Running Gear Axles Steering

Service
Workshop Manual
Golf 2004 ➤
Golf Plus 2005 ➤
Running gear, axles, steering
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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
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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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3.17 Renewing mounting
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3.18 Removing aand
uth installing anti-roll bar . . . . . . . . . . . . . . . .e o.r a. . . . . . . . . . . . . . . . . . . . . . . . . 51
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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
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6.3 Removing and installing drive shaft with constant velocity joint . . . . . . . . . . . . . . . . . . . . . . 79
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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Contents
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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 170
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5 Assembly overview: shock absorber, coil spring (front-wheel drive) . . . . . . . . . . . . . . . . . . 173 pt

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5.1 Removing and installing coil spring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 173 y li

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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

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8.2 Overview of rear axle (steel) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 185

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 t. C rig
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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. V. . . . . . . . . . . . . . . . . . . . . . . .t .gu.a.ra. . . . . . 226
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12.3 Removing and installing upper transversetholink . . . . . . . . . . . . . . . . . . . . . . . . . . . . . t.ee.o. . . 227
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12.4 Removing and installing lower transverse ss
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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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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
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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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16 Assembly overview - shock absorber, coil spring (four-wheel drive, subframe made from steel gh ht
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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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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
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7 Tyre pressure monitor (TPM) . o.lk.s.w.ag. e. . . . . . . . . . . . . G. d. o.e.s .no. . . . . . . . . . . . . . . . . . . . . . . . 302
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7.1 Button behaviour . . . . . . .ed. b.y . . . . . . . . . . . . . . . . . . . . . . . . . g.u.ar.a . . . . . . . . . . . . . . . . . . . 302
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7.2 Assembly overview - tyre utho pressure sensor . . . . . . . . . . . . . . . . . . .e.or. . . . . . . . . . . . . . . . 303
7.3 Removing and installing ss
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8 Wheel alignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 305

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8.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 305
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8.2 Test prerequisites . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 307
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8.3 Test preparations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 307
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8.4 Wheel alignment specifications, Golf . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 308
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8.5 Wheel alignment specifications, Golf Plus, CrossGolf . . . . . . . . . . . . . . . . . . . . . . . . . . . . 309
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8.6 Overview - wheel alignment procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 311
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8.7 Correcting front axle camber . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 312
8.8 Adjusting camber on rear axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 314
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8.9 Adjusting toe at rear axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 315
8.10 Adjusting front axle toe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 316
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8.11 Basic setting for steering angle sender G85 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 317
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8.12 Vehicle data sticker . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . f inform 317

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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

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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
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10 Instructions for changing or fitting wheels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 321
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10.1 Fitting wheels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 322
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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
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4.4 Handling and transporting steering column . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 345
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4.6 Removing and installing mounting bracket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 346
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4.7 Removing and installing strut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 348
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5 Steering column, Golf Plus, CrossGolf . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 351
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5.1 Assembly overview: steering column . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 351
spec
5.2 Removing and installing steering column . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 351
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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
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5.5 Checking steering column for damage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 358
5.6 Removing and installing mounting bracket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 358
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5.7 Removing and installing strut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 360
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6 Electromechanical steering box up to model year 2008 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 363
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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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Damage to running gear may go unnoticed during repairs to load-
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♦ Check for flawless function from lock to lock by moving the
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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
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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 .
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erm
ab
ility
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2.1 Overview - front axle
wit
, is n
h re
hole
spec
Note es, in part or in w
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.
l purpos
♦ Bonded rubber bushes can be twisted only to a limited extent. Therefore, you should only tighten the threa‐
nf
ercia
ded connections of components with bonded rubber bushes when the wheel bearing housing is raised to
o
unladen position, Golf ⇒ page 6 ; Golf Plus, CrossGolf ⇒ page 8 .
rm
m
atio
om
n in
or c
thi
e
I - Assembly overview - sub‐

t
sd
iva
frame, anti-roll bar, suspen‐
o
r
rp
cu
sion links ⇒ page 10
o
m
f
en
ng
t.
yi Co
II - Assembly overview - wheel Cop py
t. rig
bearing ⇒ page 56 opyri
gh by
Vo
ht
c lksw
III - Assembly overview - sus‐
by
cted agen
Prote
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
olksw not
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aut ra
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un
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wit
is n
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ole,
spec
t to the co
Caution
rrectne
All bolts on running gear components with bonded rubber

bushes may be tightened only when the component is in the
unladen position (normal position).
ss o
cial p
Bonded rubber bushes can be twisted only to a limited extent.

inform
mer
Axle components with bonded rubber bushes must therefore

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

o
n
c
sition before being tightened.

i
or
n thi
te
sd
Otherwise, the bonded rubber bush would be subject to torsion

iva
o
r
loading, shortening its service life.

p
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Cop py
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pyri by
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Prote AG.

AG. Volkswagen AG d Running gear, axles, steering - Edition 08.2009
agen oes
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To simulate d bthis position on the lifting platform,uraise
ara
nte the respec‐
ise
tive wheel
thor suspension with the engine and gearbox ejack
or -V.A.G
1383ss auA- and support -T10149- . ac
ce
le
Before the axle on one side is raised, both sides of the vehicle
un
pt
an
must be strapped to the lifting platform arms with tensioning
d
itte
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straps -T10038- .
erm
ab
ility
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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!
rrectne
– Turn wheel hub until one of the wheel bolt holes is at the top.
– Attach support -T10149- to wheel hub using wheel bolt.
ss o
Respective nuts and bolts may be tightened only when dimension
cial p
f in
-a- between the centre of wheel hub and edge of wheel housing
form
mer
has been attained.
atio
om
The dimension -a- depends on the ride height of the installed run‐
n
c
i
or
n
ning gear:
thi
te
sd
iva
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r
Running gear 1) Ride height -a- in mm

p
cum
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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
t. rig
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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-
AG. Volkswagen AG d
agen oes
olksw not
y V gu
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pt
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itte
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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
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
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
wage the
n AG does
vehicle will slip off the lifting platform! by
Vol not
gu
ara
ed nte
ris
tho eo
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– Turn wheel hub until one of the wheel sbolt
s holes is at the top. c
ce
le
un
pt
an
d
itte
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rm
Respective nuts and bolts may be tightened only when dimension
ab
pe
ility
-a- between the centre of wheel hub and edge of wheel housing
ot
wit
has been attained.
, is n
h re
hole
spec
ning gear:
es, in part or in w
t to the co
rrectness of i
l purpos

wheels (2UC)
nform
ercia

m
wheels (G02/G07/2UC)
a
com
tion in
CrossGolf (2UB) 400 ± 10 mm
r
te o
thi
BlueMotion (G06) 373 ± 10 mm
s
iva
do
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fo
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op py
number. Which PR. No. refers to which running gear can be found . C rig
ht ht
here ⇒ page 317 .
rig by
copy Vo
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cted
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
agen oes
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Caution by Vol
gu
ara
d
rise nte
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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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nl
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hole
spec
1 - Nut
es, in part or in w
t to the co
❑ 65 Nm
❑ When tightening, coun‐
ter hold on hexagon
rrectness of i
socket of joint stub.
l purpos
❑ Self-locking
❑ Always renew after re‐
nf
ercia
moving
orm
m
2 - Coupling rod
atio
om
n in
❑ Link between anti-roll
or c
bar and suspension
thi
te
sd
a
strut
iv
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3 - Bracket
f
en
ng
t.
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❑ Fixing position t. Cop py
⇒ page 17
rig
gh ht
pyri by
Vo
❑ If bracket is renewed,
co lksw
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cted agen
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,
en AG. axles,
V steering
olkswagen AG
d
- Edition 08.2009
wa oes
olks not
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8 - Front left vehicle level sender -G78- ed
b ara
nte
ris
❑ Removing and installing ⇒ page 15 tho eo
au ra
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
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rm
❑ 9 Nm
ab
pe
ility
ot
10 - Suspension link
wit
, is n
h re
❑ 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
nform
ercia
11 - Suspension link
m
a
❑ Different versions of suspension links are possible (welded steel sheet, single-shell steel sheet).
com
tion in
r
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thi
s
iva
do
Note
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❑ If damaged, also renew swivel joint. t. Cop py
rig
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pyri by
Vo
co
❑ 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
ua
ed ran
❑ Always renew after
hor removing
is tee
t or
au ac
20 - Bracket for skid
ss plate
ce
le

un
pt
an
d
itte
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21 - Bolt
rm
ab
pe
ility
Always observe size and strength class of the bolt. Different torque specifications apply.
ot
wit
, is n
h re
❑ M10 x 75 strength class 8.8: 40 Nm and turn 90° further
hole
spec
es, in part or in w
t to the co
Caution
From model year 08,
rrectness of i
HeliCoil inserts are in‐
l purpos
stalled in the pendulum

support connection in
the 02Q gearboxes.
nform
ercia
Identification ⇒ Rep. Gr.

34
m
a
com
tion in
Use a bolt with hardness
r
te o
thi
class 10.9 for this and all
s
iva
do
other gearboxes.
r
rp
cum
fo
en
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If there is no HeliCoil in‐

n
t.
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op
sert in the 02Q gearbox, C py
t. rig
use bolts with the
gh ht
yri by
strength class 8.8 and
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 by Vo gu
ara
use bolts with the orise nte
strength class 8.8 and th eo
au ra
the corresponding tor‐ ss c
que setting.
ce
le
un
pt
an
d
itte
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erm
ab
ility
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wit
23 - Bracket to pendulum support
is n
h re
ole,
❑ Not an individual part
spec
24 - Pendulum support
t to the co
❑ Bolt first to gearbox and then to subframe
❑ Various versions
rrectne
25 - Lower bonded rubber bush for pendulum support
ss o
❑ Pressing out and in for vehicles with front-wheel drive ⇒ page 28
cial p
f inform
❑ Pressing out and in for vehicles with four-wheel drive ⇒ page 31
mer
atio
m
26 - Shield
o
n
c
i
or
n
❑ For vehicles with front-wheel drive only
thi
te
sd
va
27 - Bolt
i
o
pr
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r
fo
❑ 6 Nm
en
ng
t.
yi Co
❑ Self-locking t. Cop py
rig
gh ht
yri
28 - Subframe p by
co Vo
by lksw
cted agen
Prote AG.
❑ 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
agen oes
not
Vo
❑ 9 Nm d by gu
ara
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3 - Front left vehicle level send‐ auth
ra
er -G78- and front right vehicle ss c
ce
level sender -G289-

le
un
pt
an
d
❑ Complete with attach‐

itte
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ments
rm
ab
pe
ility
❑ Lever -arrow- must face

ot
wit
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outwards
h re
hole
❑ Removing and installing

spec
⇒ page 15
es, in part or in w
t to the co
❑ Following renewal, ba‐

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

l purpos
"Guided fault-finding" function

of vehicle diagnosis, testing
and information system
nform
ercia
VAS 5051
m
a
com
tio
4 - Suspension link
n in
r
te o
thi
5 - Nut
s
iva
do
r
❑ 9 Nm
rp
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fo
en
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❑ Self-locking
n
t.
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op
C py
t. rig
gh
moving
ht
pyri by
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co lksw
by
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
AG. Volkswagen AG d
agen oes
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Note byV
ol not
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ise nte
or
To remove front left vehicle level sender -G78-ut , steering must be
h eo
a ra
turned to right lock to ensure clearance between
ss suspension link c
and anti-roll bar.
ce
le
un
pt
an
d
itte
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rm
– Separate connector.
ab
pe
ility
ot
– Remove bolt and nut.
wit
, is n
h re
– Take out vehicle level sender.
hole
spec
es, in part or in w
Installing
t to the co
Install in reverse order. Note the following points:
rrectness of i
Note
l purpos
♦ Lever on vehicle level sender must face towards outside of

nform
ercia
vehicle.
m
♦ Thread of vehicle level sender must be screwed into front hole

a
com
tio
in suspension link. Lug of bracket for vehicle level sender must

n in
r
engage in rear hole in order to guarantee correct installation

te o
thi
position.
s
iva
do
r
rp
cum
fo
en
– Perform basic setting of headlights ⇒ "Guided fault-finding"

ng
t.
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function of vehicle diagnostic, testing and information system Cop py
VAS 5051
ht. rig
rig ht
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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
db
y conditions ⇒ Body Repairs; Rep. ara Gr.
nte
50 . tho
ris eo
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
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wit
♦ Locating pins -T10096-
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
♦ Engine and gearbox jack -V.A.G 1383 A- thi

te
sd
iva
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f
en
ng
t.
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Cop py
t. rig
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pyri by
Vo
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by c lksw
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
en AG. Vyear 2008
olkswagen AG
does
⇒ page 369 . yV
olksw not
g b ua
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
du
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
h re
Removing locating pins -T10096-
hole
spec
Remove in reverse order. Ensure that the locating pins -T10096-
es, in part or in w
are replaced one after the other with new bolts. t to the co
Specified torques
rrectness of i

l purpos
Subframe to body 70 Nm + 90°

♦ Use new bolts
nf
ercia
orm
Bracket to body 70 Nm + 90°

m
atio
m
♦ Use new bolts

o
n in
or c
thi
e
Mounting bracket to body

t
70 Nm + 90°
sd
iva
♦ Use new bolts

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Cop py
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rig ht
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3.6 Lowering subframe
co Vo
by lksw
cted agen
Prote AG.

