench -V.A.G 1332- or
a ac
ss
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
rrectness of i
Removing
– Remove wheel.
cial p
nform
– Remove wheel housing liner ⇒ Rep. Gr. 66 .

mer
a
m
ti

o
r co
n in
o
thi

te
s
a
do
ir v
p
cum
for
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.


– Remove shock absorber.
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 . gen AG
. Volkswagen AG
wa does
olks not
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ara
ed nte
ris
Specified torques tho eo
au ra
c
ss
ce
e
nl
pt
du
an
Shock absorber to body 50 Nm + 45° further
itte
y li
♦ Use new bolts
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
15.3 Repairing shock absorber
rrectness of i
1 - Shock absorber
⇒ page 259
cial p
nform
mer
of running gear
a
m
tion
o
data plate
c
in t
or
his
te
2 - Protective cap
iva
do
pr
cum
3 - Protective tube
for
en
ng
t.
yi
4 - Support ring
Co
Cop py
ht. rig
❑ Allocation ⇒ Electronic rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
5 - Bump stop
with support ring
with support ring
7 - Nut
❑ M10 x 1.0
❑ 25 Nm
moving
ing ⇒ page 261

8 - Cover
10 - Bump stop
Special tools and work‐

shop equipment re‐
quired
♦ Torque wrench -
V.A.G 1332-

T10001-
lkswage es n
o ot g
byV ua
ed ran
oris tee
th or
au ac
ss
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
Loosening and tighten‐

ing threaded connection

t to the co
for shock absorber

mounting
rrectness of i
1 - Commercially availa‐
ble ratchet handle
2 - Socket -T10001/9-
cial p
nform
3 - Ratchet handle -
mer
T10001/11-
a
m
tion
o
4 - Socket -T10001/1-
c
in t
or
his
te
iva
do
pr
cum
for
en
ng
i t.
py Co
t. Co py
rig
gh ht
yri by
y cop Vo
lksw
b
cted agen
Prote AG.

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
data sticker
⇒ page 257
5 - Bolt
❑ M14 x 1.5 x 70
❑ 180 Nm
6 - Bolt
AG. Volkswagen AG d
❑ M10 x 35 ksw
agen oes
not
Vol
❑ 50 Nm + 45° further d by gu
ara
ir se nte
❑ Renew each uth time after
o eo
ra
removingss a c
ce
le
7 - Shock absorber
un
pt
an
d
itte

y li
rm
ab
⇒ page 262
pe
ility
ot

wit
, is n
h re

hole
spec
gear versions; see

es, in part or in w

t to the co
data sticker
8 - Washer
rrectness of i

l purpos

n
ercia
fo

rmat
m
com
ion
in
r
te o
thi

sd
iva
o
r
rp
cu
fo
⇒ page 257
en
ng
t.
yi Co
op
C py
ht. rig
ht
rig
ers
py by
co Vo
by lksw
cted agen
Prote AG.

AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
ss c
ce
e
nl
pt
du
an
Removing
itte
y li
erm
ab
– Remove wheel.
ility
ot p
wit
is n
– Remove wheel housing liner ⇒ General body repairs, exterior;
h re
ole,
Rep. Gr. 66 .
spec
t to the co
rrectness of i
cial p
nfo
mer
rmatio
om
n in
or c
thi
te
sd
iva
o
pr
cu
or
m
f
en
ng
i t.
py Co
– Remove bolt -arrow-. Co py
t. rig
gh ht
yri by
– Remove shock absorber. cop by
Vo
lksw
cted agen
Prote
Installing
AG.

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
Shock absorber to body 50 Nm + 45° further
♦ Use new bolts!
16.3 Repairing shock absorber

⇒ page 260
lkswage es n
o ot g
byV ua
ed ran
oris tee
th or
au ac
ss
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
m
io
r co
n in t
o
his
ate
d
iv
o
pr
cu
or
m
f
en
ng
i t.
py Co
t. Co py
rig
gh ht
yri by
y cop Vo
lksw
b
cted agen
Prote AG.

AG. Volkswagen AG d
agen oes
olksw not
yV gu
17 Assembly overview - anti-roll bar (four-wheel drive, subframe made d b ara
ise nte
or eo
from aluminium and wheel bearing housing made from cast steel)
th
au ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
1 - Anti-roll bar
ility
ot p
wit
is n
h re
of running gear
ole,
spec
data plate
t to the co
⇒ page 265
rrectness of i
2 - Bush
❑ Always renew bushes
on both sides of the ve‐
cial p
hicle.
nform
mer
3 - Clamp
a
m
tion
o
4 - Bolt
c
in t
or
his
e
at
do
riv
❑ Tighten evenly.
p
cum
or
f
en
ng
❑ Always renew after re‐ py

i t.
Co
moving t. Co py
rig
gh
ht
yri by
cop Vo
connections in unladen by lksw
cted agen
position ⇒ page 187 Prote AG.

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
7 - Bolt
8 - Coupling rod
❑ Connects anti-roll bar to trailing arm and wheel bearing housing
9 - Subframe

17. Assembly overview - anti-roll bar (four-wheel drive, subframe made from aluminium and wheel bearing housing made from cast steel)
265
Removing
Note
AG. Volkswagen
agen AG do
ksw es n
Vol ot g
– Remove nut -1- and pull couplingedrod -2- out of
by anti-roll bar. ua
ran
ris tee
ho
aut or
ac
ss
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
rrectness of i

cial p

nform
mer

a
m
tion
co
in t
or
his
ate
do
priv
cum
or
f
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.


AG. Volkswagen AG d
the vehicle using tensioning straps -T10038- . lksw
agen oes
n o ot g
yV ua
db ran
rise tee
WARNING tho or
au ac
ss
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
n
ercia
f
– Remove anti-roll bar.
orm
m
atio
Installing
com
n in
r

te o
thi
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rp
cu
fo
m
en
ng
i t.
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– Evenly tighten bolts -arrows- for anti-roll bar clamp. ht. Co py
rig
rig ht
For the right side of the vehicle only (depending on equipment) py by
co Vo
by lksw
cted agen
– Lower wheel suspension again using engine and gearbox jack Prote AG.
– Install wheel and tighten. ⇒ page 288
Specified torques
♦ Use new bolts!
17. Assembly overview - anti-roll bar (four-wheel drive, subframe made from aluminium and wheel bearing housing made from cast steel)
267

♦ Use new nut
AG. Volkswagen AG d
agen oes
olksw not
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d by ara
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au ra
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le
un
pt
an
d
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rm
ab
pe
ility
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wit
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spec
es, in part or in w
t to the co
rrectness of i
l purpos
n
ercia
form
m
atio
com
n in
r
te o
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sd
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cu
fo
m
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ng
t.
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Cop py
ht. rig
ht
rig by
copy Vo
by lksw
cted agen
Prote AG.

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
data sticker
⇒ page 269
2 - Bearing
❑ Always renew mount‐
ings on both sides of the
vehicle.
3 - Clamp
❑ M8 x 28
removing
6 - Nut
❑ M10 x 55
❑ 45 Nm
AG. Volkswagen AG d
❑ Self-locking lksw
agen oes
not
Vo gu
❑ Renew each time after db
y ara
removing ir se nte
tho eo
au ra
7 - Multi-point socket head bolt ss c
ce
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nl

pt
du
an
removing
itte
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erm
ab
8 - Coupling rod
ility
ot p
wit

is n
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ole,
spec
bearing housing
t to the co
9 - Subframe
rrectness of i

cial p
nform
mer
a
m
tion
co
in t
or
his
ate
do
priv
cum
or
f
en
ng
t.
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Cop py
ht. rig
ht
rig by
copy Vo
by lksw
cted agen
Prote AG.
18. Assembly overview - anti-roll bar (four-wheel drive, subframe made from steel and wheel bearing housing made from aluminium)
269
AG. Volkswagen AG d
agen oes
olksw not
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ara
ed
ris nte
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aut ra
ss c
ce
e
nl
pt
du
an
itte
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erm
ab
Removing
ility
ot p
wit
is n
h re
ole,
spec
Note
t to the co
rrectness of i
cial p
nform
mer
Note
a
m
tion
co
Do not loosen bolt -arrow- for track rod -3-.

in t
or
his
ate
do
priv
cum
or
f
en
ng
i t.
py Co
t. Co py
rig
gh ht
yri by
cop by
Vo
lksw
cted agen
Prote AG.



WARNING


AG. Volkswagen AG d
agen
Continuation for both sides of vehicle: Volksw
oes
not
by gu
d ara
– Remove anti-roll bar. orise nte
eo
th
u ra
Installing ss
a c
ce
e
nl
pt
du
an
itte
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erm
ab
ility
ot p
wit
is n
– Evenly tighten bolts -arrows- for anti-roll bar clamp.
h re
ole,
spec
t to the co
rrectness of i
cial p
nform
mer
a
m
tion
co
in t
or
his
ate
do
riv
– Install wheel and tighten. ⇒ page 288

p
cum
or
f
en
ng
i t.
py Co
t. Co py
rig
gh ht
yri by
cop by
Vo
lksw
cted agen
Prote AG.
Specified torques
♦ Use new bolts!
18. Assembly overview - anti-roll bar (four-wheel drive, subframe made from steel and wheel bearing housing made from aluminium)
271

♦ Use new nut.
lkswage es n
o ot g
byV ua
ed ran
oris tee
th or
au ac
ss
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un
pt
an
d
itte
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rm
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wit
, is n
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hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
n
ercia
form
m
atio
com
n in
r
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thi
sd
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cu
fo
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ng
i t.
py Co
t. Co py
rig
gh ht
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y cop Vo
lksw
b
cted agen
Prote AG.

19 Assembly overview - drive shaft

plete unit
plastic mallet
2 - Bolt
❑ M16 x 1.5 x 80
ing hexagon bolt for
drive shaft ⇒ page 274
❑ 12-point bolt, 70 Nm
AG. +
Volkswagen AG
agen does
90° further Volksw not
gu
y
❑ Loosening db and tighten‐
ara
ir se nte
ing
uth twelve-point bolt for
o eo
ra
ss drive shaft ⇒ page 275
a c
ce
e

nl
pt
du
an
moving
itte
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erm
ab
ility
Note
ot p
wit
is n
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ole,
3 - Drive shaft
spec
t to the co

4 - Hose clip
rrectness of i

moving
cial p
nform
5 - Boot
mer

a
m
tio
r co
❑ Material: (polyester elastomer).

n in
o
thi
te
6 - Hose clip
s
a
do
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p

um
for
en
ng

t.
yi Co
Cop py
ht.
7 - Dished spring
rig
rig ht
py by
Vo
co lksw
by
cted agen
Prote AG.
8 - Thrust washer
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
12 - Locking plate
13 - Bolt
❑ 40 Nm
14 - Retaining ring
❑ Remove and install with circlip pliers -VW 161 A-
15 - Seal
AG. Volkswagen AG d
❑ Checking ⇒ page 284 agen oes
olksw not
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17 - Dished spring orise nte
th eo
❑ With inner splines au ra
c
ss
❑ Installation position ⇒ page 281 ce
e
nl
pt
du
an
itte
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erm
ab
ility
19.1 Loosening and tightening drive shaft
ot p
wit
, is n
hexagon bolt
h re
hole
spec

es, in part or in w
t to the co

rrectness of i
l purpos
nform
mercia
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n in
o
thi
te
sd
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pr
cu
or
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py Co
Wheel bearings must not be subjected to load after bolt securing t. Co py
rig
gh
drive shaft to wheel hub has been loosened.
ht
yri by
cop by
Vo
lksw
If wheel bearings are loaded with weight of vehicle, bearing will cted agen
Prote AG.
♦ Procedure for loosening hexagon bolt.

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 oes
– Tighten hexagon bolt to 180
yV
oNm.
lksw not
gu
b ara
ed
– Lower vehicle onto its
horiswheels. nte
eo
t
au ra
– Turn hexagon bolt
ss 180° further. c
ce
e
nl
pt
du
an
19.2 Loosening and tightening 12-point bolt

itte
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erm
ab
for drive shaft

ility
ot p
wit
is n

h re
ole,
spec
♦ Socket AF 24 -T10361-
t to the co
rrectness of i
cial p
nform
mer
a
m
tion
co
in t
or
his
ate
do
priv
cum
or
f
en
ng
i t.
py Co
t. Co py
rig
gh ht
yri by
y cop Vo
lksw
b
cted agen
Prote AG.

wage es n
Volks ot g
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Wheel bearings must not th be subjected to load after bolt securing
o
or
au
drive shaft to wheel hub
ss has been loosened. ac
ce
e
nl
pt
du
an
itte
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ab
ility
ot p
♦ Procedure for loosening 12-point flange bolt.
wit
is n
h re
ole,
spec
as this would damage the wheel bearing. If the vehicle does have
to be moved, always note the following points:
t to the co
– Fit an outer joint in place of the drive shaft.
rrectness of i
– Tighten the outer joint to 120 Nm.
Loosening 12-point bolt
– With vehicle still standing on its wheels, loosen the twelve-
cial p
nform
point bolt a maximum of 90°, as the wheel bearing will other‐
mer
wise be damaged. atio

m

r co
n in
o
thi
e

t
sd
ir va
o
p
– Remove 12-point bolt -arrow-.

um
for
en
ng
t.
yi
Fitting 12-point bolt
Co
Cop py
ht. rig
– Renew 12-point bolt. rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
Note
aged.

– Tighten 12-point bolt to 70 Nm.
– Turn 12-point bolt 90° further.
19.3 Removing and installing drive shaft

Removing

– 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
agen AG olksw
Carry out installation in the reverse sequence, notingagethe
n AGfollow‐
.V
does
ksw
ing: by Vol not
gu
d ara
se nte
– Install wheel and tighten ⇒ page 288tho.ri e or
au ac
The threaded connections on the bearing housing may be wheel
ss
ce
le

un
pt
an
d
itte
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started has been attained ⇒ page 188 .
rm
ab
pe
ility
ot
wit
, is n
h re
Note
hole
spec
es, in part or in w
Ensure that the washer between wheel bearing housing and
t to the co
shock absorber is also installed on vehicles with aluminium wheel
bearing housing.
rrectness of i
Specified torques
l purpos

n
ercia
fo

rmat
m
♦ Use new bolt

com
ion
in
r

te o
thi
♦ Use new bolt

sd
iva
o
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rp
cu
fo
Drive shaft to flange shaft/gearbox 40 Nm

en
ng
t.
yi
♦ Use new bolts! ♦ Initially tighten diagonally to 10 Nm
Co
Cop py
t. rig
gh
ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

19.4 Dismantling and assembling drive shaft

equipment required
♦ Tube -VW 416 B-
♦ Thrust plate -VW 447 H-
wage es n
Volks ot g
y ua
edb ran
ir s tee
tho
u or
a ac
ss
ce
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nl
pt
du
an
itte
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erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
rrectness of i
cial p
nform
mer
a
m
tio
r co
n in
o
thi
te
sd
ir va
o
p
cu
or
m
f
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

♦ Circlip pliers -VW 161 A-

1331-
1332-
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
rrectness of i
cial p
nform
mer
a
m
tio
r co
n in

o
thi
te
sd
ir va
o
p
cu
or
m
f
en
ng
i t.
py Co
t. Co py
rig
gh ht
yri by
cop by
Vo
lksw
cted agen
Prote AG.