♦ Engine and gearbox jack -V.A.G 1383 A-

lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss
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e
nl
pt
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itte
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erm
ab
ility
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wit
, is n
h re
hole
spec
es, in part or in w
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.
l purpos
– Remove footwell trim by removing nuts -arrows-.
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
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f
en
ng
t.
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Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
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-.
AG. Volkswagen AG d
agen oes
olksw not
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d b ara
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tho eo
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ss c
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nl
pt
du
an
itte
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erm
ab
– Disconnect pendulum support from gearbox by removing bolts
ility
ot p
-14-.
wit
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h re
– Disconnect coupling rods from anti-roll bar.
hole
spec
es, in part or in w
– Fixing subframe in position ⇒ page 16
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
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Cop py
t. rig
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– Position engine and gearbox jack -V.A.G 1383 A- under sub‐ cop Vo
by lksw
frame. 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 V o gu
ara
⇒ Engine; Rep. Gr. 26 orise
d
nte
th eo
au ra
ss c
ce
e
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
From model year 08, HeliCoil inserts are installed in the pen‐
hole
spec
dulum support connection in the 02Q gearboxes. Identification

es, in part or in w
⇒ 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

l purpos
the strength class 8.8 and the corresponding torque setting.

nf
ercia
or
Bolt Specified torque

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

o
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or c
♦ Use new bolt

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♦ Use new bolt

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Rep. Gr.40 - Front suspension Prote AG.

♦ Use new bolt
AG. Volkswagen AG d
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M10 x 75 strength class 10.9 by
Vol
50not
Nm
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ara
♦ Use new bolt rised
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un
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an
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3.7 Removing and installing subframe with‐ itte
y li
rm
ab
out steering box
pe
ility
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es, in part or in w
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rrectness of i
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nform
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tion in
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te o
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Cop py
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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. AG. Volkswagen AG d

agen oes
olksw not
– Remove heat shield from subframe. d by
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ara
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Continuation for all vehicles ut
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s
– Remove coupling rods from anti-roll bar.
ce
le
un
pt
an
d
itte
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rm
ab
pe
ility
ot
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, is n
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hole
spec
es, in part or in w
t to the co
-14-.
rrectness of i
– Fix position of subframe ⇒ page 16 .
l purpos
– Now unscrew bolts for:

♦ steering box -3- and -6-
nform
ercia
♦ anti-roll bar -11- and -16-

m
a
com
tion in
♦ and subframe -4- and -5-.
r
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s
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Installing
do
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fo
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– Install noise insulation and tighten, specified torque ⇒ General Cop py
t. rig
body repairs, exterior; Rep. Gr. 50 ; Assembly overview - gh ht
yri by
noise insulation .
op Vo
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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
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ut or
ss
a class 10.9 for this and all other gear‐ ac
boxes.
ce
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un
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an
d

itte
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is n
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spec
t to the co
♦ Use new bolt

rrectne
♦ Use new bolt
s

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♦ Use new bolt

f inform
mer

atio
m
♦ Use new bolt

o
n
c
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or
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3.8 Removing and installing subframe with

en
ng
t.
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op
steering box
C py
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Prote AG.
♦ Ball joint puller -3287 A-

Golf 2004 ➤ , Golf Plus 2005 ➤ agen
AG. Volkswagen AG d
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Running gear, axles, steering - Edition 08.2009 olksw not
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♦ Torque wrench -V.A.G 1332- aut
ho eo
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pe
ility
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hole
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es, in part or in w
t to the co
rrectness of i
Removing l purpos
– Remove battery and battery tray ⇒ Electrical system; Rep.
nform
ercia
Gr. 27 ; Battery; Removing and installing battery .

m
a
– Disconnect cable -1- from electrics box.
com
tion in
r
te o
thi
s
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do
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cum
fo
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Cop py
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rig ht
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co Vo
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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.

AG. Volkswagen AG d
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olksw not
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ce
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un
pt
an
d
itte
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erm
ab
ility
ot p
wit
is n
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ole,
spec
t to the co
– Remove front wheels.
rrectne
– Separate connector for extended service intervals on oil sump.
ss o
cial p
f inform
– Detach coupling rods from anti-roll bar.
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
c
um
r
fo
en
ng
t.
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– Loosen nut on track rod ball joint but do not remove complete‐
Co
op py
ly.
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ht ht
rig by
py
Leave nut screwed on a few turns to protect thread on pin.
co Vo
by lksw
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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
le
un
pt
– Fix position of subframe with brackets. ⇒ page 16
an
d
itte
y li
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
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
– Place engine and gearbox jack -V.A.G 1383 A- under sub‐
r
rp
cum
frame.
fo
en
ng
t.
yi Co
– Place a wooden block -1- or similar between V.A.G 1383 A t. Cop py
and subframe.
rig
gh ht
pyri by
Vo
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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
wage es n
Exhaust system bracket to y Vsubframe
olks ot g
ua
⇒ Engine; Rep. Gr. r26 ise
d b ran
tee
tho
u or
a ac
ss
ce
le
un
pt

an
d
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pe
Caution
ility
ot
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, is n
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hole
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es, in part or in w
⇒ Rep. Gr. 34 .
t to the co
boxes.
rrectness of i

l purpos

nform
ercia

m
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com

ion in
♦ Use new bolt

r
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♦ Use new bolt

en
ng
t.
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Cop py
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27
by lksw
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Prote 3. Subframe, anti-roll bar, suspension link
AG.

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M10 x 75 strength class 8.8 yV
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40 Nmot g + 90° further
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M10 x 75 strength class 10.9 ss
a
50 Nm + 90° further ac
♦ Use new bolt
ce
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un
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ab
ility
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3.9 Repairing subframe (front-wheel drive)
is n
h re
ole,
spec
t to the co
equipment required
♦ Removal tool -3372-
rrectne
♦ Assembly tool -T10214-
s
s o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
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t.
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Cop py
t. rig
gh ht
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Vo
co lksw
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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
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The subframe must lie against the large internal db
y diameter
Vo of gu
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tube -T10244/3-. rise nte
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Pressing in bonded rubber bush
ce
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un
pt
an
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itte
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erm
ab
ility
ot p
wit
is n
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ole,
spec
– Bolt bonded rubber bushes together using original bolt, mak‐
t to the co
ing sure that both notches -arrows- line up precisely.
rrectness o
cial p
f inform
mer
atio
om
n
c
i
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n thi
te
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fo
– Insert assembled bonded rubber bushes with bolt head down‐
en
ng
t.
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wards into tube -T10214/2- .
Co
Cop py
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gh
1- Thrust piece -T10214/3-
ht
pyri by
Vo
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by
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
wage does
Volks not
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th
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ility
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hole
spec
es, in part or in w
t to the co
rrectness of i
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• 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
nform
ercia
area of the opening for the pendulum support.

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

com
tion in
the subframe opening.

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

s
iva
do
able.
r
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cum
fo
en
g
– Install subframe ⇒ page 22 .

n
t.
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Cop py
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rig ht
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Prote AG.

3.10 Repairing subframe (four-wheel drive)

lkswage es n
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byV ua
d ran
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ss
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nl
pt
du
an
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ility
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hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
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rp
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m
f
en
ng

t.
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Cop py
– Remove subframe ⇒ page 21 .
t. rig
gh ht
pyri by
Vo
o
– Press out both bonded rubber bushes at the same time as
c 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-.

– 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
y V gu
d b ara
rise nte
tho eo
– Press in bonded rubber bushes -1- until dimension -a-
ss a is ob‐
u ra
c
tained.
ce
e
nl
pt
du
an
Dimension -a- = 2 - 3 mm.
itte
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erm
ab
ility
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wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
– Align tube -T10214/2- with pressed-in bonded rubber bushes

on subframe. Corners of inner core should be parallel to edge
nf
ercia
of assembly tool -T10244- .

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

t
sd
iva
-T10244/3-.
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
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.
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au 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
• The notches in the bonded rubber bushes must be centred in

the subframe opening.
nform
ercia
• A gap -arrow- between the bonded rubber bushes is accept‐

able.
m
a
com
tio
– Install subframe ⇒ page 22 .
n in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
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Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
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- n AG. Volkswagen AG do
lkswage es n
o ot g
yV
♦ Engine and gearbox jack - ir se
d b ua
ran
V.A.G 1383 A- tho tee
or
au ac
♦ Torque/angle wrench - ss
ce
le
V.A.G 1756-
un
pt
an
d
itte
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erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
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Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
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
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lksw not
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o gu
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♦ Place engine and gearbox jack -V.A.G 1383 A-s aor
ut similar un‐
h
ra
c
derneath (danger of accident through falling parts when swivel s
ce
le
joint is pressed out).

un
pt
an
d
itte
♦ Leave nut screwed on a few turns to protect thread on swivel
y li
erm
ab
joint.
ility
ot p
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is n
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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
rrectne
key.
ss o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
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pr
cum
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fo
en
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Cop py
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rig ht
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co Vo
by lksw
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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
AG. Volkswagen AG d
agen oes
ksw
Swivel joint to wheel bearing housingby V ol not
gu
ara
60 Nm
♦ Use new nut rise
d
nte
tho eo
au ra
Drive shaft to wheel hub “hexagon
ss bolt” 200c Nm +180°
♦ Use new bolt
ce
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un
pt
an
d
itte
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Drive shaft to wheel hub “12-point bolt” 70 Nm + 90°

rm
ab
♦ Use new bolt

pe
ility
ot
wit
, is n
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hole
spec
es, in part or in w
3.13 Removing and installing suspension link

t to the co
with mounting bracket

rrectness of i

l purpos

nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c
ce
le
un
pt
an
d
itte
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rm
Removing
ab
pe
ility
ot
– Remove wheel.
wit
, is n
h re
– Remove lower noise insulation ⇒ Rep. Gr. 50 ; Assembly
hole
spec
overview - noise insulation .
es, in part or in w
t to the co
– Pull swivel joint out of suspension link.
rrectness of i
– Fixing position of mounting bracket ⇒ page 17 .
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi
– Replace bolt for left side -1- and for right side -8- with locating
Co
op py
pins -T10096- and tighten locating pins to 20 Nm.
t. C rig
gh ht
pyri by
Vo
o
by c 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 d b ➤
y gu
ara
ise nte
thor - Edition 08.2009 eo
au ra
ss c
– Remove bolts -1-.
ce
le
un
pt
an
d
– 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 o
– Start bolts -10- and -17-, but do not yet tighten.
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
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Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
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 .
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
c
Specified torques ss
ce
le
un
pt
an
d
itte
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rm
ab
Mounting bracket to bracket 50 Nm + 90°
pe
ility
♦ Use new bolts
ot
wit
, is n
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Mounting bracket to body 70 Nm + 90°
hole
spec
♦ Use new bolts
es, in part or in w
t to the co
♦ Use new nuts
rrectness of i
l purpos
link
♦ Use new nuts nform
ercia
Suspension link to bracket 70 Nm +180°

m
♦ Use new bolt

com
tion in
♦ Tighten bolt in unladen state

r
te o
thi
s
iva
do
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cum
fo
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ng
t.
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3.14 Removing and installing suspension link Cop py
t. rig
gh ht
with mounting bracket (left side for ve‐ pyri by
Vo
co lksw
by
hicles with DSG or automatic gearbox‐
cted agen
Prote AG.
es)

AG. Volkswagen AG d
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olksw not
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ce
Removing
e
nl
pt
du
an
itte
– Remove left front wheel.
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erm
ab
ility
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es, in part or in w

– Remove bolts -arrows- on heat shield. t to the co
rrectness of i
– Remove heat shield from subframe.
l purpos
Continuation for all vehicles

nform
mercia
at
om
ion
c
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or
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ate
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for
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Cop py
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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 .
AG. Volkswagen AG d
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es, in part or in w
t to the co
rrectness of i
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nf
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orm
m
atio
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c
– Loosen bolt -17-.

or
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♦ anti-roll bar -11- and -16- Cop py
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♦ subframe on right side -5- and -12-. p by
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.
Prote AG.

– 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
agen oes
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– Install lower noise insulation ⇒ General
ised b body repairs, exterior; ara
nte
Rep. Gr. 50 ; Assembly overview hor - noise insulation . eo
aut ra
s c
– Install wheel and tighten ⇒spage 288 .
ce
le
un
pt
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d
itte
Specified torques
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ility
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is n

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♦ Use new bolts

spec
t to the co

♦ Use new bolts
rrectne

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

cial p
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♦ Use new bolts

form
mer
atio
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♦ Use new bolts

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♦ Use new nuts

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♦ Use new bolts



♦ Use new bolts
boxes

Caution
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gen AG d
From model yearV08, olks HeliCoil inserts are installed
wa oes
not in the pen‐
dulum support edconnection
by in the 02Q gearboxes. Identification
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⇒ Rep. Gr.
thoris34 . nte
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au ra
Use a bolt
ss with hardness class 10.9 for this and all other gear‐
c ce
boxes.
le
un
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itte

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spec

t to the co
♦ Use new bolt

rrectne
♦ Use new bolt

ss

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♦ Use new bolt

inform
mer

atio
m
♦ Use new bolt

o
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c
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3.15 Removing and installing suspension link

t.
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op py
with mounting bracket (right side for ve‐
t. C rig
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hicles with 6-cylinder engines)
co Vo
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Removing n AG. Volkswagen AG do

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– Remove wheel. d byV ua
ran
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o
– Remove lower noise insulation au ⇒ Rep. Gr. 50 ; Assembly
th or
ac
overview - noise insulationss.
ce
le
un
pt

an
d
itte
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– Pull swivel joint out of suspension link.

rm
ab
pe
ility
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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
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
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cum
fo
en
ng
t.
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Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
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Prote AG.

– Loosen bolt -10-.

– Remove coupling rods from anti-roll bar.
♦ and subframe -4- and -5-.
– Lower subframe until bolt -10- can be unscrewed completely.
AG. Volkswagen AG d
agen oes
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y V gu
d b ara
rise nte
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– Unscrew bolts -1- and remove suspension link with bracket. ss
ce
le
un
pt
Installing
an
d
itte
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rm
ab
– Insert suspension link with mounting bracket into subframe.
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
– Start bolts -7- and -10-, but do not yet tighten.

nform
ercia
– Raise subframe back to its original position.

m
– Now replace locating pins -T10096- at positions -1-, -8-, -9-

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

s
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– Tighten bolts -7-.

fo
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t.
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Cop py
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Running gear, axles, AG. Volksw- aEdition
gensteering
gen AG
do08.2009
swa k es not
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d by ara
– Bolt suspension ris link to
e swivel joint and tighten -arrows-. nte
utho eo
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rm
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ility
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, is n
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hole
spec
es, in part or in w
t to the co
rrectness of i
– Bolt suspension link to bracket in unladen state -10-.
l purpos
– Bolt coupling rods to anti-roll bar.

– Attach lower noise insulation ⇒ Rep. Gr. 50 ; Assembly over‐
nform
ercia

m
a
com
t
ion in
r
te o
thi
s
iva
do
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cum
fo
en
ng
t.
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Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
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


♦ Use new bolt

♦ Use new bolts
boxes

wage
3.16 Renewing bonded rubber bush for suspension link lks es n
o ot g
byV ua
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equipment required
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nl
pt
du
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♦ Tube -T10219/1-
itte
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erm
ab
♦ Drift -T10219/2-
ility
ot p
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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
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
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Cop py
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by
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Prote AG.


– 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
agen oes
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un
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itte
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pe
ility
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wit
, is n
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hole
spec
es, in part or in w
– 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
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
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– Press bush back slightly in the suspension link.

en
ng
t.
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op py
1- Tube -T10219/1- t. C rig
gh ht
pyri by
co Vo
by lksw
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Prote AG.

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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ss
ce
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erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
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pr
cum
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fo
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t.
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Cop py
t. rig
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co lksw
by
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Prote AG.

♦ Tube -VW 418 A-
Pressing mounting bracket with bush

gen AG
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lkswsuspension
agen AG
d
link
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The bonded rubber bush by is available as a replacement part
Vo t gu
ara only
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ir sthe nte
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ut or
– Press mounting
ss
a bracket with bonded rubber bush off suspen‐ac
sion link.
ce
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un
pt
an
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rm
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Note
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ility
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Hold suspension link when pressing off.

h re
hole
spec
es, in part or in w
1- Thrust plate -VW 401- t to the co
2- Guide -VW 439-

rrectness of i
Pressing in mounting bracket with bush onto suspension link

l purpos
– Moisten hexagon flats of suspension link with assembly lubri‐

cant -G 294 421 A1- diluted 1:20.
nform
mercia
– Carefully press bush onto suspension link to stop.

com
tion in
r
1- Tube -VW 418 A-

te o
thi
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do
2- Bearing bracket with bonded rubber bush.

r
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3- Suspension link
n
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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
lkswage es n
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♦ Ball joint puller -3287 A- ed by V ua
ran
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d
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erm
ab
ility
ot p
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is n
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ole,
spec
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
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pr
cum
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fo
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ng
t.
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Cop py
t. rig
gh ht
pyri by
Vo
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by
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Prote AG.
Removing

– Detach coupling rods from anti-roll bar.

– Loosen nut on track rod ball joint on each side but do not re‐
move completely.
lkswage es n
o ot g
– Press track rod ball joint off wheel bearingd bhousing
yV using ball ua
ran
joint splitter -3287A-. o
ir se tee
th or
u
– Fixing position of subframe with bracket
ss
a ⇒ page 16 . ac
ce
e
nl
pt
du
an
itte
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erm
ab
ility
ot p
wit
, is n
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hole
spec
es, in part or in w
t to the co
– Unbolt anti-roll bar from subframe -11 and 16-

rrectness of i
.
l purpos

-14-.
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

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

frame.

AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
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
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
– Now lift anti-roll bar -1- forwards over bracket -2- and down
from subframe.
nf
ercia
or
Installing
m
m
atio
om

n in
or c
thi
te
sd
iva
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Note
rp
cu
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f
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t.
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♦ Coat seal on steering box with suitable lubricant, e.g. soft Cop py
t.
soap, before installing steering box.
rig
gh ht
pyri by
Vo
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♦ After fitting the steering box to the jointed shaft, ensure that
lksw
cted agen
Prote
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
agen oes
Anti-roll bar to coupling rod olksw 65 Nm not
yV gu
♦ Use new nut ed b ara
nte
ris
o eo
♦ Counterhold on multi-point socket of joint pin aut
h
ra
ss c
ce
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un
pt
an
d
♦ Use new bolts

itte
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erm
ab
ility
ot p
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♦ Use new bolt
is n
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ole,
spec
t to the co
♦ Use new bolts
rrectne
boxes
ss
o
cial p
f
♦ Use new bolt
inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
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pr
cum
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fo
Caution
en
ng
t.
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Cop py
ht. rig
rig ht
by
dulum support connection in the 02Q gearboxes. Identification copy Vo
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.
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
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a ac
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
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hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
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rp
cu
o
m
f
en
ng
t.
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Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
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Prote AG.

AG. Volkswagen AG d
agen oes
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Golf 2004 ➤ , Golf Plus by
V 2005 ➤
ol not
gu
d ara
orise steering - Edition 08.2009 nte
h eo
aut ra
ss c
4 Assembly overview - wheel bearing
ce
e
nl
pt
du
an
itte
y li
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
nf
ercia
parts catalogue “ETKA”
orm
m
atio
2 - Wheel hub with wheel bear‐
om
n in
ing (3-point mounting) - FS III
or c
brakes
thi
te
sd
iva
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r
rp
cu
⇒ page 57
o
m
f
en
ng
t.
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❑ The ABS sensor ring is
Co
op py
installed in the wheel
t. C rig
gh ht
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hub p by
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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
olksstanding
wagen A on its wheels G do
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14 - Bolt by
V ua
ed ran
❑ Torque setting ⇒ Brake oris
systems; Rep. Gr. 46 ; Repairing front brake .tee o
th
au ra
c
15 - Wheel hub with wheel (4-point mounting) bearing
ss
ce
le
un
pt
an
d
itte
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❑ The ABS sensor ring is installed in the wheel hub
erm
ab
ility
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is n
h re
ole,
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 .
rrectne
s
s o
cial p
f
❑ M12 x 1.5 x 45
inform
mer
atio
m

o
n
c
i
or
n
18 - Drive shaft
thi
te
sd
va

i
o
pr
cum
r
fo
en
ng
19 - Nut yi
t.
Co
op
❑ M12 x 1.5
C py
ht. rig
rig ht
❑ 70 Nm + 90° further py by
co Vo
by lksw
cted
❑ Self-locking
agen
Prote AG.
4.1 Removing and installing wheel bearing

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

Removing
Note
AG. Volkswagen AG d
agen oes
lksw not
During this step, vehicle must dnot by be standing on its wheels or
Vo gu
ara
wheel bearing will be damaged.orise nte
eo
h
aut ra
ss c
– Remove wheel.
ce
le
un
pt
an
– Remove brake caliper and hang from body using wire ⇒ Brake
d
itte
y li
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-.
rrectne
– Take wheel bearing unit out of wheel bearing housing.
ss
Installing
o
cial p
f inform
mer
atio
m
– Install brake caliper ⇒ Brake systems; Rep. Gr. 46 ; Repairing

o
n
c
front brake .
i
or
n thi
te
sd

iva
o
pr
cum
r

fo
en
ng
t.
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♦ Twelve-point bolt ⇒ page 78 Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
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- 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
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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
Removing
rrectness of i
l purpos

nf
ercia
orm
m
atio
m
Note
o
n in
or c
thi
e

t
sd
iva
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rp
cu
o
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f
en
ng
t.
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– Remove wheel.
Co
Cop py
ht. rig
rig ht
py by
o Vo
system; Rep. Gr. 46 ; Repairing front brake . by c lksw
cted agen
Prote AG.
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
byV gu
ara
ed
ris nte
Drive shaft to wheel hub “12-point bolt” utho
70 Nm + e90° or
♦ Use new bolt ss
a ac
ce
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nl
pt
du
an
itte
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♦ Use new bolts
erm
ab
ility
ot p
wit
, is n
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hole
spec
4.3 Removing and installing wheel bearing housing
es, in part or in w
t to the co
equipment required
rrectness of i
♦ Ball joint puller -3287A-
l purpos

1332-
nform
ercia

m
at
om
i
V.A.G 1383 A-
on
c
in t
or
♦ Torque/angle wrench -
his
ate
V.A.G 1756-
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.