♦ Puller -T10382-

– Clamp drive shaft in vice using protective jaw covers. wage es n
Volks ot g
y ua
db ran
– Fold back boot. o
ir se
tee
th or
u
– Set puller -T10382- up so that smooth side of puller
ss
a plate - ac
ce
e
nl
pt
du
an
itte
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erm
VW 771- .
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
rrectness of i
cial p
nform
mer
a
m
tio
o
n in
r c
te o
thi
s
a
do
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p
cum
for
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
Installation position of dished spring and thrust washer on outer cted agen
Prote AG.
joint
1- Dished spring
2- Thrust washer
Dismantling

Pressing off inner constant velocity joint

Assembling
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
th
au ra
ss c
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e
nl
pt
du
an
itte
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erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
rrectness of i
1- Dished spring
cial p
nform
mer
a
m
tion
co
in t
or
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ate
do
priv
cum
or
f
en
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i t.
py Co
t. Co py
rig
gh ht
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cop by
Vo
lksw
cted agen
Pressing on inner constant velocity joint Prote AG.
Note


-arrows B-.


not cant pliers).
Note

tighten the hose clip only with special pliers -V.A.G 1682- .
torque wrench -V.A.G 1331- ). n AG. Volkswagen AG do
swage es n
♦ Make sure thread of spindle -A- on pliers moves freely. Lubri‐ byV
olk ot g
ua
cate with MoS2 grease if necessary. ris
ed ran
tee
tho
or
♦ If the thread is tight (e.g. due to dirt), the required
ss
au
clamping ac
ce
e
nl
is applied.
pt
du
an
itte
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erm
ab
ility
ot p
wit
, is n
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Assembling
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
m
io
r co
n in t
o
his
e
1- Dished spring
at
d
iv
o
pr
cu
or
m
f
en
ng
i t.
py Co
t. Co py
rig
gh ht
yri by
y cop Vo
lksw
b
cted agen
Prote AG.

outer joint
1- Dished spring
2- Thrust washer
– Press joint on to stop.
– Install retaining ring.

Note


-arrows B-.

not cant pliers).
Note

tighten the hoseswclip only
agen with
AG. V special dpliers
olkswagen AG
oes -V.A.G 1682- .
k not
Vol gu
♦ Specified
se
dtorque:
by 25 Nm. ara
nte
ri
o e
♦ Useautorque
th wrench -C- with adjustment range 5 … 50oNm, ra (e.g.
ss c
ce
e
nl
pt

du
an
itte

y li
erm
ab
ility

ot p
wit
is n
h re
is applied.
ole,
spec
t to the co

rrectness of i
cial p
nform
mer
a
m
tio
o
n in
r c
te o
thi
s
a
do
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p
cum
for
en
ng
t.
yi
Co
Cop py
ht. rig
rig ht
py by
co Vo
lksw
by
cted agen
Prote
damage.
AG.

Removing
joint body.
G. Volkswagen
– Swing segment of hub into
lksw
square
agen
A
cage window.
AG do
es n
o ot g
yV ua
– Tip hub out of cage. rise db ran
tee
tho
o
The six balls fors aeach
u joint belong to a tolerance group. Check r ac
s
ce
e
nl

pt
du
an
becomes noticeable during load change jolts; in such cases, the

itte
y li
joint must be renewed. Smoothing and traces of wear of the balls

erm
ab
ility
are no reason to change the joint.

ot p
wit
is n
Installing
h re
ole,
spec

t to the co
– Fit cage with hub into joint body.

– Press in opposing balls one after the other; the original position
rrectness of i
of the hub relative to the cage and joint body must be restored.
– Fit new retaining ring into hub.
cial p
nform
– Checking function of constant velocity joint

mer
a
m
The constant velocity joint is correctly assembled if the ball hub

io
r co
n in
can be moved by hand backwards and forwards over its entire

o
thi
e
range of axial movement.

t
sd
ir va
o
p
cu
or
19.6 Checking inner constant velocity joint

f
en
ng
t.
yi Co
op py
Removing
t. C rig
gh ht
pyri by
Vo
o
c by lksw
cted agen
soiled, and to check the running surfaces and the balls for wear Prote AG.
and damage.


– 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
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
se nte
ori eo
th
– Insert hub into cage
s a via the two chamfers. The hub can be
u ra
c
installed in any position. Press balls into cage.
s
ce
e
nl
pt
du
The ball hub has two different distances between the ball tracks:
an
itte
y li
a smaller one and a larger one.
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
rrectness of i
– Insert hub complete with cage and balls into joint body, making
sure that a smaller gap -b- faces open side of joint body.
cial p
nform
– Also make sure that chamfer on inner circumference of ball

mer
hub is visible after swinging it into place.

a
m
tion
co
in t
or
his
ate
do
iv
pr
cum
or
f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

– 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-.
– Checking function of constant velocity joint
The constant velocity joint is correctly assembled if the ball hub
can be moved by hand backwards and forwards over its entire
range of axial movement.
lkswage es n
o ot g
byV ua
ed ran
oris tee
th or
au ac
ss
ce
e
nl
pt
du
an
itte
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erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
rrectness of i
cial p
nform
mer
a
m
tio
o
n in
r c
te o
thi
s
a
do
ir v
p
cum
for
en
ng
i t.
py Co
t. Co py
rig
gh ht
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y cop Vo
lksw
b
cted agen
Prote AG.

44 – Wheels, tyres, vehicle geometry

AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
ss c
ce
le
un
pt
an
d
itte
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rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
n
ercia
form
m
atio
com
n in
r
te o
thi
sd
iva
o
r
rp
cu
fo
m
en
ng
i t.
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t. Co py
rig
gh ht
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cop by
Vo
lksw
cted agen
Prote AG.
1. Appraisal of accident vehicles 287

2 Torque settings for wheel bolts lkswage

es n
o ot g
yV ua
Wheel bolt to wheel hub for all vehicles ed b ran
oris tee
th
Specified torque: 120 Nm. au or
ac
ss
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
n
ercia
form
m
atio
com
n in
r
te o
thi
sd
iva
o
r
rp
cu
fo
m
en
ng
i t.
py Co
t. Co py
rig
gh ht
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lksw
b
cted agen
Prote AG.
288 Rep. Gr.44 - Wheels, tyres, vehicle geometry

3 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.
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
th
au ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
rrectness of i
cial p
nform
mer
a
m
tio
r co
n in
o
thi
te
s
a
do
ir v
p
cum
for
en
ng
i t.
py Co
t. Co py
rig
gh ht
yri by
cop by
Vo
lksw
cted agen
289
Prote AG.
3. Fitting wheel and tyre

wage es n
Volks ot g
Golf 2004 ➤ , Golf Plus 2005 ed➤
by ua
ran
ris tee
utho - Edition 08.2009 or
a ac
ss
ce
le
un
pt
4 Removing and fitting tyres (wheels
an
d
itte
y li
with tyre pressure monitoring)
rm
ab
pe
ility
ot
wit
, is n
h re
hole
4.1 Notes on safety and conditions for re‐
spec
es, in part or in w
moving and fitting tyres (wheels with tyre
t to the co
pressure monitoring)
rrectness of i
• It is extremely important to adhere to the instructions and
warnings in the following descriptions.
l purpos
• Check whether the tyre pressure sensor should also be re‐

placed ⇒ Vehicle diagnosis, testing and information system
n
ercia
f
VAS 5051.
ormat
m
com
ion
in
Note
r
te o
thi
sd
iva
o
♦ Ensure that the tyre does not contact the tyre pressure sensor
r
rp
cu
fo
m
during removal or fitting.
en
ng
t.
yi Co
op
♦ The tyre pressure sensor must not come into contact with wa‐ C py
ht. rig
ter or be blown upon with compressed air when the wheel rim rig ht
py by
is cleaned.
co Vo
by lksw
cted agen
Prote 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, TÜV) 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 .

Tyre sets with other specified tyre inflation pressures

wage es n
If a vehicle is fitted with tyres requiring nominal tyre inflation pres‐ olks ot g
yV ua
sures other than those specified on the tank flap sticker, these isedb ran
tee
tyres (second wheel set) can also be monitored with theuthTPM or
or
system. ss
a ac
ce
e
nl
Nominal tyre inflation pressures for the second wheel set must be
pt
du
an
specified to the system with the Vehicle diagnosis, testing and
itte
y li
information system -VAS 5051B- .
erm
ab
ility
ot p
The wheel electronics for the wheels of the second wheel set are
wit
is n
not automatically detected and learned by the TPM system (unlike
h re
ole,
the wheel electronics for the wheel set with Volkswagen-ap‐
spec
proved wheel and tyre combinations).
t to the co
The following work has to be performed to switch to the second
wheel set:
rrectness of i
♦ Read ID numbers (IDs) of the wheel electronics (tyre pressure
sensors) prior to installation.
♦ Switch the TPM to wheel set 2. cial p
nform
♦ Enter the necessary nominal tyre pressures and the IDs of the
mer
wheel electronics in the system.
atio
m
r co
n
4.3 Pressing tyre off wheel rim
in
o
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te
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o
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Caution
um
for
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ng
i t.
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♦ Comply with the notes on safety and conditions Co py
t. rig
⇒ page 290
h ht
rig by
copy Vo
by lksw
cted agen
Prote AG.
– Deflate tyre by unscrewing nickel-plated valve insert.
– 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
♦ Comply with the notes on safety and conditions

⇒ 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 does
not
pletely above wheel rim flange. by
Vol gu
ara
d
ise nte
ho
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ut
sensor is in front of the assembly head. ss
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c
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un
pt
an
d
itte
Note
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rm
ab
pe
ility
♦ Check that the tyre pressure sensor is not loose or damaged.
ot
wit
, is n
If the screwed connection is loose, replace the union nut, the
h re
valve insert, the seal, the sealing washer and the valve cap
hole
spec
with new parts from the repair set ⇒ Electronic parts catalogue
es, in part or in w
“ETKA” .
t to the co
♦ If the tyre pressure sensor is damaged, then replace the com‐
plete item ⇒ page 304 .
rrectness of i
l purpos
4.5 Fitting tyre to wheel rim
n
ercia
form
Caution
m
atio
com
n in
♦ Comply with the notes on safety and conditions
r
te o
thi
⇒ page 290
sd
iva
o
r
rp
cu
fo
m
en
ng
i t.
py Co
. Co py
rig
Note
t
gh ht
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cop by
Vo
lksw
cted
When a tyre is changed, it is recommended also to change the
agen
Prote AG.
set of seals for the tyre pressure sensor.
– Coat wheel rim flanges, tyre beads and inside of upper tyre
bead generously with tyre assembly paste.
– First fit inner side of tyre.

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.
. Volkswagen AG
gen AG does
– When the tyre bead does not lie completely against the olkwheel
swa not
rim flange: deflate the tyre, press tyre bead off wheel by V flange
rim gu
ara
ed
and generously coat again with tyre assemblythopaste.
ris nte
eo
au ra
– Inflate tyre to a pressure of max. 3.3 bar (bead
ss seating pres‐ c
ce
e
sure)
nl
pt
du
an
itte
– If the tyre beads seat perfectly against the shoulder of the
y li
erm
ab
wheel rim, increase pressure to 4 bar to “seat” the tyre.
ility
ot p
wit
– Fit a new nickel-plated valve insert and inflate tyre to prescri‐
, is n
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bed inflation pressure.
hole
spec
– Then balance wheel.
es, in part or in w
– Install wheel and tighten bolts to specified torque t to the co

⇒ page 288 . rrectness of i
l purpos
nform
mercia
at
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io
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n in t
o
his
ate
d
iv
o
pr
cu
or
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f
en
ng
i t.
py Co
t. Co py
rig
gh ht
yri by
y cop Vo
lksw
b
cted agen
Prote AG.
4. Removing and fitting tyres (wheels with tyre pressure monitoring) 293
5 Removing and fitting tyres with run-

flat 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
following abbreviations DSST, Euforia, n ARFT,
G. VolkROF,
swagenRSC,
AG do SSR
wage
or ZP. The abbreviation is located Volks on the flank of the tyresfol‐
e n
ot g
y
lowing the tyre designation ed bof the respective tyre manufactur‐ uara
nte
ir s
er. tho eo
au ra
c
• It is extremely important
ss to adhere to the instructions and
ce
e
warnings in the following descriptions.

nl
pt
du
an
itte
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• Check whether the tyre pressure sensor should also be re‐

erm
ab
placed (if present) ⇒ Vehicle diagnosis, testing and information

ility
ot p
system VAS 5051.

wit
is n
h re
ole,
spec
Note
t to the co
♦ Ensure that the tyre does not contact the tyre pressure sensor
during removal or fitting.
rrectness of i
♦ 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.
cial p
nform
5.2 Installation conditions

mer
a
m
tio
r co
Warming cold tyres to minimum installation temperature

n in
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p
Note
um
for
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t.
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op
This instruction also applies to ultra-high performance tyres C py
ht. rig
(height/width ratio less than or equal to 45 % and speed symbol rig ht
py by
greater than or equal to V). co Vo
by lksw
cted agen
Prote AG.

WARNING
The minimum installation temperature of a tyre is 15 °C and

the temperature in the core of the tyreeshould not be more than
30 °C. olks
wag es n
o
yV t gu
db ara
rise nte
tho eo
• To install tyres without
sa
u damage, it is especially important to ra
c
warm the upper part of the sidewall and the inside of the upper
s
ce
e
nl
bead to at least 15 °C.
pt
du
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itte
y li
• This internal temperature is referred to as the core tempera‐
erm
ab
ture.
ility
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wit
is n
• Rubber is a poor conductor of heat, therefore a cold tyre must
h re
ole,
be left in an area with the correct temperature for a sufficiently
spec
long period so the inner rubber layers can warm up to at least
15 °C.
t to the co
• The surface temperature of the tyre during the warming up
phase is no indication of its internal temperature.
rrectness of i
• 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
cial p
warm air to “flow” around them effectively.
nform
mer
• Tyres must never be placed in front of a radiator or hot air
a
m
t
blower for warming, since this can very quickly lead to critical
io
o
n in
c
surface temperatures.
r
te o
thi
s
a
• Except for warming with warm water or warm ambient air
do
ir v
p
(max. 50 °C), there is no process available for warming tyres
cum
for
without damaging the tyre!

en
ng
i t.
py Co
Co
• When cold tyres (below 0 °C) are transferred to a warm envi‐
py
t. rig
gh
ronment (above 0 °C), a layer of condensation immediately
ht
yri by
cop Vo
forms on the surface of the tyre. This layer of condensation by lksw
cted agen
indicates that the tyre is intensively absorbing heat from its Prote AG.
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.
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. n AG. Volkswagen AG do

wage es n
olks ot g
– When pressing off a tyre using tyre fitting equipmentd by with a
V ua
ran
press-off plate, always ensure that the tyre valve/
horise
tyre pres‐ tee
sure sensor -arrow- is directly opposite theaubead breaker -1-.
t or
ac
ss
The bead breaker must be positioned no more than 2 cm from
ce
e
nl
pt
du
wheel rim flange.
an
itte
y li
erm
ab
– Remove balance weights and excessive dirt from wheel.
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
– Press both tyre beads off all round and liberally coat tyre and
wheel rim flange with tyre assembly paste -arrow-.
l purpos
nform
mercia
at
m
io
r co
n in t
o
his
ate
d
iv
o
pr
cu
or
m
f
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
5.4 Removing tyre from wheel

co Vo
by lksw
cted agen
Prote AG.
Caution

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
This action will push the depressor -1- up against
wagethe assembly
n AG. gen AG
does
head. This allows it to be removed easily. Volks not
gu
by a
ed ran
ris tee
utho or
a ac
ss
ce
e
nl
pt
du
an
itte
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erm
ab
ility
ot p
wit
is n
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ole,
spec
t to the co
sensor -2- is directly in front of assembly head -1-.
Caution
rrectness of i
The assembly head -1- must never be within area -a- of tyre
valve/tyre pressure sensor, or the assembly head will damage
cial p
the tyre pressure sensor .

nform
mer
a
m
tion
– Position assembly head -1- near tyre valve/ tyre pressure sen‐
co
in t
sor so that an assembly lever can be inserted approx. 30° next

or
his
e
to the tyre valve/ tyre pressure sensor -2-.

at
do
priv
cum

or
f
en
ng
using assembly lever -3-. i t.

py Co
Co py
– Additionally insert a plastic assembly lever -4-.
t. rig
gh ht
yri by
op Vo
– Remove assembly lever -3-. by c lksw
cted agen
Prote AG.
– 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
wagepaste.
e ks s no
Vol t
– Turn wheel rim on tyre fitting
d b unit so that tyre valve/ tyre pres‐ uara
y g
se nte
sure sensor -1- is directly
tho
ri opposite assembly head -2-. eo
au ra
– Run tyre fitting machine
ss clockwise. c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
rrectness of i
– Stop the fitting of lower bead before reaching tyre valve/ tyre
pressure sensor -arrow- to prevent damage to tyre pressure
sensor .
cial p
nform
rim may only be turned until the assembly head is just before the
mer
tyre valve/ tyre pressure sensor -arrow-.

a
m
tion
co
in t
or
his
ate
do
priv
cum
or
f
en
ng
i t.
py Co
t. Co py
rig
gh ht
yri by
y cop Vo
lksw
b
cted agen
Prote AG.