AG. VolkGolf
swage2004
n AG d ➤ , Golf Plus 2005 ➤
agen
VRunning
olksw gear, axles, steering
oes
no-t Edition 08.2009
y gu
db ara
ise nte
♦ Spreader -3424- tho
r eo
au ra
c
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
Removing
nf
ercia
o
rm
m
atio
m

o
n in
or c
thi
te
sd
iva
Note
o
r
rp
cu
o
m
f
en
ng
t.
yi
Co
op py
wheel bearing will be damaged. t. C rig
gh ht
pyri by
Vo
o
by c lksw
– Remove wheel. cted agen
Prote AG.
system; Rep. Gr. 46 ; Repairing front brake .
– Now remove backplate from wheel bearing housing.
ly.
joint splitter -3287A- and remove nut now.
gearbox).

lkswage es n
Vo ot g
Golf 2004 ➤ , Golf Plus d 2005 ➤
b y ua
ran
ir se
Running gear, axles,th steering - Edition 08.2009
o tee
or
au ac
ss
– 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
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
– Insert spreader -3424- into slot of wheel bearing housing.
nf
ercia
o
– Turn ratchet handle through 90° and detach from spreader
rm
m
-3424- .
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
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
ise nte
or eo
h
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
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
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 ut
ho eo
ra
a c
❑ Allocation ⇒ Electronic ss
ce
le
parts catalogue “ETKA” un
pt
an
d
itte
y li
2 - Bump stop
rm
ab
pe
ility
3 - Protective sleeve
ot
wit
, is n
h re
4 - Coil spring
hole
spec
es, in part or in w
⇒ page 76
t to the co
❑ Observe colour coding
rrectness of i
l purpos
Spring allocation via PR No.
These numbers are located on
nform
ercia
the vehicle data sticker.

m
a
com
t
❑ Surface of coil must not
ion in
be damaged.
r
te o
thi
s
iva
5 - Deep groove ball thrust
do
r
rp
c
bearing
um
fo
en
ng
t.
6 - Suspension strut mounting
yi Co
Cop py
❑ Note correct installation
t. rig
gh ht
yri
position ⇒ page 67
p by
o Vo
by c lksw
cted agen
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- aut
h 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
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c 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
ise nte
or eo
h
aut ra
ss c
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
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
a
com
t
aged.
ion in
r
te o
thi
s
iva
do
– Bolt swivel joint to suspension link again.
r
rp
cum
fo
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.
t. rig
gh ht
pyri by
Vo
o
by c 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 utho 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
Installation position of spring plate

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

-arrows- pointing forwards.
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

AG. Volk-sw
Edition
agen A 08.2009
n G do
wage es n
Volks ot g
Tighten hexagon bolts ed -arrows- for
by upper shock absorber uamount‐
ran
ing. oris tee
th 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
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
WARNING
nf
ercia
orm
m
atio
m

o
n in
c

or
thi
te
sd
iva

o
r
rp
under the vehicle for longer than necessary. cu

o
m
f
en
ng
t.
yi Co
Cop py
ht. rig
– Position suspension strut on wheel bearing housing. rig ht
py by
co Vo
by 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


AG. Volkswagen AG d
ksw
agen oes
not
ol
byV Running gear, gaxles,
ua steering - Edition 08.2009
ed ran
oris tee
h
– Remove nuts -arrows-.s aut or
ac
s
– Fit drive shaft in wheel hub.
ce
e
nl
pt
du
an
itte
– Fit wheel bearing housing with swivel joint in suspension link.
y li
erm
ab
ility
– Bolt swivel joint to suspension link.
ot p
wit
, is n
h re
hole
spec
Note
es, in part or in w
t to the co
rrectness of i
l purpos

nf
ercia
orm
m
atio
Note
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi
Co
Cop py
ht. rig
– Install wheel and tighten ⇒ page 288 . rig ht
py by
co Vo
by lksw
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
y V gu
d b ara
rise nte
tho eo
au ra
ss c
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
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 yV
olks es n
ot g
d b 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 joint to bend too far and be dam‐
a ac
aged.
ce
le
un
pt
an
d
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
rrectne
ss o
cial p

inform

mer
atio
om
n
c
i
or
n thi
e
– Separate threaded connection between wheel bearing hous‐

t
sd
iva
ing and suspension strut -arrow-.

pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
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.
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c
ce
le
un
pt
an
d
itte
y li
rm
ab
– Remove hexagon bolts -arrows- for upper shock absorber

pe
ility
mounting and remove suspension strut.

ot
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
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
yri by
72
op Vo
by c 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
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
Tighten hexagon bolts -arrows- for upper shock absorber mount‐
es, in part or in w
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 .
l purpos
– Install centre section of bulkhead ⇒ Rep. Gr. 50 ; Assembly

overview - plenum chamber bulkhead .
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
yri by
WARNING
op Vo
by c 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
tho eo
au ra
– Tighten threaded connection between
ss wheel bearing housing c
and suspension strut -arrow-
ce
le
un
pt
an
d
itte
y li
erm
ab
WARNING
ility
ot p
wit
is n
h re
ole,
spec
t to the co
rrectnes
s o
cial p
f i
– Fit drive shaft into wheel bearing.
nform
mer
– Fit wheel bearing housing with swivel joint in suspension link.
atio
om
n
– Bolt swivel joint to suspension link.
c
i
or
n thi
te
sd
iva
o
pr
c
Note
um
r
fo
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- s au 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
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c 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 rise nte
tho eo
au ra
– Compress coil spring -V.A.G 1752/1- withs spring compressor
s 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
om
ion
c
in t
or
his
ate
do
priv
c
– Ensure that coil spring is seated correctly in spring retainer -
um
for
V.A.G 1752/4- -arrow-.
en
ng
t.
yi Co
op py
– Unscrew hexagon nut from piston rod. t. C rig
gh ht
pyri by
– 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
olk not
yV gu
edb ara
ris nte
WARNING tho eo
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
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
Wheel bearings must not be subjected to load after bolt securing
ht. rig
rig ht
by
drive shaft to wheel hub has been loosened. copy Vo
by 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

lkswage es n
o ot g
– Remove hexagon bolt -arrow-. d byV ua
ran
ir se tee
Tightening hexagon bolt autho
or
ac
ss
– Renew hexagon bolt.
ce
le
un
pt
an
d
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.
rrectne
– Lower vehicle onto its wheels.
ss o
– Turn hexagon bolt 180° further.
cial p
f inform
mer
6.2 Loosening and tightening 12-point
atio
om
flange bolt securing drive shaft
n
c
i
or
n thi
te
sd
a

iv
o
pr
cum
r
fo
♦ Socket, 24 mm -T10361-
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

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


Loosening 12-point bolt
wage es n
– To avoid damage to wheel bearing, yV
o do not loosen 12-point bolt
lks ot g
ua
using 24 mm socket -T10361- ir se
d further than 90° with vehicle still
b ran
standing on its wheels. utho tee
or
s a ac
s
ce
le
un
pt
an
d
itte
y li
erm
ab
– Remove 12-point bolt -arrow-.
ility
ot p
wit
Fitting 12-point bolt
is n
h re
ole,
– Renew 12-point bolt.
spec
t to the co
Note
rrectne
aged.
ss o
cial p
f in
form
mer
atio
– Tighten 12-point bolt to 70 Nm.
om
n
c
i
or
n
thi
te
sd
va
– Turn 12-point bolt 90° further.

i
o
pr
cum
r
fo
en
ng
t.
yi
6.3 Removing and installing drive shaft with
Co
Cop py
t. rig
constant velocity joint
gh ht
pyri by
Vo
co lksw
by
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.
Installing olkswage es n
ot g
byV ua
Remove any paint ir seresidue and/or corrosion on thread and asplines
d r n
tee
of outer joint.autho
or
ac
ss
– Insert drive shaft.
ce
le
un
pt
an
d
– 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 o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
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 will be damaged.
b gu
ara
n
ri tee
ho
ut or
– Install
ss
a
wheel and tighten ⇒ page 288 . ac
ce
le
un
pt
an
Specified torques
d
itte
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erm
ab

ility
ot p
wit
is n

h re
ole,
♦ Use new nuts

spec

t to the co
link
♦ Use new nuts
rrectne

♦ Use new bolt
ss o
cial p

inform
♦ Use new bolt

mer
atio
om
Drive shaft to flange shaft on gearbox “M8 multi-point sock‐ 40 Nm

n
c
i
or
et” ♦ Initially tighten diagonally to 10 Nm.

thi
te
sd
♦ Use new bolts

iva
o
pr
cum
r
♦ Use new backing plates

fo
en
ng
t.
yi Co
op py
Drive shaft to flange shaft on gearbox “M10 multi-point 70 Nm
. C rig
ht ht
socket” ♦ Initially tighten diagonally to 10 Nm.
rig by
opy Vo
♦ Use new bolts by c 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-
lkswage es n
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byV ua
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ir se 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
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
Removing
a
com
– Loosen drive shaft bolt at wheel hub ⇒ page 78 . tion in

r
te o
thi
s
iva
do
r
rp
Caution
cum
fo
en
ng
t.
yi Co
During this step, vehicle must not be standing on its wheels. Cop py
t. rig
gh ht
yri
The wheel bearing can be damaged by the weight of the vehi‐ p 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 prevent
au it from falling.
th ra
ss c
ce
le
un
pt
an
d
itte
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erm
ab
ility
ot p
wit
is n
h re
ole,
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 o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
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
n AG. Volkswaggrease
en AG -G
060 735 A2- lkswage does
not
Vo y gu
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– 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
wit
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Note
hole
spec
es, in part or in w
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.
l purpos
Caution
nform
ercia
For this check, pull only on constant velocity slip joint, not on
m
at
om
drive shaft.
on
c
in t
or
his
ate
do
riv
– Detach tensioning strap -T10038- .

p
cum
for
en
g

n
t.
yi Co
Cop py
t. rig
gh ht
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– Bolt swivel joint to suspension link -arrows-. p 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 ed b ara
nte
oris eo
th
Component ss
au
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
, is n
h re
♦ 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
nform
mercia
a
com
t
ion in
equipment required
r
te o
thi
s
iva
♦ Multi-purpose tool -VW
do
r
rp
c
771-
um
fo
en
ng
t.
yi
Co
Cop py
t. rig
♦ Drive shaft puller -T10382-
gh ht
pyri by
Vo
co lksw
by
♦ 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.
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
– Set up drive shaft puller -T10382- . ut
hor eo
a ra
s c
For the constant velocity slip joint -1-, notch -arrow- in the puller s
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
nform
mercia
a
com
tion in
r
te o
thi
– Using tensioning strap -T10038- e.g. on lifting platform arm,

s
iva
do
pull suspension strut with attachments back until the drive

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

en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
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.
AG. Volkswagen AG d
agen oes
olksw not
yV gu
– Detach tensioning strap -T10038- ed.b ara
nte
ris
ho eo
– Guide outer joint into wheel ahub
ut splines as far as possible. ra
c
ss
ce
e
nl

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

hole
spec
es, in part or in w
t to the co

– Tighten drive shaft bolt at wheel hub ⇒ page 78 .
rrectness of i
l purpos
Note
nform
ercia

m
at

om
ion
c
in t
or

his
ate
do
priv
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

♦ Use new bolt
6.6 Removing and installing drive shafts

with triple roller joint AAR2600i
lkswage es n
o ot g
byV ua
d ran
ir se 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
h re
hole
spec
es, in part or in w
t to the co
♦ Wedge -T10161-
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
. rig
Removing
t
gh ht
pyri by
Vo
co
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
agen oes
olksw not
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– Insert wedge -T10161- edbetween gearbox housing and tripleuara
b
nte
is
roller joint. ho
r eo
aut ra
– Press inner joints out of gearbox by striking wedge -T10161-
s c
ce
e
with a hammer.
nl
pt
du
an
itte
– Remove drive shaft.
y li
erm
ab
ility
Installing
ot p
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.
nform
ercia
Note
m
at
om
io

n
c
in t
or
his
ate
– Check that drive shaft is seated securely in gearbox by pulling

do
priv
on joint body against resistance of retaining ring.

um
for
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
hole
spec
es, in part or in w
t to the co
link
♦ Use new nuts
rrectness of i
♦ Use new bolt
l purpos
nform
ercia
♦ Use new bolt

m
at
om
ion
c
in t
or
his
te
6.7 Removing and installing drive shafts

a
do
priv
with triple roller joint AAR3300i

um
for
en
ng
t.
yi Co
op
Special tools and workshop equipment required C py
t. rig
gh ht
yri by
♦ Torque wrench -V.A.G 1332- cop 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‐d by Vo gu
ara
fied torque. orise nte
eo
th
u ra
– Install lower noise insulation. ⇒ Rep. Gr. 50 ; Assembly
ss a over‐ c
ce
le
un
pt
an
d

itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
Note
t to the co
rrectne
s
s o
cial p
f inform
Specified torques
mer
atio
m

o
n
c
i
or

thi
te
sd
a
♦ Use new nuts

iv
o
pr
cum
r
fo
en
Swivel joint to sheet steel or forged aluminium suspension

ng
yi 100 Nm t.
Co
link t. Cop py
♦ Use new nuts
rig
gh ht
pyri by
Vo
co lksw
by
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
is nte
Running gear, axles,thosteering
r - Edition 08.2009 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
hole
spec
socket” ♦ Initially tighten diagonally to 10 Nm.
es, in part or in w
♦ Use new bolts
t to the co
rrectness of i
6.8 Removing and installing intermediate
l purpos
shaft
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
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

. Volkswagen AG
bearing -2- contacts bearing w agen AG -1- without
bracket “gap”
does
ks not
-arrow-. Vol gu
by a
ed ran
ris tee
tho or
au ac
ss
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
– Tighten bolts -arrows- to prescribed torque.
– Install drive shaft ⇒ page 80 .
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
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Specified torques ht. Cop py
rig
rig ht
py by
co Vo
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
byV gu
ara
ed
is nte
7 Repairing drive shaft - overview of drive shafts or eo
h
aut ra
ss c
ce
le
un
pt
I - Assembly overview - drive
an
d
itte
y li
shaft with VL90 or VL100 con‐
erm
ab
stant velocity joint
ility
ot p
⇒ page 97
wit
is n
h re
II - Assembly overview - drive
ole,
spec
shaft with VL107 constant ve‐
locity joint (bolt-on)
t to the co
⇒ page 107
III - Assembly overview - drive
rrectne
shaft with VL107 constant ve‐
locity slip joint (push-on)
⇒ page 116
ss o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by 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
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss
ce
e
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
hole
VL90 VL100 VL107 (bolt- VL 107 (push- AAR2600i AAR3300i

spec
on) on)
es, in part or in w
t to the co
Diameter of 90 100 107 - - -

inner joint in
mm
rrectness of i
Cover be‐ - - X - - -
l purpos
tween inner
joint and drive
flange
nform
ercia
With bearing - - X - - X
m
at
bracket on
om
ion
right side
c
in t
or
his
e
Inner joint fit‐ - - - - X -

at
do
riv
ted in gearbox
p
cum
for
Inner joint - - - x - -
en
ng
t.
yi
pushed onto
Co
Cop py
stub shaft
t. rig
gh ht
pyri by
Vo
co lksw
by
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
yV t gu
db ara
ir se nte
ho eo
aut ra
ss c
ce
e
nl
pt
du
an
itte
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erm
ab
ility
ot p
wit
Four-wheel drive:
, is n
h re
hole
spec
es, in part or in w
t to the co
Nuts -1- 20 Nm
♦ Initially tighten all nuts to
10 Nm
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
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
❑ Checking ⇒ page 103 . Volkswagen AG
gen AG does
swa
2 - Bolt y Volk not
gu
db ara
❑ M16 x 1.5 x 80orise nte
eo
h
ut
❑ Hexagonssbolt, 200 Nm
a ra
c
and turn +180° further
ce
e
nl
pt
du
❑ 12-point bolt, 70 Nm +
an
itte
y li
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
nf
ercia
orm
m
5 - Boot
atio
om
❑ Check for splits and

n in
or c
chafing
thi
te
sd
iva
❑ Material: Hytrel (poly‐

o
r
rp
cu
ester elastomer)
o
m
f
en
ng
t.
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6 - Hose clip t. Cop py
rig
gh ht
pyri by
moving
o Vo
by c 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 agen
AG. Volkswagen AG d
oes
olksw not
14 - Multi-point socket head bolt byV gu
ara
ed
ris nte
❑ Initially tighten diagonally to 10 Nm and then
ut
h tighten diagonally to specified torque.
o eo
ra
s a c
s
M8 bolt: 40 Nm
ce
e
nl
pt
du
an
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
hole
❑ Remove and install with -VW 161- A.
spec
es, in part or in w
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
l purpos
❑ Pressing off ⇒ page 102

❑ Pressing on ⇒ page 102
nform
ercia

m
at
om
io
18 - Dished spring
n
c
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.

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
ise nte
or eo
h
aut ra
ss c
ce
e
nl
pt
du
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♦ Circlip pliers -VW 161 A-

1331-
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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

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– Install new retaining ring.

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Pressing off inner constant velocity joint ut
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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
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force for the clip will not be attained although the correct torque
t to the co
is applied.
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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. agen
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– Press in opposing balls one after the other; ethe d by original position gu
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– Fit new retaining ring into hub. ss c
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Removing h re
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soiled, and to check the running surfaces and the balls for wear
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– Press out joint body in direction of arrow.

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– Press balls out of cage.

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Note
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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 into place.
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– Swing ball hub into place by swinging hub out of cage as

t to the co
shown in figure -arrows-.

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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
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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
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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 lkswage es n
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18 - Cap o
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❑ Drive off carefully withssdrift
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M8 bolt: 40 Nm
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M10 bolt: 70 Nm
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21 - Hose clip
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22 - 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-
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– Pull constant velocity joint from drive shaft with puller -T10382- Prote
cted AG.
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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 AG. Volkswagen AG d

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– Remove retaining ring. ed by ara
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Pressing off inner constant velocity joint
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Assembling
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Installation position of dished spring at inner joint p by
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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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– Using bolts -arrows-, align new cover in relation to bolt holes.
mercia
The alignment must be very accurate, because no further align‐
a
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n in
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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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♦ Because a stainless steel hose clip is required due to the hard
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es, in part or in w
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Checking outer constant velocity joint ⇒ page 103
or
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Checking inner constant velocity joint ⇒ page 104

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Checking function of constant velocity joint ⇒ page 106 en

ng
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9.2 Repairing intermediate shaft

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Special tools and workshop yV
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♦ Thrust plate
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♦ Thrust piece -3118-
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♦ Separating device Kukko
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-15-2-
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Pressing off bearing

– Press bearing off intermediate shaft as shown in figure.
The jaws of the Kukko splitter -15-2- must be facing shaft.
1- Intermediate shaft with bearing
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-
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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
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⇒ page 118 spec

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5 - Dished spring
❑ Installation position
⇒ page 118
rrectness of i
6 - Clamp
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9 - Drive shaft
10 - Clamp
11 - Boot for constant velocity slip joint
12 - Circlip

AG. Volkswagen AG d
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13 - Clamp
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❑ 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
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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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Driving on inner constant velocity slip joint

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sure jaws of tool contact corners -arrows B- of hose clamp.
not cant pliers).
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terial of the joint boot (compared to rubber), it is possible to
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10.2 Checking outer constant velocity joint rrectness of i
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10. Assembly overview - drive shaft with VL107 constant velocity slip joint (push-on) 119
joint body.
– Swing segment of hub into square cage window.

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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
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11.1 Dismantling and assembling drive shaft with triple roller joint AAR2600i

equipment required
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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.

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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)

– If necessary, coat splines of drive shaft and triple roller spider
with lubricant paste G 052 142 A2.
roller joint.
– Tighten both hose clips with hose clip pliers -V.A.G 1275- .
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12 Assembly overview - drive shaft with triple roller joint AAR3300i
ara
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5 - Hose clip
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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
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12.1 Dismantling and assembling drive shaft with triple roller joint AAR3300i

equipment required
♦ Press tool -VW 408 A- agen
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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.
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rrectness of i

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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.

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To make it easier to insert the multi-point socket-head bolts when
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42 – Rear suspension
AG. Volkswagen AG d
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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
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♦ It is not permitted to weld or straighten load-bearing or wheel-

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♦ Bonded rubber bushes can be twisted only to a limited extent.

n in
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Therefore, you should only tighten the threaded connections

te o
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iva
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bearing housing is raised to unladen position, Golf

rp
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⇒ page 136 ; Golf Plus, CrossGolf ⇒ page 138 .

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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 d by gu
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V.A.G 1383 A-
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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:

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Standard running gear (2UA) 380 ± 10 mm swagen AG. V does
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Heavy-duty running gear (2UB) 400 ± 10 ed mm
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es, in part or in w
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BlueMotion (G04/2UC) 365 ± 10 mm
rrectness of i
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here ⇒ page 317 .

nf
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until dimension -a- is attained.

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♦ Do not leave the engine and gearbox jack under the ve‐
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– 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
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To simulate this position on the lifting platform, raise the axle on
one side using the engine and gearbox jack -V.A.G 1383 A- and
support -T10149- .

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 AG. Volkswagen AG d
agen
number. Which PR. No. refers to which running gear can be found Volksw
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– Raise wheel bearing housing using engine and gearbox
au
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mer
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139
AG.
2. Repairing rear suspension (front-wheel drive)
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3 Assembly overview: subframe, transverse link, track rod (front-wheel
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❑ For camber adjustment
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❑ Check wheel alignment
whenever this compo‐
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nent is loosened
⇒ page 305 .
l purpos
2 - Nut
❑ M12 x 1.5
nform
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❑ 95 Nm
m
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Golf ⇒ page 136 p by
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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
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3. Assembly overview: subframe, transverse link, track rod (front-wheel drive)
22 - Washer
23 - Bolt
Golf ⇒ page 136 AG. Volkswagen AG d
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3.1 Removing and installing rear axle

equipment required
1332-
♦ Engine/gearbox jack -
V.A.G 1383/A -
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Removing subframe with attachments

spec
– Remove wheels.
t to the co
– Removing coil springs ⇒ page 174

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

s o
wiring connection -1-.

cial p
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– Remove ABS speed sensor out of wheel bearing housing.

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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.
AG. Volkswagen AG d
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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.

AG. Volkswagen AG d
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– Now secure vehicle to hoist using tensioning straps -T10038

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Running gear,au axles, steering - Edition 08.2009 ac
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frame using universal gearbox mounting -V.A.G 1359/2- and
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– Unscrew bolt -1- or -2- on both sides.

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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

AG. Volkswagen AG d
Running agenaxles, steering
gear, - Edition
no 08.2009
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Shock absorber to wheel bearing housing 180 Nm
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♦ Use new bolts
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Handbrake cable to trailing arm
⇒ Brake systems; Rep. Gr. 46
rrectness of i
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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- . AG. Volkswagen AG d
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1 - Subframe uthor eo
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2 - Lower transverse link s
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❑ Renewing in vehicle
⇒ page 148
l purpos
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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
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ss of vehicle diagnosis,
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Specified torques
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Rear left vehicle level sender -G76- to lower transverse link 5 Nm
hole
spec
and subframe
es, in part or in w
3.4 Removing and installing upper trans‐ t to the co

rrectness of i
verse link
l purpos

nf
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Removing
– Remove wheel.
– Remove coil spring ⇒ page 173 .
– Unhook speed sensor line -arrow A- from upper transverse

link.
– Remove bolt -1-.
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– Mark position of eccentric bolt -arrow- relative to subframe us‐
ss
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Installing
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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.
rrectne
Golf ⇒ page 137
ss
o
cial p
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– Bolt upper transverse link to subframe and tighten new nut to
mer
specified torque.
atio
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n
c
– Observe mark made for position of eccentric bolt -arrow- rel‐
i
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– 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
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– Remove wheel. orise nte
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– Remove coil spring. ⇒ page 173 . ss a c
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– Remove bolt -arrow- for lower transverse link -1-.

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Vehicles with dynamic headlight range control

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Golf 2004 ➤ , Golf Plus 2005 n➤
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– Remove bolts -1- from
tho lower transverse link. or
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Continuation for all vehicles s
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– Disconnect and lower rear part of exhaust system.
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– Remove lower transverse link.
es, in part or in w
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Installing
– Install lower transverse link on vehicle and tighten bolts hand
rrectness of i
tight.
l purpos
The transverse link may be bolted only when dimension “a” has
been attained ⇒ page 137 .
nform
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– Bolt upper transverse link to subframe and tighten new nut

m
at
-arrow- only to specified torque.
om
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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
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Removing rise
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– Remove wheel.
ss au ra
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– Remove nut -1- and pull coupling rod -2- out of anti-roll bar.
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– Remove bolt -arrow- for track rod -3-.

wit
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– Remove bolts -arrows- for anti-roll bar clamp.

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– 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

n AG. Volnew
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– Connect coupling rod -2- to anti-roll bar and tighten nut -1-. cop Vo
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AG. Volkswagen AG d Golf 2004 ➤ , Golf Plus 2005 ➤
agen Runningnot gear, axles, steering - Edition 08.2009
oes
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Specified torques hor eo
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Component s
Specified torque
ce
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un
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Track rod to wheel bearing housing 130 Nm + 90°
an
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spec
Track rod to subframe 90 Nm + 90°
t to the co
Anti-roll bar to subframe 25 Nm +45°
♦ Use new bolts
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s
s o
cial p
f inform
mer
♦ Use new nut
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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 AG. Volkswagen AG d
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5 - Bolt by Vo gu
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❑ 90 Nm +45° further rise nte
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❑ Observe tightening se‐ ss a c
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6 - Trailing arm
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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-
nform
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10 - Bonded rubber bush

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❑ Renewing ⇒ page 161

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11 - Nut
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AG.
Rep. Gr.42 - Rear suspension
AG. Volkswagen AG d
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13 - Brake disc s au ra
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14 - Grease cap
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❑ Pressing off and driving in ⇒ page 164
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15 - Bolt
es, in part or in w
❑ M16 x 1.5 x 70
t to the co
❑ Loosen and tighten with bit XZN 18 -T10162-
rrectness of i
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16 - Wheel hub with wheel bearing

❑ ABS sensor ring is installed in wheel bearing.
nform
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at
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The wheel bearing and wheel hub are assembled one housing.
n
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This wheel bearing/wheel hub unit is maintenance-free and has zero play. Adjustments and repairs are not
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18 - Backplate
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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
AG. Volkswagen AG d
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– Install bolts for track rod -1-, upper transverse link -2- and low‐
ot p
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wit
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– Attach coupling rod -arrow- to wheel bearing housing hand

spec
tight.
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Threaded connection for trailing arm and wheel bearing housing

may be tightened only after all other components (particularly the
spring and shock absorber) of respective wheel suspension have
been installed. To tighten, wheel suspension must be in extended
position. Only then do trailing arm and wheel bearing housing
move to the necessary position -arrows-.
It is important to keep to the specified sequence for the following
operations.
– Position trailing arm and mounting bracket on wheel bearing

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

– Install backplate.
– Install wheel bearing/wheel hub unit.
Bolt connections on wheel bearing housing may be tightened only
when dimension “a”swhas AG. Volkswagen AG
agenbeen obtained ⇒dopage
es 137 .
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– Tighten bolt for track rod -1-.