– 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.
– Check to ensure that tyre bead is seated correctly on assembly
head and run tyre fitting machine clockwise.
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
se nte
ori eo
th
au ra
ss c
ce
le
un
pt
an
d
itte
– Stop the fitting of upper bead before reaching tyre valve/ tyre
y li
rm
ab
pressure sensor -arrow- to prevent damage to tyre pressure
pe
ility
sensor .
ot
wit
, is n
h re
hole
rim may only be turned until the assembly head is just before the
spec
tyre valve/ tyre pressure sensor -arrow-.
es, in part or in w
t to the co
– Remove depressor from wheel rim.
rrectness of i
sure)
l purpos
Caution
n
ercia
for
Never increase the inflation pressure when the tyre bead does
m
m
atio
not lie completely against the wheel rim flange.
com
n in
r
This would lead to damage to the tyre and/or the wheel rim.
te o
thi
sd
iva
o
r
rp
cu
fo
m
– When the tyre bead does not lie completely against the wheel
en
ng
t.
yi
rim flange: deflate the tyre, press tyre bead off wheel rim flange
Co
Cop py
and generously coat again with tyre assembly paste.
t. rig
gh ht
pyri by
Vo
o
c by lksw
cted agen
sure) Prote AG.
– 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 .
6 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
the TPM warning lamp -K220- lighting up in the instrument cluster.
agen
AG. Volkswagen AG d
oes
A tyre's rolling circumference may change as a result of: Volksw not
g by ua
ed ran
♦ Insufficient tyre inflation pressure. oris tee
th or
au ac
♦ Structural tyre damage. ss
ce
le
un
♦ One-sided loading of vehicle.
pt
an
d
itte
y li
♦ Increased load on one axle, e.g. due to towing a trailer.
rm
ab
pe
ility
♦ Use of snow chains.
ot
wit
, is n
h re
♦ Spare wheel installed.
hole
spec
es, in part or in w
♦ Wheel renewal.
t to the co
System fault in the ABS system.
If a fault in the ABS is displayed by the ESP and TCS warning
rrectness of i
lamp -K155- or the traction control system warning lamp -K86- ,
then the tyre pressure monitor warning lamp -K220- -arrow- will
l purpos
also light up. However, no fault will be stored in the system for the
tyre monitor display.
n
ercia
fo
The warning lamp cannot be extinguished by pressing the TPM
rm
m
atio
button -E492- . In this case, please carry out the following steps:
com
n in
– Connect vehicle diagnosis, testing and information system -

r
te o
thi
VAS 5051- and select “Guided fault finding” ⇒ Vehicle diag‐

sd
iva
nosis, testing and information system VAS 5051.

o
r
rp
cu
fo
m
en
ng
t.
Running gear yi Co
Cop py
ht. rig
Brake system py
rig by
ht
co Vo
Anti-lock brake system ABS/TCS Mark 70 or anti-lock
by lksw
cted agen
Prote AG.
brake system ABS/EDL/TCS/ESP Mark 60 EC
Functions
Tyre pressure monitor display / Tyre pressure warning
Follow instructions on screen to perform basic setting.

Perform basic setting

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.
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
r
tho eo
au ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
rrectness of i
cial p
nform
mer
atio
m
r co
n in
o
thi
te
sd
ir va
o
p
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
6. Tyre monitor display 301

7 Tyre pressure monitor (TPM)

AG. Volkswagen AG d
agen oes
For detailed information on the tyre pressure monitor (TPM), refer Vol
ksw not
gu
to ⇒ Self-study programme No. 347 ; Tyre Pressure Monitoringsed by ara
nte
Systems . tho
ri eo
au ra
c
The tyre pressure monitor system includes wheel electronics
ss
ce
e
mounted on each wheel.
nl
pt
du
an
itte
y li
At regular intervals, the wheel electronics transmit data which the
erm
ab
central locking and anti-theft alarm system aerial receives and
ility
ot p
forwards to the tyre pressure monitor control unit -J502- .
wit
is n
h re
This control unit is integrated with its own diagnostic address into
ole,
spec
the convenience system central control unit -J393- .
t to the co
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
rrectness of i
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.
cial p
nform
The driver can switch between partial and full load, poll the status
mer
and switch the TPM system on or off via a SET button -2- in the
atio
m
r co
centre console.
n in
o
thi
te
sd
ir va
Caution
o
p
cum
for
en
ng
t.
yi
This button is not available for the North American region
Co
op py
(NAR). Therefore, the function described above is omitted in t. C rig
gh ht
this region. pyri by
Vo
co lksw
by
cted agen
Prote AG.
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).
Time for which the button is pressed

Up to 2 seconds 3-7 seconds 8-10 seconds 11-15 seconds
State or action Actual state Switch Confirm Deactivation
Messages: Messages: Messages: Messages:
Desired functions:
Switch from full to Full tyre load moni‐ Partial tyre load on! On release:
partial load tored Confirmation of
(gong) switching via gong
Switch from partial to Partial tyre load Full tyre load on! On release:
full load monitored Confirmation of
(gong) switching via gong
Switching on TPM off! Partial tyre load on! On release:
Confirmation of
switching via gong

Time for which the button is pressed

Up to 2 seconds 3-7 seconds 8-10 seconds 11-15 seconds
State or action Actual state Switch Confirm Deactivation
Deactivation Full tyre load moni‐ Partial tyre load on! TPM off!
tored or (gong)
or Full tyre load on!
Partial tyre load
monitored
(gong)
Status query For example: After releasing:
TPM off! Press longer to acti‐
or vate!
Partial tyre load or
monitored Press longer to
(gong) switch or deactivate!
7.2 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
pressure sensor swa
gen AG does
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2 - Valve core ed
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❑ Allocation ⇒autElectronic
h eo
ra
parts catalogue
ss “ETKA” c
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❑ Always renew when

un
pt
an
d
changing tyre
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3 - Sealing washer
spec
es, in part or in w
4 - Sealing ring
t to the co
❑ Will be slightly deformed

when the union
rrectness of i
⇒ Item 6 (page 303) nut

is tightened
l purpos
5 - Wheel
❑ Fitting tyres of wheels
n
ercia
fo
with tyre pressure mon‐

rmat
m
itoring ⇒ page 290

com
ion
❑ Fitting tyres with run-flat

in
r
te o
thi
capabilities ⇒ page 294

sd
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6 - Union nut
fo
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❑ 8 Nm
t.
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7 - Valve cap ht. rig
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❑ Use only genuine valve caps from repair set ⇒ Electronic parts catalogue “ETKA” .
co Vo
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7. Tyre pressure monitor (TPM) 303

AG. Volkswagen AG d
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Golf 2004 ➤ , Golf Plus ir se2005 ➤
d ara
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authsteering - Edition 08.2009 eo
ra
ss c
❑ Do not use convenience valve caps or metal valve caps.
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ility
7.3 Removing and installing tyre pressure
ot p
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sensor
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spec
Removing
t to the co
– Unscrew union nut -1-.
– Remove tyre pressure sensor -2- from bed of wheel rim.
rrectness of i
Installing
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Caution
nform
mer
♦ Before installing tyre pressure sensor , clean valve hole.
a
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– Install tyre pressure sensor -2- along with a new seal and Cop py
ht. rig
sealing washer and push it into wheel rim at the points marked py
rig by
ht
by -arrows-. co Vo
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– Press tyre pressure sensor -2- into the wheel rim at the points
AG.
marked by -arrows-.
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
Union nut to tyre pressure sensor 8 Nm

AG. Volkswagen AG d
agen oes
olksw not
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8 Wheel alignment d b ara
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au ra
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equipment required
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♦ Wheel alignment computer
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-V.A.G 1813- or VW/Audi-
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approved wheel alignment
h re
computer
ole,
spec
♦ Brake pedal actuator -
t to the co
V.A.G 1869/2-
♦ Tool insert 18 mm -T10179-
rrectness of i
T10001-
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mer
rmatio
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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‐ Alignment necessary Rear axle component re‐ Alignment necessary
newed newed
Yes No Yes No
Lower suspension link X Lower transverse link X
Bonded rubber bush X 1) Upper transverse link X
for suspension link
Wheel bearing housing X Track rod X
Track rod/track rod ball joint X Wheel bearing housing X
Steering box X Subframe X
Subframe X Coil spring X
Suspension strut X
Shock absorber X
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olks X Anti-roll
ot g bar X
db ua
ran
Anti-roll bar o
ir se X 1) Trailing arm
tee X
th or
au ac
1) Prerequisite:
ss the
positions of the subframe and brackets fixed
ce
e
before they were removed ⇒ page 16 .

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Components removed and installed

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Front axle component re‐ Alignment necessary Front axle component re‐ Alignment necessary
spec
moved and reinstalled moved and reinstalled

t to the co
Yes No Yes No
Lower suspension link X 1) Lower transverse link X
rrectness of i
Wheel bearing housing X Upper transverse link X

Track rod/track rod ball X Track rod X
joint
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Steering box X Wheel bearing housing X

mer
Subframe X 1) Subframe X
a
m
tion
o
Suspension strut X Coil spring X

c
in t
or
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Subframe bracket X 1) Shock absorber X

at
do
priv
Anti-roll bar X 1) Anti-roll bar X

um
or
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Trailing arm X
Co
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Rep. Gr.44 - Wheels, tyres, vehicle geometry
agen
Prote AG.

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

before they were removed ⇒ page 16 .
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8.2 Test prerequisites risedb
y ua
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tee
tho
or
• Check suspension, wheel
au bearing, steering and steering link‐ ac
ss
age for excessive play and damage.
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• Tread depth difference of no more than 2 mm on one axle. du
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• Tyres inflated to correct pressure.
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• Vehicle unladen.
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• Fuel tank must be full.
spec
• Spare wheel and vehicle tools are stowed in correct locations.
t to the co
• The fluid reservoir for the windscreen/headlight washer sys‐
tem must be full.
rrectness of i
• When checking wheel alignment, ensure that sliding plates
and turn tables are not touching end stop.
cial p
Please note!
nform
mer
• The test equipment must be properly adjusted and attached
a
to the vehicle; observe device manufacturer's operating in‐
m
tio
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n in
structions.
o
thi
te
If necessary, contact the manufacturer for familiarisation with the
s
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do
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proper use of the wheel alignment equipment.

p
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for
en
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Wheel alignment platforms and wheel alignment units and com‐

t.
yi Co
op
puters can lose their calibration over a period of time. C py
ht. rig
rig ht
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Wheel alignment platforms and alignment units and computers co Vo
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should be checked and adjusted as necessary during inspection cted agen
Prote AG.
and maintenance at least once per year!
– 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.

– 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 Sports running Sports running Heavy-duty run‐
gear gear gear ning gear
except 18' with 18' wheels
wheels
PR numbers 2UA 2UC G02, G05, G07, 2UB
2UC
Total toe (without load) 10' ± 10′ 10' ± 10′ 10' ± 10′ 10' ± 10′
. Volkswagen AG
Camber (in straight-aheadkswag en AG
-30′ ± 30′ does -41′ ± 30′ -41′ ± 30′ -14′ ± 30′
position) byV
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Maximum permissible
thoris
differ‐ max. 30′ max. 30′
nte
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ence betweens ausides ra
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Toe-out on turns 1) at 20° left 1°38′ ± 20′ 1°40′ ± 20′ 1°40′ ± 20′ 1°38′ ± 20′
ce
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and right lock

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itte
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Caster 7° 34′ ± 30′ 7° 47′ ± 30′ 7° 47′ ± 30′ 7° 17′ ± 30′

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ility
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Maximum permissible differ‐ max. 30′ max. 30′ max. 30′ max. 30′
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ence between sides

h re
ole,
Ride height 382 ± 10 mm 367 ± 10 mm 367 ± 10 mm 402 ± 10 mm

spec
t to the co
1)
Toe-out on turns can be displayed as a negative value on the
wheel alignment computer, depending on the manufacturer.
rrectness of i
Front axle Sports running Sports running Sports running BlueMotion

gear GTI gear GTI US ver‐ gear R32
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sion
nform
mer
PR numbers G08 G11 G09 G04/2UC

atio
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Total toe (wheels not press‐ 10' ± 10′ 10' ± 10′ 10' ± 10′ 10' ± 10′
n in
o
ed)
thi
te
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Camber (in straight-ahead -44′ ± 30′ -30′ ± 30′ -43′ ± 30′ -41′ ± 30′
o
p
cum
position)
for
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Maximum permissible differ‐ py
max. 30′ max. 30′ max. 30′ max. 30′
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ence between sides t. rig
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Toe-out on turns 1) at 20° left
cop
1°22′ ± 20′ 1°38′ ± 20′ 1°20′ ± 20′ 1°40′ ± 20′
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and right lock
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Caster 7° 47′ ± 30′ 7° 34′ ± 30′ 7° 47′ ± 30′ 7° 47′ ± 30′

ence between sides

Front axle Sports running Sports running Sports running BlueMotion

gear GTI gear GTI US ver‐ gear R32
sion
PR numbers G08 G11 G09 G04/2UC
1)

Rear axle, front-wheel drive Standard running Sports running Sports running Heavy-duty run‐
and 4WD gear gear gear ning gear
wheels
Camber -1° 20′ ± 30′ -1° 20′ ± 30′ -1°45' ± 30' -1°20' ± 30'
ence between sides
Total toe (at specified cam‐ +10′ ± 12.5′ +10′ ± 12.5′ +10′ ± 12.5′ +10′ ± 12.5′
ber)
Max. permissible deviation max. 20′ max. 20′ max. 20′ max. 20′
from direction of travel
Rear axle, front-wheel drive Sports running Sports running Sports running BlueMotion
and 4WD gear GTI gear GTI US ver‐ gear R32
sion
lksw
Camber -1°45' ± 30' agen -1° 20′ ± 30′
AG. Vo agen AG
does -1°45' ± 30' -1° 20′ ± 30′
olksw not
Maximum permissible differ‐ max.
ed
b 30′
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max. 30′ max.
gu
ara 30′ max. 30′
ence between sides h oris nte
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ut ra
Total toe (at specified cam‐ ss a +10′ ± 12.5′ +10′ ± 12.5′ +10′ ± 12.5′ c +10′ ± 12.5′
ber)
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erm
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spec
8.5 Wheel alignment specifications, Golf

t to the co
Plus, CrossGolf
rrectness of i

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en
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Cop py
ht. rig
ht
rig by
copy Vo
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The ride heights shown in the table refer to dimension -a-.
Front axle Standard running Sports running Sports running Heavy-duty run‐
gear gear gear ning gear
wheels
PR numbers 2UA 2UC G02, AG. Volkswagen
agen G07, 2UC AG does 2UB
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Vol g
Total toe (without load) 10' ± 10′ 10' ± s10′
ed
by 10' ± 10′ 10' ± u10′
ara
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ori
Camber (in straight-ahead -30′ ± 30′ -41′
au
th ± 30′ -41′ ± 30′ -14′ ± 30′ e or a
position) ss c
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pt
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ence between sides
itte
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erm
ab
Toe-out on turns 1) at 20° left 1°38′ ± 20′ 1°40′ ± 20′ 1°40′ ± 20′ 1°38′ ± 20′
ility
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and right lock
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Caster 7° 34′ ± 30′ 7° 47′ ± 30′ 7° 47′ ± 30′ 7° 17′ ± 30′
ole,
spec
ence between sides
t to the co
rrectness of i
1)
cial p
nform
mer
a
m
t
io
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n in
o
thi
Front axle CrossGolf Golf Plus BlueMotion
te
sd
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PR numbers 2UB G06 o

p
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or
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f
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Total toe (wheels not pressed) 10' ± 10′ 10' ± 10′

n
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py Co
Co py
Camber (in straight-ahead position) -14′ ± 30′ -37′ ± 30′
t. rig
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Maximum permissible difference between sides max. 30′ max. 30′
y cop Vo
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1°38′ ± 20′
Prote
Toe-out on turns 1) at 20° left and right lock 1°27′ ± 20′
AG.
Caster 7° 17′ ± 30′ 7° 40′ ± 30′