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– Tighten bolt for lower transverse link -3-.

ole,
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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
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Wheel bearing housing to lowerut suspension link 90
r a Nm + 90°
sa c
♦ Use new nuts and bolts s
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Wheel bearing housing to track rod 130 Nm + 90°

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

♦ Use new bolts
rrectne
Coupling rod to wheel bearing housing 45 Nm

ss
♦ Use new nut

o
cial p
f inform
Splash plate to wheel bearing housing 12 Nm

mer
atio
ABS speed sensor to wheel bearing housing 8 Nm

om
n
c
Shock absorber to wheel bearing housing

or
180 Nm
n thi
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Brake disc to wheel bearing housing. 4 Nm

iv
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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
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es, in part or in w
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at
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c
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Removing
at
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priv
cum
– Remove wheel.
for
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t.
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– Remove coil spring ⇒ page 173 . t. Cop py
rig
gh ht
– Remove wheel bearing/wheel hub unit ⇒ page 164 . yri
p by
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by c 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
or
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ss
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3- Press tool -30 - 506 B-

an
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5- Sleeve -3160-
is n
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6- Thrust piece -3350/2-

spec
7- Spindle -3346/2-
t to the co
– Pull in bonded rubber bush by turning spindle.

rrectne
Note
ss o
cial p
♦ Do not use lubricant.

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

atio
om
n
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Installing
i
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– Install backplate.
iv
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– Install wheel bearing/wheel hub unit.

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t.
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op
Bolt connections on wheel bearing housing may be tightened only
C py
t. rig
gh
when dimension “a” has been obtained ⇒ page 137 .
ht
pyri by
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Prote AG.

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

AG. Volkswagen AG d
oes
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– Install coil spring ⇒ page 173 . d by V gu
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– Install brake disc. autho eo
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un
Gr. 46 .
pt
an
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ot
wit
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hole
spec
es, in part or in w
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Specified torques
rrectness of i
l purpos
Wheel bearing housing to lower suspension link 90 Nm + 90°

nform
ercia

m
a
com
tion in
r
te o
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Cop py
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Prote AG.
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-
AG. Volkswagen AG d
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spec
Removing
t to the co
– Raise vehicle.
– Remove wheel.
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
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pr
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fo
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t.
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Cop py
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rig ht
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co Vo
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Prote AG.

Loosen grease cap from seat by tapping lightly on the claw of hub
grease cap puller -VW 637/2-.
lkswage es n
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ss
– Lever off grease cap. ce
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– Remove brake carrier with brake caliper and hang from body an
d
itte
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with wire ⇒ Brake systems; Rep. Gr. 46 .
erm
ab
ility
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wit
is n
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Note
ole,
spec
Hang brake caliper from body.

t to the co
– Remove cross-head screw for brake disc and remove brake

disc.
rrectne
– Remove multi-point socket head bolt using socket insert -

s
T10162- .
s o
cial p
f i
– Pull wheel hub/wheel bearing unit off stub axle.

nform
mer
Installing
atio
om
n
c
– Carefully push wheel bearing/wheel hub unit onto stub axle.

i
or
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te
sd
Ensure that the wheel bearing/wheel hub unit does not cant!
iva
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– Use a new multi-point socket head bolt and tighten it.

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t.
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Cop py
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Note
yri
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Prote
♦ 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
AG. Volkswagen AG d
agen oes
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spec
es, in part or in w
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tion in
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Removing
do
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fo
– Remove wheel.
en
ng
t.
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op
– Remove coil spring ⇒ page 173 . C py
ht. rig
rig ht
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co Vo
by lksw
cted agen
Prote AG.

– Remove bolt -arrow- securing handbrake cable -1- to trailing

arm -2-.
AG. Volkswagen AG d
agen oes
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an
d
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ab
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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
nform
mercia
a
com
tion in
– Unbolt coupling rod -1- from trailing arm.
r
te o
thi
s
iva
do
r
rp
cum
– Mark installation position of mounting bracket on body.
fo
en
ng
t.
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Cop py
t. rig
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pyri by
Vo
co lksw
by
cted agen
Prote AG.

– 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.

AG. Volkswagen AG d
1- Mounting bracket ksw
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Vol
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2- Trailing arm ised ara
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– Tighten bolt when dimension -a- is set. s aut ra
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Installing
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Position: threaded connection between trailing arm and wheel
bearing housing
rrectness of i
operations.
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
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t.
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– Position trailing arm and mounting bracket on wheel bearing C py
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– Attach coupling rod -3- to trailing arm but do not tighten nut cted agen
Prote AG.
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.
AG. Volkswagen AG d
agen oes
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d by ara
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– Bolt handbrake cable -1- to trailing arm -2- -arrow-.

an
d
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ab
pe
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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ercia

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

com
tion in
r

te o
thi
s
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r
rp
cum
fo

en
ng
t.
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op py
– Perform wheel alignment ⇒ page 305 . t. C rig
gh ht
pyri by
Vo
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by c lksw
cted agen
Prote AG.
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

wage
4.5 Repairing trailing arm lks es n
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Special tools and workshop ss
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equipment required
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hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
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cum
fo
en
ng
t.
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Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

– 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
no
yV t gu
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Dimension -A- = 114 mm
ility
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t to the co
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cial p
f inform
mer
atio
There are two different types of bonded rubber bushes. On both

om
types, the marked line must be between the projections -1- after
n
c
i
or
being pressed in.

thi
te
sd
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pr
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t.
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Cop py
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rig ht
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– Set up tools as shown in figure.y Volks ot g
ua
b
ed ran
1- Tube -T10230/5- thoris tee
or
au ac
2- Thrust plate -T10230/12-
ss (chamfer must face bonded rubber
ce
e
bush)
nl
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du
an
itte
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erm
ab
ility
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wit
, is n
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hole
spec
– Press bonded rubber bush in flush.
es, in part or in w
t to the co
– Attach mounting bracket to trailing arm ⇒ page 167 .
– Install trailing arm ⇒ page 168 .
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
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Cop py
t. rig
gh ht
pyri by
Vo
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by
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Prote AG.

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
data plate n AG. Volkswagen AG do
lkswage es n
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7 - Lower transverse link ir se
d b ran
o tee
❑ Removing and installing auth or
ac
⇒ page 151 ss
ce
e
nl
pt

du
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erm
ab
⇒ page 157
ility
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hole
spec
es, in part or in w
5.1 Removing and installing coil spring

t to the co

rrectness of i
♦ Suspension strut clamp -V.A.G 1752-

l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
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t.
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Cop py
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Prote AG.
5. Assembly overview: shock absorber, coil spring (front-wheel drive) 173

♦ Spring retainer -V.A.G 1752/4-
lkswage es n
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♦ Adapter -V.A.G 1752/9- , not illustrated
ility
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Removing
h re
hole
spec
– Remove wheel.
es, in part or in w
t to the co
– Insert spring compressor -3-.
WARNING
rrectness of i
l purpos
Ensure that coil spring is correctly seated in spring retainers -

V.A.G 1752/4- -2- (accident risk).
nf
ercia
orm
m
atio
– Use a spanner or a reversible ratchet handle to compress
om
spring compressor.
n in
or c
thi
e
– Compress coil spring until it can be removed.

t
sd
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cu
– Remove spring.
o
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t.
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Co
Cop py
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2- Adapter -V.A.G 1752/9-
ht
pyri by
Vo
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by
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Prote AG.
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
swa es n
– Install wheel
by
Voand
lk tighten ⇒ page 288 . ot g
ua
ed ran
oris tee
th or
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ss
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un
pt
an
d
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ab
5.2 Removing and installing shock absorb‐
pe
ility
ot
wit
ers
, is n
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hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
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cum
fo
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t.
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Removing t. Cop py
rig
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– Remove wheel. yri
p by
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by c lksw
cted
– 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-.
lkswage es n
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tho
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un
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, is n
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hole
spec
es, in part or in w
t to the co
– Install wheel housing liner ⇒ General body repairs, exterior;
Rep. Gr. 66 .
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
Specified torques
r
rp
cum
fo
en
ng

t.
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Cop py
.
Shock absorber to body 50 Nm +45°
t rig
gh ht
yri by
♦ Use new bolts cop Vo
by lksw
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Prote AG.

n AG. VolkswageGolf
n AG d2004 ➤ , Golf Plus 2005 ➤
wage oes
y Volks Running gear, axles, steering
not
gu - Edition 08.2009
d b ara
ir se nte
5.3 Repairing shock absorber ho
t eo
au ra
ss c
ce
le
un
pt
an
1 - Shock absorber
d
itte
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erm
ab
ility
ot p
⇒ page 175
wit
is n
h re
ole,
of running gear
spec
data plate
t to the co
2 - Protective cap
rrectne
3 - Protective tube
4 - Support ring
ss o
cial p
f i
nform
mer
5 - Bump stop
atio
om
❑ For shock absorbers
n
c
i
or
n
with support ring
thi
te
sd
a
⇒ Item 4 (page 177)

iv
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fo
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ng

t.
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Cop py
6 - Shock absorber mounting
t. rig
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pyri by
co Vo
by lksw
cted
with support ring
agen
Prote AG.
7 - Nut
❑ M10 x 1.0
❑ 25 Nm
moving
❑ Loosening and tighten‐
ing ⇒ page 178
8 - Cover
❑ For shock absorbers without support ring ⇒ Item 4 (page 177)
10 - Bump stop

♦ Shock absorber set -T10001-
AG. Volkswagen AG d
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Dismantling and assembling
wit
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Loosening and tightening threaded connection for shock absorb‐
hole
spec
er mounting
es, in part or in w
t to the co
1- Commercially available ratchet handle
2- Socket -T10001/9-
rrectness of i
3- Ratchet handle -T10001/11-
l purpos
4- Socket -T10001/1-
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
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rp
cum
fo
en
ng
t.
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Cop py
ht. rig
rig ht
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by lksw
Specified torque cted agen
Prote AG.

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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Golf Plus, CrossGolf byV ua
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⇒ page 138 ir se tee
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6 - Nut
an
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❑ 45 Nm
ab
ility
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❑ Self-locking
wit
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hole
moving
spec
es, in part or in w
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
l purpos
one ball joint and one bonded rubber bush. The end with the bonded rubber bush is bolted to the anti-roll bar.
A mixed installation is not permissible.

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

m
at
om
io
8 - Shield
n
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
riv
and one bonded rubber bush), no shield is installed. See also ⇒ Item 7 (page 179) .
p
cum
for
9 - Subframe
en
ng
t.
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Cop py
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Prote AG.
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.
u ra
c
s
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le
– Remove anti-roll bar.

un
pt
an
d
itte
Installing
y li
rm
ab
pe
ility
– Install anti-roll bar in vehicle.

ot
wit
, is n
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hole
spec
es, in part or in w
t to the co
rrectness of i
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– Evenly tighten bolts -arrows- for anti-roll bar clamp.

nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
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cum
fo
en
ng
t.
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Cop py
t. rig
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co lksw
by
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Prote AG.

Running
en AG. Vgear,
olkswaaxles,
gen AG steering - Edition 08.2009
ag does
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y Vol gu
– Connect coupling rod -2- to anti-roll bar and ed tighten nut
b -1-. ara
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th
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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
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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.
lkswage es n
I - Assembly overviewbyV
o - sub‐ ot g
ua
frame, final rdrive
ise
d
(four-wheel ran
tee
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drive, aluminium)
auth ⇒ page 189 or
ac
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II - Assembly overview - control
ce
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un
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arm, track rod (four-wheel

an
d
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drive, subframe made from

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aluminium and wheel bearing

pe
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housing made from cast steel)

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⇒ page 212
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spec
es, in part or in w
t to the co
rrectness of i
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8. Repairing rear suspension (four-wheel drive) 183

III - Wheel bearing housing,

trailing link (four-wheel drive,
subframe made from alumini‐
um and wheel bearing housing
made from cast steel)
⇒ page 234
IV - Shock absorber, coil spring
(four-wheel drive, subframe
made from aluminium and
wheel bearing housing made
from cast steel) ⇒ page 257
. 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
horis eo
housing made from scastau steel) ra
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⇒ page 265 s
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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
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II - Assembly overview
tho
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sa
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drive, subframes made from
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nl
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⇒ page 223
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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
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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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straps -T10038- .
WARNING


ning gear:

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here ⇒ page 317 .
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until dimension -a- is attained.
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WARNING
nf
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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
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3 - Rear bonded rubber bush olks
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4 - Front bonded rubber
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6 - Bolt
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7 - Final drive
h re
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es, in part or in w
⇒ Rep. Gr. 39 ; Remov‐
t to the co
ing and installing rear fi‐
nal drive
8 - Bolt rrectness of i
❑ M12 x 1.5 x 85
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9 - Washer
m
10 - Bracket
a
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11 - Bolt
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9. Assembly overview - subframe made from aluminium, final drive (four-wheel drive) 189
AG. Volkswagen AG d
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Golf 2004 ➤ , Golf Plus 2005 ➤ d by
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Running gear, axles, steering - Edition 08.2009 horis
eo
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Note
on in
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Please note that subsequent assembly work for which the hexa‐
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gon or twelve-point bolt of the drive shaft has to be loosened
r
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requires that the vehicle is stood on its wheels. Loosen hexagon
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bolt ⇒ page 274 or loosen twelve-point bolt of drive shaft
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– Remove wheels. cted agen
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– 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.

AG. Volkswagen AG d
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– Unclip speed sensor wire from retainer -1-d-arrows-.
by
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– Disconnect brake pipes, items-1- and -2-.

rrectness of i
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nf
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– 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
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– Unbolt rear propshaft
by
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– Unscrew centre bearing bolts -arrows- two turns.

rrectness of i
l purpos
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– Support propshaft on tunnel support using a wooden block.

– Push rear propshaft tube towards gearbox as far as possible.
– Now secure vehicle to lifting platform on both sides using ten‐

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

the vehicle will slip off the lifting platform!
swa
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– Unscrew one hexagon bolt -1- or -2- on each side.

om
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Only the left side of vehicle is shown to improve clarity.

t.
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– 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.
Installing subframe with attachments lkswage es n
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Install in reverse order. In the process, note the or following:
is tee
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Attach propshaft to rear final drive ⇒ Final
ss drive 02D; Rep. Gr.
a ac
39 ; Removing and installing propshaft .
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es, in part or in w
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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 .
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Specified torques
nform
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9.2 Repairing subframe

equipment required
♦ Hydraulic press -VAS
6178-
V.A.G 1383 A-
♦ Foot pump -VAS 6179-
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Pulling out front or rear bonded rubber bushes

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

l purpos
– Remove front and rear exhaust system silencer ⇒ Rep. Gr.

26 ; Exhaust system; Removing and installing parts of the ex‐
haust system .
nform
ercia

m
at
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body.
on
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– Remove anti-roll bar ⇒ page 265 .

his
ate
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p
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– Now secure vehicle to lifting platform on both sides using ten‐

sioning straps -T10038-.
AG. Volkswagen AG d
WARNING agen oes
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If the vehicle is not strapped down, thor there
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the vehicle will slip off the lifting
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– Position engine and gearbox jack -V.A.G 1383 A- with univer‐
es, in part or in w
sal gearbox support -V.A.G 1359/2- beneath subframe and
t to the co
secure with strap.
rrectness of i
l purpos
nform
mercia
a
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tion in
r
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– Unscrew one hexagon bolt -1- or -2- on each side.

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– 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
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– Set up special tools witholkbonded
swa
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3 - Thrust piece -T10263/3-
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4 - Subframe
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7 - Hydraulic press -VAS 6178-

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9 - Nut -T10263/5-
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mer
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agen
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does
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10 Assembly overview - subframe made from steel, final drive (four-wheel ss aut ra
c
drive)
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1 - Subframe
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2 - Rear bonded rubber bush
t to the co
3 - Front bonded rubber bush
rrectne
4 - Final drive
ss
o
cial p
f
⇒ Rep. Gr. 39 ; Remov‐
inform
ing and installing rear fi‐
mer
nal drive .
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n
c
5 - Bolt
i
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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 AG. Volkswagen AG d
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♦ Engine/gearbox jack -V.A.G 1383 A- d b ara
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Note
nform
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Please note that subsequent assembly work for which the hexa‐
a
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tio
gon or twelve-point bolt of the drive shaft has to be loosened
n in
requires that the vehicle is stood on its wheels. Loosen hexagon
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te o
thi
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p by
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– 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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– Markauinstallation
t position of mounting bracket on body. ra
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– Check whether a mark is present on the flexible coupling and

the final drive flange (coloured dot) -arrows-. If no mark is
present, mark the position of the flexible coupling and the final
nform
ercia
drive flange to one another -arrows-.

m
– Disconnect connectors for rear right speed sensor -G44- and

com
tion in
rear left speed sensor -G46- .

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– 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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– Support propshaft -A- on tunnel support -1- using a wooden
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block.
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– Push rear propshaft tube towards gearbox as far as possible.
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– Disconnect Haldex coupling connector above final drive.
wit
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To secure the subframe in place, ensure that at positions -1- and
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-2- the locating pins -T10096- are screwed in one after the other
erm
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on both sides of vehicle.
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– Unscrew one hexagon bolt -1- or -2- on both sides.
h re
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– Replace the subframe securing bolts on both sides one after
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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
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shock absorber is also installed.
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♦ Renew the damaged brake line clips on the subframe.
ab
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♦ If an aluminium subframe has to be replaced, a new brake line
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must also be installed ⇒ Braking systems; Rep. Gr. 47 ; Brake
h re
hole
line repair and ⇒ Electronic parts catalogue“ETKA” .
spec
es, in part or in w
t to the co
Attach propshaft to rear final drive ⇒ Final drive 02D/0AV; Rep.
Gr. 39 ; Removing and installing propshaft .
rrectness of i
Specified torques
l purpos

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Subframe to body 90 Nm + 90° further

♦ Use new bolts!
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Mounting bracket to body 50 Nm + 45° further

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♦ Use new bolts!

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AG. Volkswagen AG d
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oes
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10.2 Repairing subframe r nte
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un
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♦ Tensioning strap -T10038- ot
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V.A.G 1383 A-
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♦ Hydraulic press -VAS
6178- and thrust piece -
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T10205/13-
♦ Foot pump -VAS 6179-
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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
– Removing coil spring ⇒ page 257 .
system .
body.
– Remove anti-roll bar ⇒ page 265 .
– Remove track rods ⇒ page 231 .
Note
AG. Volkswagen AG d
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– Now strap vehicle to the lifting platform arms on both sides of s
ce
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the vehicle using tensioning straps -T10038- . un
pt
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WARNING
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secure with strap.

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Note


AG. Volkswagen AG d
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Golf 2004
eo ➤
, Golf Plus 2005 ➤
ra
ss Running gear, axles, steering - Edition 08.2009
c
ce
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un
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be damaged.
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1383 A- .
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– Mark installation position of bonded rubber bush relative to
or
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subframe using e.g. a felt tip pen.

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– Position special tools as shown in illustration.
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1 - Nut -T10263/5-
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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 lkswage es n
o ot g
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Distinguishing features of bonded rubber bushes thor is tee
or
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I - Front bonded rubber bush ss
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The front bonded rubber bushes have two notches on the upper
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side -arrows- and differ to the rear slightly in height ⇒ Electronic
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parts catalogue “ETKA” .
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hole
spec
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– Insert bonded rubber bush -1- in subframe so that the nose
l purpos
and the plate -arrows- face perpendicular to direction of travel.

– Apply thrust piece -T10263/3- -2- so that flattened sides also
nform
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face perpendicular to direction of travel.

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– Insert special tools with bonded rubber bush into subframe as
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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 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
– Removing coil spring ⇒ page 257 .
system .

Note
– Now strap vehicle to the lifting platform arms on both sides of

WARNING


secure with strap.
AG. Volkswagen AG d
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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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The outer ring of the bush shears off when pulling out the bonded
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– The bonded rubber bush must be removed from the tube -

es, in part or in w
T10356/6- once the bush has been pulled out.

t to the co
– Clamp tube -T10356/6- on the intended surfaces in a vice.

rrectness of i
– Insert a screwdriver between tube -T10356/6- and bonded

rubber bush and lever bush out of tube -arrow-. If necessary,
l purpos
apply a drift to bush and drive out with light hammer blows.
Pulling in rear bonded rubber bush
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AG. Volkswagen AG d
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Distinguishing
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I - Front
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II - Rear bonded rubber bush

nl
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The front bonded rubber bushes have two notches on the upper
erm
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side -arrows- and differ to the rear slightly in height ⇒ Electronic
ility
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parts catalogue “ETKA” .
wit
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spec
es, in part or in w
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rrectness of i
– Insert bonded rubber bush -1- in subframe so that the nose
and the plate -arrows- face perpendicular to direction of travel.
l purpos
– Apply thrust piece -T10263/3- -2- so that flattened sides also

face perpendicular to direction of travel.
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– Insert special tools with bonded rubber bush into subframe as
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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
❑ Self-locking
❑ Always renew after re‐ AG. Volkswagen AG d
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4 - Eccentric bolt
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⇒ page 305 .
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6 - Nut
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❑ M12 x 1.5
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❑ Always tighten threaded connections in unladen position ⇒ page 187
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7 - Subframe
8 - Bolt
❑ M12 x 1.5 x 125

9 - Lower transverse link AG. Volkswagen AG d

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❑ Removing and installing ⇒ page 217 ed by
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10 - Nut aut
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11 - Bolt
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12 - Threaded rivet
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13 - Spreader rivet
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15 - Bolt
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❑ 8 Nm
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16 - Nut
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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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♦ The vehicle level sender is availablerisas a replacement part only complete with ntecoupling rod and upper and
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lower retaining plates. ut
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♦ Control unit for headlight range control -J431-
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1 - Subframe
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3 - Bolt
❑ 5 Nm
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outwards
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⇒ page 215
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and information system
VAS 5051


Removing
– Remove bolts -2- and -3-.
– Take out sender.
Installing
Lever on sender must face outwards.
– Perform basic setting of headlights following replacement.
AG. Volkswagen AG d
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Specified torques orise nte
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Rear left vehicle level sender -G76- to subframe 5 Nm
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11.3 Removing and installing upper trans‐
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Removing cted agen
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– Remove wheel.
cast steel) 215


link.
AG. Volkswagen AG d
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– Remove upper transverse link.
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spec
Installing
es, in part or in w
t to the co
ing:
The threaded connections of the wishbone may only be tightened
rrectness of i
when the dimension measured between the centre of wheel hub
l purpos
and edge of wheel housing before starting the work has been at‐
tained ⇒ page 187 .
nform
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Note

Specified torques

AG. Volkswagen AG d
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oes - Edition 08.2009
olk not
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Component utho Specified etorque
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Upper transverse link to subframe ss 95 Nm
ce
le
♦ Use new nut ♦ To tighten nuts, set torque wrench -V.A.G
un
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1332- to 80 Nm.
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the normal running position. ♦ Applies only in conjunction with insert tool,
pe
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verse link
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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. AG. Volkswagen AG d
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– Reinstall rear section of exhaust system. d by V gu
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Vehicles with dynamic headlight range control utho eo
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– Install bolts -1- in lower transverse link.
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– Carry out basic setting of headlights ⇒ Maintenance ; Booklet
38
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♦ Tighten threaded connections only when vehicle is in cted agen
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♦ Use new nut


AG. Volkswagen AG d
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Removing by Vo gu
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– Measure distance from centre
utho of wheel to lower edge of wheel eo
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housing ⇒ page 187 . ss a c
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– Remove wheel.
un
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spec
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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 .
For the right side of the vehicle only (depending on equipment)
AG. Volkswagen AG d
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nf
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or
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– Raise wheel hub with support -T10149- and engine and gear‐
n in
or c
box jack -V.A.G 1383 A- far enough that bolts of right anti-roll
thi
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bar clamp are accessible.
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Continuation for both sides of vehicle:
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– Remove nut -arrow- and remove bolt towards rear.