Ride height 400 ± 10 mm 373 ± 10 mm
1)


Rear axle, front-wheel drive Standard running Sports running Sports running Heavy-duty run‐
and 4WD swgear
agen gear
AG. Volkswagen AG do
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byV
olk except 18'ot gu with 18' wheels
ris
ed wheels ara
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tho or
Camber au -1° 20′ ± 30′ -1° 20′ ± 30′ -1°45'± 30'
ac -1°20' ± 30'
ss
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pt
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ence between sides
an
itte
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Total toe (at specified cam‐ +10′ ± 10′ +10′ ± 10′ +10′ ± 10′ +10′ ± 10′
erm
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ility
ber)
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h re
hole
spec
es, in part or in w
t to the co
rrectness of i
Rear axle, front-wheel drive and 4WD CrossGolf Golf Plus BlueMotion
l purpos
Camber -1°20' ± 30' -1° 20′ ± 30′

nform
ercia
Total toe (at specified camber) +10′ ± 10′ +10′ ± 10′

m
a
Max. permissible deviation from direction of max. 20′ max. 20′
m
tio
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travel
n in
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thi
Ride height 395 ± 10 mm 370 ± 10 mm
te
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or
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8.6 Overview - wheel alignment procedure Cop py
ht. rig
rig ht
py by
Always adhere to the following procedure!
co Vo
by lksw
cted agen
Prote AG.
– Observe instructions on your wheel alignment device.
Alignment procedure
Start → Carry out wheel run-out → Bounce springs.

compensation.
↓
Turn steering wheel to ← Measure vehicle height. ← Fit brake pedal depressor -V.A.G
straight-ahead position 1869/2- .
and lock in place 1)
↓
Check front axle camber → Is actual value within toler‐ → No
ance?
↓ ↓
↓ ← ← Yes Adjust ⇒ page 312 .
↓ ↓
↓ ← ← ← ← ←

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Volks ot g
y ua
edb ran
ris tee
ho
Golf 2004 ➤ , Golf Plus 2005 ➤ aut or
ac
Running gear, axles, steering - Edition 08.2009 ss
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pt
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an
itte
↓
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→ →
ility
Check rear axle camber Is actual value within toler‐ No
ot p
ance?
wit
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ole,
↓ ↓
spec
t to the co
↓ ↓
↓ ← ← ← ← ←
rrectness of i
↓
Check rear axle toe → Is actual value within toler‐ → No
ance?
cial p
↓ ↓
nform
mer
a
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↓
o
↓
n in
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thi
↓ ← ← ← ← ←
s
a
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↓
p
cum
Check front axle caster. → for
Is actual value within toler‐ → No
en
ng
t.
yi Co
ance? . Cop py
rig
ht
↓ ↓
rig ht
py by
co Vo
by lksw
↓ ← ← Yes Prote
cted Inspect axle components and
AG.
agen
body
↓ ↓
↓ ← ← ← ← ←
↓
Check front axle toe → Is actual value within toler‐ → No
ance?
↓ ↓
End ← Yes Adjust ⇒ page 316 .
↑ ↓
↑ ← ← ← ← ←
1)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- .
8.7 Correcting front axle camber


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Note byV ua
ed ran
oris tee
th or
♦ Camber correction is necessary only
ss after body repairs. The
au ac
camber is not adjustable, but can be equalized by moving the
ce
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brackets and/or the subframe.
pt
du
an
itte
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♦ Move subframe only to left or right, but never in or opposite to
erm
ab
direction of normal travel!
ility
ot p
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is n
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– Remove noise insulation.
ole,
spec
– Loosen bolts -1- for bracket attachment and subframe to body
t to the co
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
rrectness of i
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
cial p
nform
at brackets.
mer
a
– Tighten bolts for subframe and brackets to body to specified
m
tio
r co
torque plus extra turn angle.
n in
o
thi
e
Following the movement of the subframe and, consequently, the

t
s
ir va
do
steering box, clearance between the steering column universal
p
cum
or
joint and the notch in the bulkhead must be checked.

f
en
ng
i t.
py Co
Co py
– Remove securing nuts -arrows- and remove footwell trim.
t. rig
gh ht
yri by
y cop Vo
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b
cted agen
Prote AG.
There must be a clearance of 5 mm all round between universal

joint -2- and recess in bulkhead.
Specified torques
♦ Use new bolts

♦ Use new bolts

8.8 Adjusting camber on rear axle

♦ Shock absorber set -T10001-
♦ Tool insert 18 mm -T10179-

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by ua
d ran
rise tee
tho
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a ac
ss
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pt
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itte
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ility
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wit
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spec
t to the co
– Loosen upper transverse link nut -A- on subframe.
rrectness of i
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nform
mer
a
m
tion
co
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or
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iva
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pr
cum
for
en
ng
– Adjust camber by turning eccentric bolt -B- with 18 mm socket

i t.
py Co
-T10001- . t. Co py
rig
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lksw
b
cted agen
Note
Prote AG.
The maximum adjustment range is 90° to the left or right of centre.

wage es n
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y ua
edb ran
ris tee
ho
aut Golf 2004 ➤ , Golf Plus 2005 ➤ or
ac
ce
e
nl
pt
du
an
itte
– Tighten nut -A-.
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erm
ab
ility
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wit
is n
h re
ole,
spec
t to the co
rrectness of i
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nform
– Use socket (18 mm) -T10179-
mer
a
m
t
– Check camber value again after tightening nut -A-.
ion
co
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or
his
ate
do
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cum
or
f
en
ng
t.
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Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
Specified torques
Upper transverse link to subframe (vehicles with front- 95 Nm
wheel drive) ♦ To tighten nuts, set torque wrench -V.A.G
♦ Use new nut 1332- to 80 Nm
♦ Tighten threaded connections only when vehicle is in ♦ Applies only in conjunction with insert tool,
the normal running position. 18 mm -T10179-
Upper transverse link to subframe (vehicles with front- 95 Nm

wheel drive) ♦ To tighten nuts, set torque wrench -V.A.G
♦ Use new nut 1332- to 80 Nm
♦ Tighten threaded connections only when vehicle is in ♦ Applies only in conjunction with insert tool,
the normal running position 18 mm -T10179-
8.9 Adjusting toe at rear axle


– Loosen nut -1-.

– Turn eccentric bolt -2- until specification is attained.
– Now tighten nut.
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ir se nte
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au ra
ss c
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un
pt
an
d
itte
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ab
pe
ility
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hole
spec
es, in part or in w
t to the co
Specified torque
rrectness of i
l purpos

♦ Use new nut
n
ercia
f
orm
m
atio
com
n in
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te o
thi
sd
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8.10 Adjusting front axle toe

fo
m
en
ng
t.
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Special tools and workshop equipment required ht.
Cop py
rig
rig ht
♦ Torque wrench -V.A.G 1332- py by
co Vo
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cted agen
Prote AG.
♦ 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.

– 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
Track rod ball joint to track rod 50 Nm
8.11 Basic setting for steering angle sender -

G85- olks
wage
es n
o
V t gu
by a
If steering wheel was ris realigned, basic settings for steering angle
ed ran
tee
sensor -G85- must uthobe checked. ⇒ Perform basic settings in gui‐ or
ded fault findingss using vehicle diagnosis, testing and information ac
a
system -VAS 5051- .
ce
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nl
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du
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Select “Select function/component” by pressing Go to button.
itte
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ab
8.12 Vehicle data sticker ility
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Explanation of “PR numbers” on vehicle data sticker
ole,
spec
Various types of running gear are installed depending on engine

t to the co
and equipment level. These are identified by the PR numbers.

The PR numbers are critical in determining the wheel alignment
specifications.
rrectness of i
The running gear version fitted in the vehicle is indicated on the

vehicle data sticker by the PR number for the front axle.
cial p
The vehicle data sticker can be found in the spare wheel well and
nform
in the service booklet.

mer
a
m
tion
Example of a vehicle data sticker

co
in t
or
In this example the vehicle is equipped with the standard running

his
ate
gear G02 -arrow-.

do
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cum
or
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Cop py
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cted agen
Prote AG.

9 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 lksw

agen
AG. Volkswagen AG d
oes
not
o
byV gu
The tyre sealant in the bottle has a limited shelf-life. rised ara
nte
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The bottle therefore has an expiry date -arrow-. au ra
c
ss
ce
e
In this example, the expiry date of 05/2003 has been exceeded

nl
pt
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and the bottle must be renewed.
an
itte
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erm
ab
If the bottle has been opened, e.g. to repair a tyre, then it must
ility
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also be renewed.
wit
is n
h re
ole,
spec
t to the co
rrectness of i
9.3 Removing a tyre
cial p
nform
Tyres which have been filled or sealed using tyre sealant must be
mer
drained before removal.
a
m
tion
co
in t
WARNING
or
his
te
iva
do
r
♦ Avoid eye and skin contact with tyre sealant.

p
cum
for
en
ng
♦ It is a health hazard and may cause eye irritation and al‐

i t.
py Co
lergies. Co py
t. rig
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♦ Wear eye protection and protective gloves whilst working cop Vo
by lksw
on the tyre. cted agen
Prote AG.
– Place wheel on a flat surface.

– Remove valve insert of tyre valve.

– 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. n AG. Volkswagen AG do
wage es n
olks ot g
– Inflate tyre to approx. 3 bar . . . 4 bar. The bead of the tyre mustd by V ua
ran
slip audibly over the hump of the rim. orise tee
th or
u
– Screw in valve insert. ss
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– Correct inflation pressure to prescribed pressure.

un
pt
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– Balance wheel.
rm
ab
pe
ility
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hole
spec
es, in part or in w
9.5 Tyre sealant disposal
t to the co
♦ Tyre sealant or residue must not be mixed or disposed of with
other fluids.
rrectness of i
♦ Excess tyre sealant must be collected and stored in a plastic
l purpos
container. The plastic container can be disposed of through

the disposal system along with the breakdown set (when the
n
expiry date is exceeded).
ercia
form
m
♦ The items can be returned or disposed of through the existing
atio
com
workshop disposal system.
n in
r
te o
thi
♦ Request information through your service provider or the dis‐
sd
iva
posal representative at your distribution centre or importer.

o
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9.6 Alloy wheels with metal valves
en
ng
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Cop py
.
As of model year 2005, hollow-chamber wheels have been fitted
ht rig
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as part of certain equipment variants. These hollow-chamber copy Vo
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wheels are fitted with metal valves instead of the usual rubber cted agen
Prote AG.
valves. Metal valves must be renewed completely each time a
tyre is changed.
9. Wheels, tyres 319

1 - Wheel
2 - Valve cap
3 - Nut
❑ 4 Nm
4 - Washer
5 - Sealing ring
6 - Metal valve
AG. Volkswagen AG d
agen oes
olksw not
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d by ara
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or eo
th
au ra
ss c
ce
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un
pt
an
d
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rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
n
ercia
form
m
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te o
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t. Co py
rig
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cop by
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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.
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
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r
tho eo
– Check to ensure sthat
s a contact surface -arrow- on inner side of
u ra
c
wheel (rim) and also centring seat of rim are free of corrosion
ce
e
nl
and dirt.
pt
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– The spherical caps * in the holes for the wheel bolts and the
erm
ab
ility
threads of the wheel bolts must also be free of corrosion and

ot p
dirt, oil or grease.

wit
is n
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ole,
*A spherical cap is the curved surface of a section of a sphere

spec
cut by a plane.
t to the co
rrectness of i
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nform
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a
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n in
o
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Cop py
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321
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Prote AG.
10. Instructions for changing or fitting wheels

AG. Volkswagen AG d
agen oes
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Golf 2004 ➤ , Golf Plus 2005 ➤ by
Vol
gu
ara
d
Running gear, axles, steering - Edition
rise 08.2009 nte
tho eo
u ra
sa c
– Check whether the wheel bolts can be easily screwed in by
s
ce
e
hand. The thread of the wheel bolts must not come into contact
nl
pt
du
an
the bore in the brake disc -arrow-.
itte
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erm
ab
If the thread of the wheel bolt touches the hole -arrow-, turn the
ility
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brake disc relative to the wheel hub accordingly.
wit
is n
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Remove dirt and corrosion, oil or grease from the contact surfa‐
ole,
spec
ces, threads in the wheel hub and/or wheel bolts as necessary.
t to the co
WARNING
rrectness of i
Damaged, badly corroded or difficult to remove wheel bolts
must be renewed.
cial p
nform
mer
10.1 Fitting wheels
a
m
tio
r co
n in
– Preserve wheel centring seat ⇒ page 323 .
o
thi
te
s
1- When fitting the wheel, screw in all wheel bolts uniformly by
a
do
ir v
hand.
p
cum
for
en
ng
2- Tighten the wheel bolts in diagonal sequence to approx. 30

t.
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op
Nm.
C py
t. rig
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3- Lower the vehicle to the floor and tighten all wheel bolts di‐ cop Vo
by lksw
agonally to the specified torque using the torque wrench cted agen
Prote AG.
⇒ page 288 .
WARNING
Do not use an impact driver when screwing in the bolts!

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 A2-
to prevent corrosion between the wheel centring seat and the
wheel rim.
– Remove wheel.
– Clean wheel centring seat of hub and centring ring of wheel
rim. gen AG
. Volkswagen AG
d
wa oes
olks not
– Apply wax to centring ring -arrow- with a brush. byV gu
ara
ed nte
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Ensure that only centring ring -arrow- but not contact
utho surface of eo
ra
wheel rim has been waxed. Otherwise, the brakes
ss
a
will be soiled, c
which would reduce the braking efficiency.
ce
le
un
pt
an
d
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rm
WARNING
ab
pe
ility
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Wheel bolts, contact surfaces of wheel hub and wheel rim and
h re
wheel hub threads must not be waxed. Never treat wheel se‐
hole
spec
curing bolts with lubricant or corrosion protection materials!
es, in part or in w
t to the co
rrectness of i
l purpos
n
ercia
form
m
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t. Co py
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Prote AG.
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
be caused by tyre wear. Tyre wear caused by driving n Ais
G.not
Volkalways
swagen AG
evenly spread across the entire running surface wage does
Volks of the tyre. This not
causes slight imbalances which affect ethe
d smooth running of a
by gu
ara
wheel which was previously exactlyhobalanced.
ris nte
e t or
au ac
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
ce
e
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tyre and thus reduce the tyre service life.

an
itte
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erm
Recommendation ab
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To ensure
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ole,
• optimal safety,
spec
• smoothest possible running and

t to the co
• even wear
rrectness of i
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

cial p
nform
Before you start balancing the wheels, the following requirements

mer
must be met.
atio
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r co
• The tyre pressure must be OK.

in
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te
sd
• The tyre tread must not show one-sided wear and should be
ir va
at least 4 mm deep.
p
cum
for
en
ng
• The tyre must not show any signs of damage, for example
t.
yi Co
op
cuts, piercing, foreign bodies, etc.
C py
ht. rig
ht
rig by
py
• The wheel suspension, steering and steering linkage, includ‐ co Vo
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ing the shock absorbers, must be in perfect condition.
cted agen
Prote AG.
• You must have conducted a road test.

AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
tho
r eo Golf 2004 ➤ , Golf Plus 2005 ➤
u ra
ss
a
Running gear, c axles, steering - Edition 08.2009
ce
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nl
pt
du
12.3 Conducting a road test before balancing
an
itte
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erm
wheels
ab
ility
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If a customer brings a vehicle to the workshop complaining about
h re
“vibration”, a road test is essential prior to balancing the wheels.
hole
spec
es, in part or in w
♦ This will give you information about the nature of the rough
t to the co
running.
♦ You will be able to determine in which speed range the rough
running occurs.
rrectness of i
– Raise the vehicle on a lifting platform immediately after the
l purpos
road test.
– Mark the positions of the tyres on the vehicle.
nform
mercia
Tyre position Marked with ...
at
m
io
r co
n
Front left tyre FL
in t
o
his
ate
Front right tyre FR
d
iv
o
pr
cu
or
Rear left tyre RL
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t.
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Rear right tyre RR
Co
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– Remove wheels from vehicle. pyri by
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cted
– Balance the wheels.
agen
Prote AG.
12.4 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.
– Check the wheel for radial
swa
genor
AGlateral
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agen AG
⇒
doepage
s
328 .
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– If radial and lateral
d b runout are within the specified tolerance,
y ua
ran
ise
balance thethowheel and tyre.
r tee
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c
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nl
Note
pt
du
an
itte
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erm
ab
♦ More than 60 grams of weight per tyre should not be used.

ility
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wit
♦ If more weight is required, you may be able to achieve smooth‐

is n
h re
er running by "matching" the tyre and rim. Matching tyres

ole,
spec
⇒ page 330 .
t to the co
♦ 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 .
rrectness of i
– Bolt the wheel to the vehicle.

cial p
– First hand-tighten the lowest wheel bolt to about 30 Nm.

nform
mer
– Then tighten the remaining wheel bolts diagonally to about

a
30 Nm. This process centres the wheel on the hub.

m
tio
r co
n in

o
thi
te
s
a
do
ir v
– Now use a torque wrench to tighten the wheel bolts to the

p
cum
or
specified torque in diagonal sequence.

f
en
ng
t.
yi Co
Carry out road test Cop py
t. rig
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yri
– After balancing the wheels and tyres, carry out a road test. p by
co Vo
by lksw
cted agen
Prote AG.

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-

Using the vibration control
gen AG system -VAS
. Volkswagen AG 6230- you can perform
does
more functionsVthan
lkswajust stationary balancing.not
o g
y ua
db r
A specialorifeature
se of this system is the testing of theanradial
tee force of
the wheel
auth
and tyre while rolling. or
a
ss c
A roller presses against the wheel with a force of about 635 kg.
ce
le
un
pt
This simulates the vertical tyre force against the road surface
an
d
itte
during travel.
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rm
ab
pe
ility
Radial and lateral runout in the wheel and tyre and differences in
ot
wit
the stiffness of the tyre cause the vertical force of the wheel to
, is n
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vary.
hole
spec
The -VAS 6230- detects and stores the position of the maximum
es, in part or in w
t to the co
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.
rrectness of i
l purpos
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ercia
form
12.6 Finish balancer

m
atio
com
n in
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te o
thi
sd
iva
Note
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♦ Before working with a finish balancer , the mechanic needs to

i t.
py Co
have been instructed by the manufacturer of the balancer.
Co py
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♦ To balance the wheels, set the wheels of the driven axle on
by
y cop Vo
lksw
the sensor platforms (only the front wheels of a front-wheel
b
cted agen
Prote AG.
drive vehicle, all four wheels of a four-wheel drive vehicle).
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.

Running gear, axles, steering - Edition 08.2009 AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
r
Note utho eo
ra
a c
ss
The imbalance should always be less than 20 grams before you
ce
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un
pt
change the balance weight.
an
d
itte
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rm
ab
pe
ility
– If necessary, remove the wheel bolts again.
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, is n
– Rotate the wheel relative to the hub once more, turning it one
h re
hole
or two wheel bolt holes further.
spec
es, in part or in w
– Tighten the wheel bolts using the method described above.
t to the co
Note
rrectness of i
l purpos
Do not try to reduce the imbalance using balance weights until
the imbalance is less than 20 grams.
n
ercia
for
– Balance the wheels until the imbalance is less than 5 grams.
m
m
atio
com
– Tighten wheel bolts to specified torque if you have not already
n in
r
done so.
te o
thi
sd
iva
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WARNING
fo
m
en
ng
i t.
py Co
Always tighten wheel bolts to specified torque using a torque t. Co py
rig
gh
wrench!
ht
yri by
cop by
Vo
lksw
cted agen
Prote AG.
12.7 Radial and lateral runout of wheels and

tyres
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
Wheel with tyre Radial runout (mm) Lateral runout (mm)
Passenger cars 0.9 1.1
(1.3 in vicinity of lettering)
12.8 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.

– 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
tyre ⇒ page 330 . lkswagen oes
n o ot g
yV ua
edb ran
ris
12.9 Checking radial and lateral runout on
tee
ho
aut or
ac
ss wheel
ce
e
nl
pt
du
an
– Mount the wheel on the wheel balancer .

itte
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erm
ab
– Use the wheel balancing machine centring system -VAS

ility
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5271- .
wit
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h re

ole,
spec

t to the co

S - Lateral runout
rrectness of i
H - Radial runout
– Compare the measured values with the specifications in the
cial p
table ⇒ page 329 .

nform
mer
a
m
tion
Note
co
in t
or
his
te
Extreme values on the tyre gauge due to small irregularities may

a
do
iv
pr
be disregarded.
cum
or
f
en
ng
i t.
py Co
Co py
Specifications for radial and lateral runout on wheel
t. rig
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cop Vo
Wheel Radial runout (mm) Lateral runout (mm)
by lksw
cted agen
Prote AG.
Steel wheel 0.5 0.5

Wheel Radial runout (mm) Lateral runout (mm)

Alloy wheel 0.5 0.8
Note
AG. Volkswagen AG d
agen oes
olksw not
V gu
by
If the measured valuesed exceeds the specification, acceptably
ara
nte
ri
smooth running uth cannot be attained.
o eo
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a c
ss
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pt
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an
itte
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12.10 Matching
erm
ab
ility
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General
wit
is n
h re
ole,
When radial or lateral runout of the wheel and tyre coincide, the
spec
imbalance of the wheel is amplified by the tyre.
t to the co
For technical reasons, 100% true running is not possible
⇒ page 328 .
rrectness of i
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 .
cial p
Procedure for match mounting
nform
mer
– Deflate the tyre.
a
m
tio
– Press the tyre beads off the rim flanges.
o
n in
r c
te o
thi
– Coat the tyre bead all round with tyre fitting paste .
s
a
do
ir v
p
– Rotate the tyre 180° relative to the wheel.

um
for
en
ng
t.
yi
– Inflate the tyre to approx. 4 bar.
Co
Cop py
t. rig
gh
– Mount the wheel with tyre on the wheel balancer.
ht
pyri by
Vo
co lksw
by
– Check true running, that is, radial and lateral runout. cted agen
Prote 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).

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 AG. Volkswagen AG d

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Flat spots caused by hard bybraking cannot be repaired. Suchgtyres
V ua
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Reasons for flat spots caused by storage or handling:
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♦ The vehicle has been left standing in one place without being
itte
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moved for several weeks.

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♦ The tyre inflation pressure is too low.

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♦ The vehicle was placed in a paint shop drying booth after being
hole
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painted.
es, in part or in w
t to the co
♦ 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.
rrectness of i
Eliminating flat spots caused by storage or handling

l purpos
♦ Flat spots caused by storage or handling cannot be eliminated

from the tyre using workshop equipment.
n
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♦ Flat spots caused by storage or handling can be removed only

mat
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by running the tyres warm.

com
ion
in
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♦ The method described below is not recommended in cold and

te o
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Requirements and conditions:

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– Check and, if necessary, correct inflation pressures. Cop py
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331
AG.
12. Rough running due to wheels/tyres - causes and rectification

– 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.
wage es n
– Raise the vehicle immediately
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– Remove the wheels from
ho
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s tee
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– Balance the wheels
ss on a stationary wheel balancer
⇒ page 325 .
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48 – Steering
be found under ⇒ page 1 . AG. Volkswagen
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1. Appraisal of accident vehicles 333

2 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 n AG d
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♦ From model year 2009, a new, 3rd yV
olgeneration,
ks steering box iss not gu
being used. Notes on differentiating
isedb between 2nd and 3rd ara
nte
generations ⇒ page 399 u.thor eo
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2.2 Gaskets and seals
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♦ Always renew gaskets and seals.

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♦ After removing all seals, inspect the contact faces on housings

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and shafts for burrs and damage and remove all which are
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♦ Completely remove all residue from liquid sealants from the

sealing surfaces, making sure that no residual sealant gets

t to the co
into the steering box housing.
2.3 Nuts and bolts

rrectness of i
♦ Loosen and tighten bolts and nuts securing covers and hous‐
ings diagonally.
cial p
♦ Avoid canting sensitive parts such as servo motor with control

nform
unit. Loosen and tighten them diagonally in stages.

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♦ Specified torques given are for unlubricated nuts, bolts and

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screws.
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♦ Always renew self-locking nuts and bolts.

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334 Rep. Gr.48 - Steering

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
– Before working on electrical ocomponents,
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does
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object, such as a water pipe
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ori electrical connectors with bare hands. ante
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2.5 Guided fault-finding, vehicle self-diag‐
nosis and test instruments
cial p
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♦ Before performing repair work on the electromechanical steer‐
a
ing box, determine the cause of damage as precisely as
m
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possible using the vehicle diagnosis, testing and information
o
system -VAS 5051- in “guided fault finding”, “vehicle self-di‐
thi
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2. General repair instructions 335

3 Steering wheel
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3.1 Removing and installing steering wheel V ot g
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Removing
nform
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– Remove driver side airbag unit ⇒ Rep. Gr. 69 ; Airbag; Re‐
a
m
t
moving and installing driver side airbag unit .
io
o
n in
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– Separate connections -1 and 2- for coil connector.
thi
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– Centre steering wheel (wheels in straight-ahead position).

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– Remove bolt -3- and pull steering wheel from steering column.
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– Set steering wheel onto steering column. cop Vo
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– Centre markings of steering wheel and steering column
AG.
-arrows- must align.
3. Steering wheel 337

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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
Steering wheel to steering column 30 Nm + 90° further
♦ Always renew bolt

n AG. Volkswagen AG do Golf 2004 ➤ , Golf Plus 2005 ➤
wage
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4 Steering column, Golf
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Note
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1 - Bolt
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❑ 20 Nm
atio
m
2 - Cross member for steering

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column
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❑ 20 Nm
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moving
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

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Removing
mer
atio
Only the complete steering column is supplied as a replacement
m
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part. Repair is not possible.
in
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The steering lock housing can be transferred ⇒ Electrical system;
sd
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Rep. Gr. 94 ; Ignition switch and lock cylinder .
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The following are prerequisites before starting work on the by lksw
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electrical system and removing the steering wheel: Prote AG.
♦ Disconnect earth strap from battery ⇒ Electrical system;

Rep. Gr. 27 ; Battery; Disconnecting and reconnecting
battery
♦ 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 .

– 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.
AG. Volkswagen AG d
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– Unscrew securing
uthor
nuts -arrows- and remove footwell trim -1-.ee or
a ac
ss
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es, in part or in w
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rrectness of i
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– Remove earth cable -arrow- and cable g-1- Afrom

G. Volsteering
kswagen Acol‐
a en G do
umn. Vol
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– Remove bolts -2-. oris tee
th or
au
Vehicles with crash bars ss ac
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spec
es, in part or in w
t to the co
– Remove ground cable -arrow- and cable -1- from steering col‐
umn.
rrectness of i
l purpos
nform
mercia
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– Remove bolt -1- and remove crash bar for clutch pedal -2-. . C rig
ht ht
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– Remove bolt -3- and remove crash bar for brake pedal -4-.
co Vo
by lksw
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– 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.

– 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-.
AG. Volkswagen AG d
agen oes
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– Attach ground cable -arrow- and cable -1- to steering column.

ole,
spec

t to the co
rrectness of i
cial p
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mer
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– Fit universal joint -2- onto steering box pinion and tighten bolt
-1-.
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– Install footwell trim -1- and secure with nuts -arrows-. auth or
ac
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ility
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– Install cable duct -1- below steering column.
The lugs -arrow- must engage in the guide on both sides.
cial p
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– 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 .
– Perform basic settings for steering angle sensor -G85- using
vehicle diagnosis, testing and information system -VAS
5051B- .

Specified torques
♦ Use new bolt
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.
AG. Volkswagen AG d
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Proper steering column handling and transport by Vo not
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♦ Use both hands to transport steering column.
thor eo
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♦ Hold steering column upper jacket tube and in area of upper
s
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universal joint.
un
pt
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4. Steering column, Golf
AG.

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
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Improper handling of steering column with safety risks
es, in part or in w
t to the co
The following methods of handling will damage the universal joint
bushes of the lower steering column bearing:
rrectness of i
♦ Transporting the steering column with one hand on the jointed
shaft.
l purpos
♦ Bending the joints more than 90°.
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4.5 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.
4.6 Removing and installing mounting

bracket

Removing
– Remove steering column ⇒ page 351 .
– Remove dash panel insert ⇒ AElectrical
agen
G. Volkswagsystem;
en AG
doesRep. Gr. 90 ;
Dash panel insert; Removing
Vol
ksw and installing dash panel
not
g
insert .
y ua
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– Remove bolts
ho
ri-arrows-
se under bracket. tee
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– Push connector -1- in -direction of arrow- and remove from

support in mounting bracket.
– Unscrew bolt -arrow A-.
cial p
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– Remove bolts -arrows B- securing bracket to body.

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Bolts -arrows B- are screwed in from cross member.

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– Unscrew bolts -1- and -2- and remove mounting bracket from
agen
Prote AG.
body.
Installing

– Insert mounting bracket and screw in bolts -1- and -2-.
– Install bolts -arrows B-. agen

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– Screw in bolt -arrow A-.
ab
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– Insert connector -1- into support in mounting bracket and push
wit
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to stop opposite -direction of arrow-.
h re
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spec
es, in part or in w
t to the co
– Install bolts -arrows- under bracket.
rrectness of i
– Install steering column ⇒ page 354 .
l purpos
– Install dash panel insert ⇒ Electrical system; Rep. Gr. 90 ;

Dash panel insert; Removing and installing dash panel insert .
nform
ercia

m
at
5051B- .
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Co py
Specified torques
t. rig
gh ht
yri by
cop Vo
by lksw
cted agen
Prote AG.
Mounting bracket to body 20 Nm
Strut to mounting bracket 20 Nm
4.7 Removing and installing strut


lkswage es n
o ot g
byV ua
ed ran
oris tee
th or
Removings au ac
s
ce
e
– Remove plenum chamber bulkhead ⇒ General body repairs,

nl
pt
du
exterior; Rep. Gr. 50 ; Assembly overview - plenum chamber
an
itte
y li
bulkhead .
erm
ab
ility
ot p
– Remove bolt -arrow- in plenum chamber.
wit
is n
h re
ole,
spec
t to the co
rrectness of i
cial p
nform
mer
a
m
tio
o
n in

r c
te o
thi
s
– Remove bolt -2- and remove strut -3-.

a
do
ir v
p
cum
or
Installing
f
en
ng
i t.
py Co
t. Co py
rig
gh ht
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lksw
b
cted agen
Prote AG.
– Secure strut to body by tightening bolt -arrow-.

– Install securing bolt -2- and tighten.

– Tighten bolt -1- for strut -3-.
– Install plenum chamber bulkhead ⇒ General body repairs,
bulkhead .
5051B- .
AG. Volkswagen AG d
Specified torques agen oes
olksw not
V gu
d by ara
Component o
ir se Specified torque nte
eo
th
u ra
Strut to mounting bracket ss
a 20 Nm c
ce
e
Strut to body 20 Nm
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
rrectness of i
cial p
nform
mer
a
m
tio
o
n in
r c
te o
thi
s
a
do
ir v
p
cum
for
en
ng
t.
yi Co
Cop py
ht. rig
ht
rig by
copy Vo
by lksw
cted agen
Prote AG.

5 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 gen AG
. Volkswagen AG
does
swa
❑ 20 Nm by Volk not
gu
d ara
❑ Alwaysorise
renew after re‐ nte
eo
moving
auth
ra
ss c
5 - Steering column
ce
le
un
pt
an

d
itte
y li
⇒ page 351
rm
ab
pe
ility
6 - Handle
ot
wit
, is n
h re
7 - Bolt
hole
spec
❑ 3 Nm
es, in part or in w
t to the co
8 - Crash bar for brake pedal

9 - Crash bar for clutch pedal
rrectness of i
10 - Bolt
l purpos
❑ 30 Nm
n
ercia
moving
format
m
11 - Strut
com
ion

in
r
te o
thi
⇒ page 360
sd
iva
o
r
rp
cu
12 - Bolt
fo
m
en
ng
❑ 20 Nm
t.
yi Co
Cop py
t.
13 - Bolt
rig
gh ht
pyri by
Vo
❑ 20 Nm
co lksw
by
cted agen
Prote AG.
5.2 Removing and installing steering col‐

umn
5. Steering column, Golf Plus, CrossGolf 351

♦ Torque wrench -V.A.G 1332- agen

AG. Volkswagen AG d
oes
olksw not
byV gu
ara
ed
ris nte
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aut ra
ss c
ce
e
nl
pt
du
an
itte
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erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
Removing
rrectness of i
Only the complete steering column is supplied as a replacement
part. Repair is not possible.
The steering lock housing can be transferred ⇒ Electrical system;
cial p
Rep. Gr. 94 ; Ignition switch and lock cylinder .
nform
mer
a
m
t
WARNING
ion
co
in t
or
his
e
The following are prerequisites before starting work on the

at
do
riv
electrical system and removing the steering wheel:

p
cum
or
f
en
ng
♦ Disconnect earth strap from battery ⇒ Electrical system;

i t.
py Co
Rep. Gr. 27 ; Battery; Disconnecting and reconnecting Co py
t. rig
battery gh ht
yri by
cop by
Vo
lksw
♦ Wheels must be in straight-ahead position. Prote
cted AG.
agen
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,

– 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 .
wage es n
Volks ot g
d by ua
ran
ir se tee
tho
or
s au ac
s
ce
le
un
pt
an
d
itte
y li
rm
ab
– Remove cable duct -1- below steering column. To do this,
pe
ility
raise lugs -arrow- slightly on both sides and pull cable duct out
ot
wit
, is n
from guide on steering column.
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
n
ercia
form
m
atio
– Unscrew securing nuts -arrows- and remove footwell trim -1-.

com
n in
r
te o
thi
sd
iva
o
r
rp
cu
fo
m
en
ng
t.
yi Co
Cop py
ht. rig
ht
rig by
copy Vo
by lksw
cted agen
Prote AG.

– Remove earth cable -arrow- and cable -1- from steering col‐
umn.
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
r
– Remove ground cableuth-arrow-
o and cable -1- from steering col‐ eo
ra
umn. ss
a c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
rrectness of i
– Remove bolt -1- and remove crash bar for clutch pedal -2-.
– Remove bolt -3- and remove crash bar for brake pedal -4-.
cial p
nform
mer
a
– Lower steering column slightly and carefully pull out upwards.
m
tion
co
in t
r
Installing
o
his
ate
do
riv
– Hook steering column into installation aid on mounting brack‐

p
cum
r
et.
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote
– Align steering column to mounting bracket.
AG.
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.


– 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-.
lkswage es n
o ot g
byV ua
ed ran
oris tee
th or
au ac
ss
ce
e
nl
pt
du
an
itte
y li
erm
ab
– Attach ground cable -arrow- and cable -1- to steering column.

ility
ot p
wit

, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
m
io
r co
n in t
o
his
ate
d
iv
o
pr
cu
or
m
f
en
ng
i t.
py Co
t. Co py
rig
gh ht
yri by
y cop Vo
lksw
b
cted agen
Prote AG.

– Fit universal joint -2- onto steering box pinion and tighten bolt
-1-.
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
se nte
ori eo
th
au ra
– Install footwell trim
ss -1- and secure with nuts -arrows-. c
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
– Install cable duct -1- below steering column.
n
ercia
The lugs -arrow- must engage in the guide on both sides.
format
m
com
ion
in
r
te o
thi
sd
iva
o
r
rp
cu
fo
m
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
– 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- .

Specified torques
Component n AG. Volkswagen AG do Specified torque
wage es n
Volks ot g
Universal joint to steering
d by box ua
ran 30 Nm
ir se
♦ Use new boltth o tee
or
s au ac
s
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
5.3 Basic setting for steering angle sensor
wit
is n
G85 steering angle sender must be
h re
ole,
spec
checked after the following repair work:
t to the co
♦ When vehicle steering angle sensor -G85- is removed or re‐
newed,
rrectness of i
♦ If steering column was removed or renewed;
♦ If steering lock housing with steering column switch was re‐
moved or renewed;
cial p
nform
♦ If steering box was removed or renewed;
mer
a
♦ If steering wheel was repositioned.
m
tion
co
in t
r
5.4 Handling and transporting steering col‐

o
his
ate
do
iv
umn
pr
cum
or
f
en
ng
t.
yi Co
op
WARNING C py
ht. rig
ht
rig by
opy Vo
♦ Adherence to proper steering column handling is essen‐ by c lksw
cted agen
tial. Prote 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.

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°.
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
th
au ra
ss c ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
is n
5.5 Checking steering column for damage

h re
ole,
spec
Visual check
t to the co
– Check all steering column parts for damage.

Checking function
rrectness of i
– Check that steering column turns smoothly and easily.

– Check that steering column can be adjusted in reach and
height.
cial p
nform
5.6 Removing and installing mounting

mer
a
m
bracket
ion
co
in t
or
his
e

at
do
iv
pr
cum
or
f
en
ng
i t.
py Co
t. Co py
rig
gh ht
yri by
cop by
Vo
lksw
cted agen
Prote AG.

AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
th
au ra
Removing
ss c
ce
e
nl
pt
du
an
itte
y li
– Remove dash panel insert ⇒ Electrical system; Rep. Gr. 90 ;
erm
ab
ility
ot p
wit
is n
– Remove bolts -arrows- under bracket.
h re
ole,
spec
t to the co
rrectness of i
cial p
nform
mer
a
m
tio
r co
n in
o
thi
– Push connector -1- in -direction of arrow- and remove from

te
s
ir va
do
support in mounting bracket.

p
cum
for
– Remove bolts -arrows- from bracket to body.

en
ng
i t.
py Co
t. Co py
rig
gh ht
yri by
cop Note by
Vo
lksw
cted agen
Prote AG.
Bolts -arrows- are screwed in from cross member.
– Unscrew bolt -1- and remove mounting bracket from body.

Installing

– Insert mounting bracket and screw bolt -1- in.
– Install bolts -arrows-.
Note
Bolts -arrows- are screwed in from cross member.

AG. Volkswagen AG d
agen oes
ksw
– Insert connector -1- into support in mounting by
Vol bracket and push not
gu
to stop opposite -direction of arrow-. ir se
d ara
nte
tho eo
au ra
ss c
ce
le
un
pt
an
d
itte
y li
rm
ab
– Install bolts -arrows- under bracket.
pe
ility
ot
wit
, is n
h re
hole
– Install dash panel insert ⇒ Electrical system; Rep. Gr. 90 ;
spec
es, in part or in w
t to the co
5051B- .
rrectness of i
l purpos
n
ercia
form
m
atio
com
Specified torques
n in
r
te o
thi

sd
iva
o
r
Mounting bracket to body 20 Nm

rp
cu
fo
m
en
ng

t.
yi Co
op py
C
ht. rig
ht
rig by
copy Vo
by lksw
cted agen
Prote AG.
5.7 Removing and installing strut


Removing
– Remove plenum chamber bulkhead ⇒ General body repairs,
bulkhead .
– Remove bolt -arrow- in plenum chamber.
olkswagen AG
en AG. V
– Remove steering column o⇒
lkspage
wag 351 . does
not
yV gu
db ara
rise nte
tho eo
s au ra
c
s
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
– Remove bolt -1-. t to the co
– Remove strut -2-.

rrectness of i
Installing
cial p
nform
mer
a
m
tio
o
n in
r c
te o
thi
s
a
do
ir v
p
cum
for
en
ng
i t.
– Secure strut to body by tightening bolt -arrow-.
py Co
t. Co py
rig
gh ht
yri by
y cop Vo
lksw
b
cted agen
Prote AG.

AG. Volkswagen AG d
agen oes
ksw
– Install securing bolt -1- and tighten. byV
ol not
gu
ara
ed
is nte
– Install steering column ⇒ page 354 . thor eo
u ra
sa c
– Install plenum chamber bulkhead ⇒ General body repairs,
s
ce
e
nl
pt
du
an
bulkhead .
itte
y li
erm
ab
ility
ot p
wit
, is n
5051B- .
h re
hole
spec
es, in part or in w
t to the co
Specified torques
rrectness of i
l purpos
nform
ercia
Strut to body 20 Nm
m
at
m
io
r co
n in t
o
his
ate
d
iv
o
pr
cu
or
m
f
en
ng
i t.
py Co
t. Co py
rig
gh ht
yri by
cop by
Vo
lksw
cted agen
Prote AG.

6 Electromechanical steering box up to

model year 2008
AG. Volkswagen AG d
agen oes
ksw
6.1 Assembly overview - electromechanical steering box, left-hand drive (1st ol not
V gu
d by ara
e
and 2nd generations) up to model year 2008 ris nte
tho eo
au ra
ss c
ce
e
nl
pt
du
Note
an
itte
y li
erm
ab
♦ There are no 2nd generation steering boxes available as spare parts.
ility
ot p
wit
is n
♦ If the steering box has to be replaced, a new 3rd generation steering box will have to be fitted.
h re
ole,
spec
♦ 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 catalogue“ETKA” .
t to the co
♦ 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
rrectness of i
housing with connector position assurance -1J0 973 803- ⇒ Electronic parts catalogue“ETKA” .
cial p
1 - Universal joint
nform
mer
2 - Hexagon bolt
a
m
tion
o
❑ 30 Nm
c
in t
or
his
e

at
do
riv
moving
p
cum
or
f
3 - Wiring
en
ng
t.
yi Co
op py
4 - Power steering box t. C rig
gh ht
yri by
❑ With power steering cop Vo
by lksw
control unit -J500- cted agen
Prote AG.
❑ 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 .
6 - Nut
❑ M12 x 1.5
❑ Self-locking
moving
6. Electromechanical steering box up to model year 2008 363

7 - Subframe with brackets

8 - Bolt
❑ Always renew clamp for steering box
9 - Shield
10 - Bolt
❑ 6 Nm
❑ Self-locking
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
th
au ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
rrectness of i
cial p
nform
mer
a
m
tio
r co
n in
o
thi
te
s
ir va
do
p
cum
for
en
ng
i t.
py Co
t. Co py
rig
gh ht
yri by
cop by
Vo
lksw
cted agen
Prote AG.

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 catalogue“ETKA” .
♦ 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 catalogue“ETKA” .
1 - Universal joint
2 - Bolt
❑ M8 x 35 AG. Volkswagen AG d
agen oes
❑ 30 Nm Volksw not
gu
by ara
❑ Always renew after re‐ rised
nte
o
moving auth eo
ra
ss c
3 - Wiring
ce
e
nl
pt
du
an
4 - Shield
itte
y li
erm
ab
5 - Torx bolt
ility
ot p
wit
❑ 6 Nm
is n
h re
ole,
❑ Self-locking
spec
6 - Clamp
t to the co
moving
rrectness of i
7 - Rubber mounting
8 - Power steering box
❑ With power steering
cial p
nform
control unit -J500-
mer
a
m
tion

co
in t
V187-
or
his
te
❑ With steering torque

a
do
riv
sender -G269-
p
cum
or
f
en
ng
❑ Can be checked in gui‐ i t.

py Co
ded fault finding of the t. Co py
rig
vehicle diagnosis, test‐ yri
gh by
ht
ing and information sys‐ cop Vo
by lksw
tem -VAS 5051B-
cted agen
Prote AG.

⇒ page 374
❑ Observe notes
⇒ page 365 .
9 - Connecting piece
11 - Nut
❑ M12 x 1.5
❑ 50 Nm

❑ Self-locking
12 - Subframe
13 - Bolt
❑ M10 x 70
6.3 Removing and installing steering box, left-hand drive (1st and 2nd genera‐
tions) up to model year 2008

equipment required
1331-
♦ Torque wrench -V.A.G n AG. Volkswagen AG do
wage es n
1332- Volks ot g
d by ua
ran
ir se
♦ Engine and gearbox jack - tho tee
or
V.A.G 1383 A- ss au ac
ce
e

nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
rrectness of i
cial p
nform
mer
atio
m
r co
n in
o
thi
te
sd
ir va
o
p
cum
for
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

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 catalogue“ETKA” .
♦ 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
catalogue“ETKA” .
– Disconnect battery. ⇒ Rep. Gr. 27 ; Battery; Disconnecting

and reconnecting battery.
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
ss c
ce
e
nl
pt
du
an
itte
y li

erm
ab
ility
ot p
wit
is n
ly.
h re
ole,
spec
Caution
t to the co

rrectness of i
cial p
nform
mer
a
m
tion
co
in t
or
his
ate
do
priv
cum
or
f
en
ng
i t.
py Co
t. Co py
rig
gh ht
yri by
y cop Vo
lksw
b
cted agen
Prote AG.

– Press track rod ball joint off wheel bearing housing with
-3287A-.

-14-.
– Remove exhaust system retainer on subframe.
wage es n
Volks ot g
y ua
db ran
– Remove bolts -arrows- on heat
o
ir s shield.
e
tee
th or
u
– Remove heat shield from
ss subframe.
a ac
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
rrectness of i
cial p
nform
mer
a
m
tion
co
in t
or
his
ate
do
priv
cum
or
f
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

Volkswa
– Now remove bolts -3, 6, 11 and wa16-
gen Afor
G. steering boxdand
gen AG
oes anti-
roll bar. Volks not
gu
by a d ran
se
– Fix position of subframe
tho
ri and brackets. ⇒ page 16 tee
or
au ac
ss
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
rrectness of i
cial p
nform
mer
a
m
tio
r co
frame.
n in
o
thi
e
– Place a wooden block -1- or similar between V.A.G 1383 A

t
s
ir va
do
and subframe.
p
cum
for
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.


– Remove heat shield -1- over steering box.

– Remove cable guide from subframe -arrow-.

. Volkswagen AG
gen AG does
– Unclip all remaining cable clips on steering
Vol
ksw box.
a
not
by gu
d ara
– Disconnect all electrical connections
orise on steering box. nte
eo
h
ut ra
– Lower subframe using engine ss a and gearbox jack -V.A.G 1383 c
A- far enough that the steering box can be removed.
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
n
ercia
format
m
com
ion
in
r
te o
thi
sd
iva
o
r
rp
cu
fo
m
en
ng
i t.
py Co
t. Co py
rig
h ht
rig by
copy Vo
by lksw
cted agen
Prote AG.

– 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
♦ Coat seal on steering box with suitable lubricant, e.g. soft

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
ge G do
swa es
– Connect bbattery.
yV
olk ⇒ Rep. Gr. 27 ; Battery;
not
Disconnecting
gu
ara
and
reconnecting
ris
ed battery. nte
tho eo
– Carry
ss
au out basic setting for -G85 - steering angle sender-
ra
c using
vehicle diagnosis, testing and information system -VAS 5051-
ce
e
nl
⇒ Vehicle diagnosis, testing and information system VAS

pt
du
an
5051.
itte
y li
erm
ab
After installation, position of steering wheel must be checked dur‐

ility
ot p
ing road test.

wit
is n
h re
ole,
If steering wheel is not in straight-ahead position or if a new steer‐

spec
ing box was installed, front axle tracking must be checked and if
necessary adjusted!
t to the co
– Check wheel alignment. ⇒ page 305

rrectness of i
If new steering box has been installed, adapt power steering con‐
trol unit -J500- using vehicle diagnostic, testing and information
system -VAS 5051- .
cial p
– Carry out basic setting for power steering control unit -J500-
nform
using vehicle diagnosis, testing and information system -VAS

mer
5051- ⇒ Vehicle diagnosis, testing and information system

a
m
VAS 5051.
io
r co
n in
o
thi
te
s
ir va
do
p
cum
for
en
ng
i t.
py Co
t. Co py
rig
gh ht
yri by
y cop Vo
lksw
b
cted agen
Prote AG.

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
♦ Use new bolts

♦ Use new bolts

♦ Use new nut

♦ Use new nuts

link
♦ Use new nuts

♦ Use new bolts AG. Volkswagen AG d
agen oes
olksw not
V gu
♦ Always renew clamp by ara
ed nte
oris eo
th
Universal joint to steering box au 30 Nm
ra
c
ss
♦ Use new bolt
ce
le
un
pt
an
d
itte
y li
Shield to steering box 6 Nm

erm
ab
ility
ot p
wit
is n

h re
ole,
♦ Use new nut

spec
t to the co

rrectness of i
cial p
nform
mer
a
m
tio
r co
n in
o
thi
te
sd
iva
o
pr
cu
r
fo
m
en
ng
t.
yi Co
Cop py
ht. rig
ht
rig by
copy Vo
by lksw
cted
372
agen
Prote AG.
Rep. Gr.48 - Steering

Caution
⇒ Rep. Gr. 34 .
boxes.

♦ Use new bolt n AG. Volkswagen AG do
wage es n
Volks ot g
M10 x 35 strength class 10.9 d by ua
ran 50 Nm + 90° further
♦ Use new bolt rise tee
tho
u or
a ac
ss
ce
e
nl
♦ Use new bolt
pt
du
an
itte
y li
erm
ab
ility
ot p
♦ Use new bolt
wit
is n
h re
ole,
spec
t to the co
rrectness of i
cial p
nform
mer
a
m
tion
co
in t
or
his
ate
do
iv
pr
cum
or
f
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

6.4 Removing and installing steering box, right-hand drive (2nd generation) up
to model year 2008

equipment required
1331-
1332-
V.A.G 1383 A-
wage es n
Volks ot g
by ua
d ran
rise tee
tho
u or
a ac
ss
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
n
ercia
format
m
com
ion
in
r
te o
thi
sd
iva
o
r
rp
cu
fo
m
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

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.
♦ In addition, the electrical wiring harness from the E-box towathe
olks
ge es n
ot g
steering box will then also have to be renewed. Thisd bisy Vincluded ua
ran
with the order for the new steering box via the o⇒ ris Electronic
e
tee
parts catalogue“ETKA” . auth or
ac
ss
♦ The electrical wiring harness will be delivered with the cable
ce
e
nl
pt
for the service interval display.
du
an
itte
y li
♦ In vehicles without a service interval display, the unused 3-pin erm
ab
ility
connector must be sealed by a flat contact housing with con‐
ot p
wit
nector position assurance -1J0 973 803- ⇒ Electronic parts
is n
h re
catalogue“ETKA” .
ole,
spec
– Disconnect battery ⇒ Rep. Gr. 27 ; Battery; Disconnecting
t to the co
and reconnecting battery .
– Remove nuts -1- and remove footwell trim -2-.
rrectness of i
cial p
nform
mer
atio
m
r co
n in
o
thi
te
sd
ir va
o
p
cum
for
en
ng
i t.
py Co
t. Co py
rig
gh ht
yri
– Remove bolt -1- for universal joint and pull universal joint -2-
by
cop Vo
off steering box.
by lksw
cted agen
Prote AG.
ly.
Caution
Leave nut screwed a few turns onto pin to protect thread.

joint puller -3287A- and remove nut now.
overview - noise insulation . AG. Volkswagen AG d
agen oes
olksw not
yV gu
– Remove coupling rod from anti-roll bar. ed b ara
nte
ris
ho eo
aut ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
rrectness of i
cial p
nform
mer
a
m
tion
co
in t
or
his
ate
do
riv

p
cum
r
-13-.
fo
en
ng
i t.
py Co
t. Co py
rig
gh ht
yri by
cop by
Vo
lksw
cted agen
Prote AG.



– Remove bolts -5- and -6- for steering box.
wage es n
Volks ot g
d by ua
ran
ir se tee
tho
or
s au ac
s
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
is n
– Remove bolts -7- and -8- for anti-roll bar.
h re
ole,
spec
t to the co
rrectness of i
cial p
nform
mer
a
m
tion
co
in t
or
his
ate
do
priv
cum
or
f
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

– 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.
– Remove heat shield -1- over steering box. n AG. Volkswagen AG do

lkswage es n
– Remove bolts -arrows-. d byV
o ot g
ua
ran
rise tee
tho
u or
a ac
ss
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
– Unclip all remaining cable clips on steering box.
rrectness of i
– Disconnect connectors from steering box.

l purpos
– Lower subframe carefully with engine/gearbox jack -V.A.G

1383 A- .
n
ercia
form
m
atio
com
n in
r
te o
thi
sd
iva
o
r
rp
cu
fo
m
en
ng
i t.
py Co
t. Co py
rig
gh ht
yri by
y cop Vo
lksw
b
cted agen
Prote AG.

– Now lift anti-roll bar -1- forwards over subframe -2- and down
while turning anti-roll bar slightly.
– Unbolt steering box from subframe.
wage es n
Volks ot g
d by ua
ran
ir se tee
tho
or
s au ac
s
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of
l purpos
in
ercia
forma
m
com
tion
in
r
te o
thi
sd
iva
o
r
rp
cu
fo
m
en
ng
t.
yi Co
Cop py
ht. rig
ht
rig by
copy Vo
by lksw
cted agen
Prote AG.


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 ge G do
swa es n
If steering wheel is crooked or a new steering boxbwas
y V installed,
olk ot g
ua
wheels must be aligned. ris
ed ran
tee
tho or
– Perform wheel alignment ⇒ page 305 .ss au ac
ce
le
un
pt
an

d
itte
y li
system -VAS 5051- .

rm
ab
pe
ility
ot
wit
, is n

h re

hole
spec
VAS 5051.
es, in part or in w
t to the co
Note
rrectness of i
If parking aid 2 is fitted in the vehicle, the power steering control

l purpos
unit -J500- must be recoded ⇒ Vehicle diagnosis, testing and in‐

formation system VAS 5051.
n
ercia
form
m
Specified torques
atio
com
n in
r

te o
thi
sd
iva

o
r
rp
cu
♦ Use new bolts

fo
m
en
ng
t.
yi Co
Cop py
ht. rig
ht
rig by
copy Vo
by lksw
380
cted agen
Prote
Rep. Gr.48 - Steering
AG.


♦ Use new bolts

♦ Use new nut

♦ Use new nuts

link
♦ Use new nuts

♦ Use new bolts
♦ Always renew clamp

♦ Use new bolt
Shield to steering box AG. Volkswagen AG d 6 Nm

agen
Vol
ksw
oes
not
y gu
db ara
ise nte
Track rod ballthojoint
r
to wheel bearing housing eo 20 Nm + 90°
♦ Use newss au
nut ra
c
ce
e
nl
pt

du
an
itte

y li
erm
ab
ility
ot p
wit
is n
h re

ole,
spec
t to the co
Caution
rrectness of i

⇒ Rep. Gr. 34 .
cial p
boxes.
nform
mer

a
m

ion
co
in t
or
his
te
iva
do
r

p
cum
for
en
ng

t.
yi Co
op
♦ Use new bolt C py
ht. rig
rig ht
py by
o Vo
by c lksw
cted agen
♦ Use new bolt Prote AG.

♦ Use new bolt

♦ Use new bolt

wage es n
Volks ot g
y ua
edb ran
ir s tee
tho
u or
a ac
ss
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
m
io
r co
n in t
o
his
ate
d
iv
o
pr
cu
or
m
f
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

7 Electromechanical steering box after

model year 2009
. Volkswagen AG
gen AG
7.1 Assembly overview - electromechanical steering nobox, left-hand drive (3rd
wa oes d
olks t gu
yV
generation) after model
is year 2009
d b ara
e nte
or e th or
au ac
ss
1 - Wiring
ce
le
un
pt
an
d
itte
2 - Universal joint
y li
rm
ab
pe
ility
3 - Bolt
ot
wit
, is n
❑ M8 x 35
h re
hole
❑ 30 Nm
spec
es, in part or in w
t to the co
moving
4 - Torx bolt
rrectness of i
❑ 6 Nm
l purpos
❑ Self-locking
5 - Shield
n
ercia
fo
rmat
m
com
ion
control unit -J500-
in
r
te o
thi
sd
iva
o
r
rp
cu
fo
m
V187-
en
ng
i t.
py Co
❑ With steering angle Co py
sender -G85- ht. rig
rig ht
py by
❑ With steering torque
co Vo
by lksw
cted
sender -G269-
agen
Prote AG.
❑ Can be checked in gui‐

ded fault finding of the
vehicle diagnosis, test‐
ing and information sys‐
tem -VAS 5051B-
⇒ page 385
7 - Wheel bearing housing left
8 - Nut
❑ M12 x 1.5
❑ Self-locking
9 - Bolt
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
control unit -J500-
V187-
❑ With steering angle
sender -G85-
❑ With steering torque olks
wage es n
ot g
sender -G269- d by
V ua
ran
ir se
❑ Can be checked in gui‐ tho tee
or
ded fault finding ofssthe
au ac
vehicle diagnosis, test‐
ce
e
nl
ing and information sys‐

pt
du
an
tem -VAS 5051B-

itte
y li
erm
ab

ility
ot p
⇒ page 391
wit
is n
h re
7 - Wheel bearing housing left

ole,
spec
8 - Nut
t to the co
❑ M12 x 1.5
rrectness of i
❑ Self-locking
9 - Bolt
cial p
nform
mer

atio
m
r co
10 - Subframe
in
o
thi
te
sd
ir va
11 - Wheel bearing housing right

o
p
cum
for
en
ng
t.
yi Co
Cop py
ht. rig
ht
rig by
copy Vo
by lksw
cted agen
Prote AG.

Running
gen AG. gear,
Volkswaaxles,
gen AGsteering - Edition 08.2009
d
wa oes
olks not
yV gu
7.3 Removing and installing steering box, left-hand drive (3rd generation) after
b ara
ed nte
ris
tho eo
model year 2009 ss
au ra
c
ce
e
nl
pt
du
an
itte
y li
erm
equipment required
ab
ility
ot p
wit
is n
1331-
h re
ole,
spec
1332-
t to the co
V.A.G 1383 A-
rrectness of i
cial p
nform
mer
a
m
tion
co
in t
or
his
ate
do
priv
cum
or
f
en
ng
i t.
py Co
t. Co py
rig
gh ht
yri by
y cop Vo
lksw
b
cted agen
Prote AG.
Removing steering box

– Disconnect battery. ⇒ Rep. Gr. 27 ; Battery; Disconnecting
and reconnecting battery.

ly.
Caution
– Press track rod ball joint off wheel bearing housing with
-3287A-.

-14-.
– Remove exhaust system retainer on subframe. wage es n
Volks ot g
y ua
edb ran
ir s tee
tho
u or
a ac
ss
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
rrectness of i
cial p

nform
mer

atio
m
r co
n in
o
thi
te
sd
ir va
o
p
cum
for
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

– 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
wage es n
Volks ot g
by ua
d ran
rise tee
tho
u or
a ac
ss
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i

l purpos
frame.
– Place a wooden block -1- or similar between V.A.G 1383 A
nform
ercia
and subframe.
m
at
m
io
r co
n in t
o
his
ate
d
iv
o
pr
cu
or
m
f
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.



lkswage es n
o ot g
byV ua
ed ran
oris tee
th or
au ac
– Remove cable guide from subframe -arrow-. ss
ce
e
nl
pt
du
an
itte
y li
– Disconnect all electrical connections on steering box.
erm
ab
ility
ot p
– Lower subframe using engine and gearbox jack -V.A.G 1383
wit
, is n
A- far enough that the steering box can be removed.
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
m
io
r co
n in t
o
his
ate
d
iv
o
pr
cu
or
m
f
en
ng
i t.
py Co
t. Co py
rig
gh ht
yri by
y cop Vo
lksw
b
cted agen
Prote AG.


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 G do
swa es n
by
Vol
k ot g
ua
ed ran
ris tee
ho
Before inserting subframe bolts,
au
t position steering box on sub‐ or
ac
frame and insert bolts for steering
ss box and anti-roll bar.
ce
e
nl
pt
– Connect electrical connections to steering box.
du
an
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
Note
t to the co
rrectness of i
– Bolt universal joint to steering box.
– Connect battery. ⇒ Rep. Gr. 27 ; Battery; Disconnecting and
reconnecting battery.
cial p
nform
– Carry out basic setting for -G85-Geber für Lenkwinkel- using
mer

atio

m
r co
5051.
in
o
thi
te

sd
ir va
ing road test.

p
cum
for
en
ng
If steering wheel is not in straight-ahead position or if a new steer‐

t.
yi Co
op
ing box was installed, front axle tracking must be checked and if C py
ht. rig
necessary adjusted! rig ht
py by
co Vo
by lksw
– Check wheel alignment. ⇒ page 305 cted agen
Prote AG.
system -VAS 5051B- .
5051B- ⇒ Vehicle diagnosis, testing and information system
VAS 5051.
Specified torques
♦ Use new bolts

AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
Golf 2004 ➤ , Golf Plus
tho 2005 ➤
r eo
u ra
ss steering - Edition 08.2009
a c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
♦ Use new bolts
wit
is n
h re
ole,
spec
♦ Use new nut
t to the co
rrectness of i
♦ Use new nuts

cial p
link
nform
♦ Use new nuts
mer
a
m
tion
co
in t
r
o
his
ate
do
iv
pr
cum
or
♦ Use new bolts

f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
yri
♦ Use new bolt p by
co Vo
by lksw
cted agen
Prote AG.

♦ Use new nut


M10 x 35 50 Nm + 90° further
♦ Use new bolt
M10 x 75 50 Nm + 90° further

♦ Use new bolt

wage es n
7.4 Removing and installing steering box, right-hand drive (3rd generation) after d by
Volks ot g
ua
ran
model year 2009 tho
ir se tee
or
s au ac
s
ce
e
nl
pt
du
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V.A.G 1383 A-
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Prote AG.
Removing
– Disconnect battery ⇒ Rep. Gr. 27 ; Battery; Disconnecting
and reconnecting battery .
– Remove nuts -1- and remove footwell trim -2-.

– Remove bolt -1- for universal joint and pull universal joint -2-
off steering box.
ly.
Caution
joint puller -3287A- and remove nut now.
– Remove coupling rod from anti-roll bar.
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spec
-14-.
t to the co
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mer
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gen AG d
– Remove bolts
Vol
-5-
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a oes
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th
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spec
es, in part or in w
t to the co
rrectness of i
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n
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format
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in
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olkswagen AG
Running gear, axles, steering - Edition 08.2009swagen AG. V does
olk not
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– Remove bolts -11- and -16- for anti-roll bar.orise nte
h eo
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– Fix position of subframe ⇒ page 16 . ss a c
ce
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nl
pt
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spec
t to the co
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mer
a
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co
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or
– Position
his
ate
engine and gearbox jack -V.A.G 1383 A- under subframe.
do
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gearbox jack -V.A.G 1383 A- and subframe. py Co
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– Remove bolts -4- and -5- and lower subframe slightly. In the
process, observe electrical wiring.



– Disconnect connectors from steering box.

– Lower subframe carefully with engine/gearbox jack -V.A.G
1383 A- .
lkswage es n
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– Now lift anti-roll bar -1- forwards over subframe -2- and down
an
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while turning anti-roll bar slightly.

rm
ab
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– Unbolt steering box from subframe.

ot
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spec
es, in part or in w
t to the co
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Prote AG.
7. Electromechanical steering box after model year 2009


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
wage
n AGbox
. Volkand
swaganti-roll
en AG
doebar.
ks s no
Vol t
– Attach lower noise ed insulation ⇒ Rep. Gr. 50 ; Assemblyranover‐
by gu
a
view - noise tinsulation
horis . tee
or
au ac
– Bolt universal
ss joint to steering box.
ce
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nl
pt
– Connect battery ⇒ Rep. Gr. 27 ; Battery; Disconnecting and

du
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reconnecting battery .
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is n
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5051.
spec
t to the co

ing road test.
If steering wheel is crooked or a new steering box was installed,
rrectness of i
wheels must be aligned.

cial p
nform

mer
system -VAS 5051- .

a
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or

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If parking aid 2 is fitted in the vehicle, the power steering control Prote AG.
unit -J500- must be recoded ⇒ Vehicle diagnosis, testing and in‐

formation system VAS 5051.
Specified torques
♦ Use new bolts

AG. Volkswagen AG d
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Component Volksw
oes
not Specified torque
by gu
ara
Anti-roll bar to subframe o
ir se
d
20nteNm + 90°
♦ Use new bolts auth eo
ra
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nl
pt
du
♦ Use new nut
an
itte
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ab
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♦ Use new nuts ole,
spec
t to the co
link
♦ Use new nuts
rrectness of i
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nform
mer
♦ Use new bolts
atio
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♦ Use new bolt
thi
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M10 x 35 50 Nm + 90° further
♦ Use new bolt
M10 x 75 50 Nm + 90° further

♦ Use new bolt

Golf 2004 ➤ , GolfwaPlus
gen A2005
G. Volks➤
wagen AG
does
ks
Running gear,
by V axles, steering - Edition 08.2009
o l not
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au
8 Distinguishing between steering box‐c
a
ss
ce
e es (1st and 2nd generations), Golf
nl
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At the start of production of the Golf 2004 ▸, the 1st generation
ility
ot p
steering box was fitted. During the 2004 model year, this was re‐
wit
placed with the 2nd generation steering box.
, is n
h re
hole
Vehicles fitted with a 1st generation steering box can be retrofitted
spec
with a 2nd generation steering box ⇒ page 400 .
es, in part or in w
t to the co
To identify the type of steering box while it is fitted, count the
number of screws on the steering pinion bearing cover.
rrectness of i
– Raise vehicle.
l purpos
– Turn steering in both directions to count the number of screws

-1-.
nform
ercia
The 1st generation steering box has 4 bolts for the bearing cover
and the 2nd generation steering box has 2.
m
at
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The figure shows a 1st generation steering box.
in t
o
his
te
Continuation with 1st generation steering box ⇒ page 401 .

a
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Continuation with 2nd generation steering box ⇒ page 406 .
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9 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.
AG. Volkswagen AG d
agen oes
olksw not
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wit
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spec
es, in part or in w
t to the co
rrectness of i
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nform
mercia
at
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ate
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9. Differentiating between 2nd and 3rd generation steering boxes 399

10 Exchanging 1st generation ysteering Vol
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box for 2nd generation osteering box,
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Golf
th or
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un
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Note
y li
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ot
♦ There are no new 1st generation steering boxes available as
wit
, is n
parts for renewing 1st generation steering boxes.
h re
hole
spec
♦ Therefore, 2nd generation steering boxes must be fitted.
es, in part or in w
t to the co
♦ 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.
rrectness of i
l purpos
The parts in the following list must be renewed when a 1st gen‐
eration steering box is exchanged:
n
ercia
♦ The wiring harness generally must be exchanged.
form
m
♦ Subframes from Part No. 1K0.199.369 through and including
atio
com
1K0.199.369.E. must be exchanged. Subframes from Part No.
n in
r
1K0.199.369.F need not be exchanged. To order parts via the

te o
thi
⇒ Electronic parts catalogue “ETKA” , the assembly
sd
iva
o
1K0.199.313 must be ordered with the respective index.
r
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♦ For left-hand-drive vehicles, the right bracket from Part No.

t.
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1K0.199.296 through and including 1K0.199.296.C must be C py
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exchanged. Brackets from Part No. 1K0.199.296.D need not
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be exchanged.
cop Vo
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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.
The allocation of the respective parts can be determined in the ⇒
Electronic parts catalogue “ETKA” .

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
1275-
1332-
♦ Tool insert 24 mm -V.A.G
1332/11-
♦ Locking pliers for Phaeton
steering box -VAS 6199- n AG. Volkswagen AG do
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wit
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spec
t to the co
rrectness of i
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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.
– 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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not
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♦ If the steering rack shows hori signs of corrosion, damage, wear or
s nte
eo
soiling, renew the complete
aut
steering box. ra
c
ss
♦ Likewise, if there is no film of grease on the steering rack, the
ce
le
un
pt
steering box must be renewed.
an
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Installing
ot
wit
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hole
Caution
spec
es, in part or in w
t to the co
Do not grease steering rack.
rrectness of i
l purpos
– Thread new clamps and rubber boot onto track rod.

– Screw in track rod to mark made during removal. n
ercia
format
m
– Tighten lock nut -3- to specified torque while counterholding

com
ion
track rod ball joint -2-.

in
r
te o
thi
– Lightly lubricate seal point between boot and track rod with
sd
iva
grease -G 052 168 A1- (from repair kit Fuchs Renolit JP1619).
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rig
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Prote AG.
– 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
– Push rubber boot onto steering box housing to stop.

– 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 .
ks wage es n
– Carry out basic setting for steering angle sender -G85- Vol using ot g
by ua
⇒ vehicle diagnostic, testing and information rsystem
ise
d -VAS ran
tee
5051B- , “guided fault finding” . ut
ho or
sa ac
– Then carry out basic setting for steering using
s
⇒ vehicle di‐
ce
e
nl
agnostic, testing and information system -VAS 5051B- , “gui‐
pt
du
an
ded fault finding” .
itte
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ab
ility
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Specified torques
wit
is n
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ole,
spec
t to the co
rrectness of i

cial p
nform
equipment required
mer
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tion
co
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or
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1275-
at
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or
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en
1332-
ng
t.
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♦ Open jaw insert, 38 mm -
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♦ Locking pliers for Phaeton Prote AG.
steering box -VAS 6199-

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.
ly. agen
AG. Volkswagen AG d
o w es n
olks ot g
Leave nut screwed on a few turns to protect
ed
bythread on pin.
V ua
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ris tee
ho
aut or
ac
ss
ce
e
nl
pt
du
an
itte
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erm
ab
ility
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wit
is n
h re
ole,
joint puller -3287 A- and now remove nut.
spec
– Loosen spring-type clamp (item -1- in figure N44-10005
t to the co
⇒ page 404 ) on rubber boot using hose clip pliers -V.A.G
rrectness of i
cial p
nform
mer
a
m
tio
o
n in
r c
te o
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– Unscrew track rod from steering rack using open jaw insert,
s
a
do
ir v
38 mm -V.A.G 1923- .
p
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Note C py
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rig ht
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♦ If the steering rack shows signs of corrosion, damage, wear or
by c lksw
cted agen
soiling, renew the complete steering box.
Prote AG.

Installing track rod
Caution


– 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- .
– Push rubber boot onto steering box housing to stop. n AG. Volkswagen AG do
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nl
pt
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itte
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erm
ab
ility
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wit
is n
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– Install wheel and tighten. ⇒ page 288 .
ole,
spec
t to the co
rrectness of i
⇒ vehicle diagnostic, testing and information system -VAS
5051B- , “guided fault finding” .
– Then carry out basic setting for steering using ⇒ vehicle di‐
cial p
agnostic, testing and information system -VAS 5051B- , “gui‐

nform
ded fault finding” .
mer
atio
m
r co
Specified torques
in
o
thi
te
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or

f
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t.
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Cop py
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♦ Use new nut
ht ht
rig by
copy Vo
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cted
Track rod to steering rack in steering box 100 Nm
agen
Prote AG.

AG. Volkswagen AG d
agen o
Golf 2004 ➤ , Golf PlusVol 2005 ➤
ksw es n
ot g
by ua
Running gear, raxles,
ise
d steering - Edition 08.2009 ran
t ee
ho
aut or
ac
ss
12 Repairing electromechanical steer‐
ce
e
nl
pt
du
an
ing box (2nd and 3rd generations)
itte
y li
erm
ab
ility
At present, there is no provision for performing repairs on the
ot p
wit
steering box (2nd and 3rd generations).
is n
h re
ole,
12.1 Removing and installing boot
spec
t to the co
equipment required
rrectness of i
1275-
cial p
nform
1332-
mer
a
♦ Tool insert 24 mm -V.A.G
m
tio
r co
n in
1332/11-
o
thi
te
sd
ir va
o
p
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or
m
f
en
ng
t.
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Cop py
t. rig
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pyri by
Vo
co lksw
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cted agen
Prote AG.
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.

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
♦ Likewise, if there is no film of grease
lksw on the steering rack, ethe
agen AG do
sn
steering box must be renewed. db
yV
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Installing boot s au ac
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un
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Caution
an
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ility
ot
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hole
spec
es, in part or in w
t to the co
– Screw in track rod to mark made during removal.
rrectness of i
– Tighten lock nut -3- to specified torque while counterholding
l purpos
track rod ball joint -2-.

n
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orm
m
atio
com
n in
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te o
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t.
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– Push rubber boot -2- onto track rod -1- as shown in figure.
Prote AG.

V.A.G 1275- .
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 n AG. Volkswagen AG do

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Component edb ran Specified torque
ir s tee
tho
or
Track rod ball joint to track
au rod ac 50 Nm
ss
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pt
du
an
itte
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erm
ab
ility
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wit
is n
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ole,
spec
equipment required
t to the co
1275-
rrectness of i
1332-
cial p
♦ Open jaw insert, 38 mm -

nform
V.A.G 1923-
mer
a
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tion

co
in t

or
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ate
do
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or
f
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ng
t.
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Cop py
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rig ht
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by lksw
cted agen
Prote AG.

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- .
wage es n
olks ot g
Noted by V ua
ran
rise tee
tho
or
♦ Ifs the
au steering rack shows signs of corrosion, damage, ac wear or
s
ce
e
nl
pt
du

an
itte
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erm
ab
ility
ot p
wit
Installing track rod

is n
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ole,
spec
Caution
t to the co

rrectness of i

cial p
nform
mer
a
m
tio
r co
n in
o
thi
te
s
ir va
do
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for
en
ng
t.
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Cop py
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rig ht
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co Vo
by lksw
cted agen
Prote AG.
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-.

V.A.G 1275- .

Continue installation in reverse order. agen
AG. Volkswagen AG d
oes
olksw not
yV gu
Specified torque for fitting wheels ⇒ spageed b 288 . ara
nte
ri
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Check wheel alignment after completing
aut
h
the installation. ra
ss c
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Service: Golf 2004 Golf Plus 2005

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Copyright:

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Service: Golf 2004 Golf Plus 2005

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Service

Service Department. Technical Information

Downloaded from www.Manualslib.com manuals search engine

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4.1 Removing and installing wheel bearing housing (3-point mounting) . . . . . . . . . . . . . . . . . . 57

4.2 Removing and installing wheel bearing housing (4-point mounting) . . . . . . . . . . . . . . . . . . 58

4.3 Removing and installing wheel bearing housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60

5 Assembly overview: suspension strut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64

5.1 Removing and installing suspension strut, Golf . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65

5.2 Removing and installing suspension strut, Golf Plus, CrossGolf . . . . . . . . . . . . . . . . . . . . 70

5.3 Repairing suspension strut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75

6.1 Loosening and tightening drive shaft hexagon bolt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77

6.8 Removing and installing intermediate shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92

7 Repairing drive shaft - overview of drive shafts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94

7.1 Heat shields for drive shafts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96

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8.2 Checking outer constant velocity joint . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103

42 - Rear suspension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134

5 Assembly overview: shock absorber, coil spring (front-wheel drive) . . . . . . . . . . . . . . . . . . 173

5.1 Removing and installing coil spring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 173

5.3 Repairing shock absorber . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 177

6 Assembly overview: anti-roll bar (front-wheel drive) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 179

6.1 Removing and installing anti-roll bar . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 179

8.1 Overview of rear axle (aluminium) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 183

8.3 Rear axle in unladen state (aluminium and steel) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 187

9.1 Removing and installing rear axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 189

9.2 Repairing subframe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 195

10.1 Removing and installing rear axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 199

10.2 Repairing subframe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 205

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11.2 Renew vehicle level sender in vehicle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 215

14.3 Removing and installing wheel bearing/wheel hub unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . 255

15.1 Removing and installing coil spring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 257

15.2 Removing and installing shock absorbers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 259

44 - Wheels, tyres, vehicle geometry . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 287

8 Wheel alignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 305

8.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 305

8.3 Test preparations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 307

8.6 Overview - wheel alignment procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 311

8.11 Basic setting for steering angle sender G85 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 317

9 Wheels, tyres . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 318

9.2 Tyre sealant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 318

9.3 Removing a tyre . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 318

9.4 Fitting a new tyre . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 319

9.5 Tyre sealant disposal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 319

11 Protecting wheel centring seat against corrosion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 323

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2 General repair instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 334

5 Steering column, Golf Plus, CrossGolf . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 351

5.1 Assembly overview: steering column . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 351

5.6 Removing and installing mounting bracket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 358

6 Electromechanical steering box up to model year 2008 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 363

to model year 2008 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 365

year 2008 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 366

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1 Checklist for evaluating running gear

♦ Visual examination for deformation and cracks

♦ Examination for play in track rod joints and steering box

♦ Visual examination for tears in boots

♦ Examine electrical and hydraulic lines and hoses for chafing,

cuts and kinks.

♦ Examine hydraulic lines, threaded connections and steering