– Remove track rod.
Installing
The track rod may only be bolted when dimension “a” has been

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

– Remove tensioning strap -T10038- .
– Tighten bolt -arrow- for track rod -3-.
Note
Ensure that a washer is installed

wage
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kswagen AG
doenut and the wheel
bearing housing. y Volks s no
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b ara
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– Connect
au coupling
th rod -2- to anti-roll bar and tighten nutor a-1-.
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The threaded connections of the track rod may be tightened only

ility
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and lower edge of wheel housing before starting the work has
h re
ole,

spec

t to the co
Specified torques
rrectne

s
Track rod to wheel bearing housing 130 Nm + 90°

s o

cial p
f inform

mer
atio

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or

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Anti-roll bar to subframe yi

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Co 25 Nm +45°
♦ Use new bolts t. Cop py
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cast steel) 221


♦ Use new nut
AG. Volkswagen AG d
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spec
t to the co
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by lksw
cted agen
Prote AG.

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
AG. Volkswagen AG d
3 - Eccentric washer agen oes
olksw not
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❑ Inner hole with lug ised b ara
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or eo
h
4 - Eccentric bolt s aut ra
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s
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nl
pt
du
an
itte
nent is loosened
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erm
ab
⇒ page 305 .
ility
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hole

spec
maximum adjustment
es, in part or in w
position). t to the co
rrectness of i

l purpos
6 - Nut
❑ M12 x 1.5
nf
ercia
❑ 95 Nm
orm
❑ Self-locking
m
atio
om
❑ Can be loosened and tightened up to 5 times for adjustment work

n in
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Note
Co
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Prote AG.
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
agen oes
olksw not
Golf 2004 ➤ , Golf Plus 2005d➤ by
V gu
ara
e nte
horis
- Edition 08.2009 eo
aut ra
ss c
7 - Subframe
ce
le
un
pt
an
d
8 - Bolt
itte
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erm
ab
❑ M12 x 1.5 x 125
ility
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spec
t to the co
10 - Nut
rrectne
❑ Self-locking
ss o
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f in
form
mer
atio
11 - Bolt
om
n
c
❑ M12 x 1.5 x 75
i
or
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sd
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pr
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12 - Threaded rivet
fo
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t.
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❑ M6
Co
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gh
13 - Spreader rivet
ht
pyri by
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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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itte
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erm
ab
ility
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, is n
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hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
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ate
do
priv
cum
for
en
ng
t.
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Cop py
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rig ht
py by
co Vo
by lksw
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
AG. Volkswagen AG d
3 - Bolt agen oes
olksw not
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❑ M5 x 20 ised b ara
nte
or eo
❑ 5 Nm aut
h
ra
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ce
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nl
pt
er -G76-
du
an
itte
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erm
ab
ments
ility
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wit
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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

nf
ercia
and information system orm
VAS 5051
m
atio
om
n in
or c
thi
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t.
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Cop py
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rig ht
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Prote AG.


Removing
– Remove bolts -arrows- from subframe.
– Remove rear left vehicle level sender -G76- .
Installing AG. Volkswagen AG d
agen oes
o lksw not
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Install in reverse order. Note the following points: d by ara
rise nte
ho eo
The lever of rear left vehicle level sender -G76-
aut must face outside ra
c
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
hole
spec
es, in part or in w
t to the co
and subframe
rrectness of i
l purpos
12.3 Removing and installing upper trans‐

verse link
nform
mercia
at

om
ion
c
in t

or
his
ate
do
priv
cum
for
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ng
t.
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Cop py
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Prote AG.
Removing
– Remove wheel.
aluminium) 227

link. AG. Volkswagen n AG do
wage es n
– Remove bolt -1-. Volks ot g
by ua
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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
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
– Remove upper transverse link -1-.
l purpos
Installing
nf
ercia
– Install upper transverse link on vehicle and tighten bolts hand
or
tight.
m
m
atio
om
The transverse link may only be bolted when dimension“a” has
n in
or c

thi
te
sd
iva
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rp
cu
o
m
f
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ng
– Bolt upper transverse link -1- to subframe and tighten new nut
t.
yi Co
-arrow-. Cop py
t. rig
gh ht
yri
p by
co Vo
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-
rise nte
tho eo
au ra
c
ss
ce
e
nl
pt
du
an
itte
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verse link
erm
ab
ility
ot p
wit
, is n
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hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
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ion
c
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or
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ate
do
riv
Removing
p
cum
for
en
ng
t.
– Remove wheel.
yi Co
Cop py
t. rig
– Remove coil spring ⇒ page 257 . gh ht
pyri by
Vo
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by c 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
yV gu
db ara
rise nte
tho eo
au ra
c
ss
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
Lower transverse link to wheel bearing housing 90 Nm + 90° further

rrectness of i

l purpos

♦ Use new nut.
nform
ercia

m
at
om

on
c
in t
or
his
ate
do
priv
cum
for
en
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t.
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Cop py
t. rig
gh ht
pyri by
Vo
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by c lksw
cted
230
agen
Prote AG.

AG. Volkswagen AG d
agen oes
olksw not
♦ Torque wrench -V.A.G 1332- d by V gu
ara
rise nte
tho eo
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
hole
spec
es, in part or in w
t to the co
rrectness of i
Removing
l purpos
– Remove wheel.
nform
ercia
m
at
om
io

n
c
in t
or
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ate
do
priv
cum
for
en
ng
t.
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Cop py
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gh ht
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by
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Prote AG.

aluminium) 231

WARNING


AG. Volkswagen AG d
agen oes
olksw not
V gu
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– Remove nut -arrow- and remove bolt towards rear. s
ce
e
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
hole
spec
es, in part or in w
Note
t to the co
Note different versions of track rods: downwards open or forwards

closed.
rrectness of i
l purpos
The track rod may only be bolted when dimension “a” has been
nf
ercia
or
– Bolt track rod -1- to subframe and tighten new nut -arrow- to
m
m
atio
prescribed torque.
om
n in
or c
thi
te
sd
iva
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rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
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by c lksw
cted agen
Prote AG.


– 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
y li
erm
ab

ility
ot p

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

spec
es, in part or in w

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

♦ Use new bolts!
rrectness of i

l purpos

nform
ercia
♦ Use new nut.

m
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
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
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have to be exchanged ised b ara
nte
and/or installed in addi‐ ut
hor eo
tion when replacing ss a ra
c
⇒ page 235
ce
le
un
pt
an
d
6 - Trailing arm
itte
y li
erm
ab

ility
ot p
⇒ page 243
wit
is n

h re
ole,
spec
7 - Drive shaft
t to the co
❑ Assembly overview
⇒ page 273 .
rrectne
⇒ page 276
8 - Bolt
ss o
❑ M12 x 1.5 x 45
cial p
f inform
mer
atio

om
n
c

or
n thi
te
sd
a

iv
o
pr
cum
❑ Installing with wheel bearing housings made from aluminium is permissible ⇒ Electronic parts catalogue
r
fo
en
ng
“ETKA”
t.
yi Co
op py
. C rig
ht ht
rig
tain parts have to be exchanged and/or installed in addition when replacing ⇒ page 235 py by
co Vo
by lksw
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

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 l wage
ksavailable as replacement es nparts. Therefore, cer‐
o ot g
tain parts have to be exchanged and/or installed ein yV
d b addition when replacing ⇒ page 235 ua
ran
is tee
or
19 - Splash plate au
th or
ac
ss
❑ Only wheel bearing housings made from aluminium are available as replacement parts. Therefore, cer‐ ce
le
un
tain parts have to be exchanged and/or installed in addition when replacing ⇒ page 235 pt
an
d
itte
y li
rm
ab
pe
ility
ot
13.1 Changing from wheel housing bearing

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

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
a
com
tion in
♦ Brake carrier
r
te o
thi
♦ Bolts (qty. 2) for backing plate

s
iva
do
r
rp
cum
♦ Bolt, nut and washer for top control arm to wheel bearing
fo
en
g
housing
n
t.
yi Co
Cop py
t.
♦ Bolt, nut and washer for track rod to wheel bearing housing
rig
gh ht
pyri by
Vo
co lksw
by
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
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
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erm
ab
ility
ot p
wit
, is n
h re
hole
Removing
spec
es, in part or in w
t to the co
– Loosen outer threaded connection for drive shaft
⇒ page 274 .
rrectness of i
– Remove wheel.
l purpos
– Remove brake carrier with brake caliper and tie to body with
wire ⇒ Rep. Gr. 46 .
nform
mercia
at
om
Note
on
c
in t
or
his
e

at
do
priv
cum
for
en

ng
t.
yi Co
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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erm
ing:
ab
ility
ot p

wit
is n

h re
ole,

spec

t to the co

rrectne

ss
bearing housing
o
cial p
f inform

mer
operations.
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
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
utho eo
– Position trailing arm on wheelssbearing
a housing using bolts ra
c
-2- but do not tighten yet.
ce
e
nl
pt
du
an
– Attach coupling rod -3- to trailing arm but do not tighten nut
itte
y li
yet.
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

nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
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.
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


n AG. Volkswagen AG
age does
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Vol
Wheel bearingedhousing to track rod
by gu
ara 130 Nm + 90°
♦ Use new tho
rnuts
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°
erm
ab
♦ Use new bolts
ility
ot p
wit
is n
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ole,
♦ Use new nut
spec
t to the co
rrectne
ss
o
cial p
f i
♦ Use new bolt
nform
mer
atio
om
♦ Use new bolt

c
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or
n thi
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pr
cum
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fo
en
ng
t.
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Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
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- agen
AG. Volkswagen AG d
oes
olksw not
byV gu
ara
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ris nte
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aut ra
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un
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an
d
itte
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erm
ab
ility
ot p
wit
is n
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ole,
spec
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
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

disc.
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
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aut ra
ss c
ce
e
nl
pt
du
an
1 - -3346/3-
itte
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erm
ab
2 - -3301-
ility
ot p
wit
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3 - -3301/3-
h re
hole
spec
4 - -41-501-
es, in part or in w
t to the co
5 - -3350/1-
6 - -3346/2-
rrectness of i
– Pull out bonded rubber bush by tightening spindle.
l purpos
Pulling in bonded rubber bush
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
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cu
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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
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Specified torques tho
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or
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Component ss Specified torque
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t to the co

rrectness of i
13.4 Removing and installing wheel bearing/

l purpos
wheel hub unit

nf
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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
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Carry out installation in the reverse sequence, noting theedfollow‐
by ua
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– Use a new hexagon bolt and tighten ⇒ page 274 ss .
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Specified torques
h re
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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
a
com
tion in
r

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Removing
– Remove wheel.
– Remove bolt -arrow- securing handbrake cable -1- to trailing
arm -2-.
AG. Volkswagen AG d
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Vehicles with retainer for handbrake cable ss c
ce
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nl
pt
du
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erm
ab
ility
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, is n
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es, in part or in w
t to the co
rrectness of i
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– Unbolt coupling rod -1- from trailing arm.

nf
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m

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AG. Volkswagen AG d
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byV gu
ar
is Running gear, axles, steering - Editiona08.2009
ed
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– Remove bolts -arrows-. ss c
ce
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nl
pt
– Remove trailing arm with mounting bracket.
du
an
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erm
If the trailing arm is to be renewed, the mounting bracket must be
ab
ility
removed from the longitudinal member.
ot p
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The position of the mounting bracket must then be adjusted in
h re
hole
relation to the trailing arm.
spec
es, in part or in w
t to the co
rrectness of i
l purpos
Determining position of mounting bracket in relation to trailing arm
nform
ercia
Dimension -a- is 34 mm.

m
at
om
ion
c
2 - Trailing arm
in t
or
his
ate
– Tighten bolt when dimension -a- is set.
do
priv
cum
or
Installing
f
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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.


AG. Volkswagen AG d
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olksw not
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spec
es, in part or in w
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rrectness of i
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nf
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m
atio
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– Bolt handbrake cable -1- to trailing arm -2- -arrow-.

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AG. Volkswagen AG d
Vehicles with retainer for handbrake cable agen oes
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– Attach retainer -1- by pushing in inner pin of rivet -arrow-.
rised
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Continuation for all vehicles ss a ra
c
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After installation, toe setting must be checked on wheel alignment
un
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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
a
com
t
♦ Use new bolt
ion in
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te o
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♦ Use new bolts
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Coupling rod to trailing arm. 45 Nm
yi Co
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AG.

13.6 Repairing trailing arm

equipment required
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ir se tee
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ss
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un
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an
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ab
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– Remove trailing arm ⇒ page 243 .

ility
ot
wit
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spec
es, in part or in w
t to the co
rrectness of i
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248
by lksw
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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
byV gu
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Dimension -A- = 114 mm s
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There are two different types of bonded rubber bushes. On both

o
cial p
f i
types, the marked line must be between the projections -1- after
nform
being pressed in.

mer
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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 .
AG. Volkswagen AG d
agen oes
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d b ara
rise nte
tho eo
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nl
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du
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erm
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spec
es, in part or in w
t to the co
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nform
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at
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ion
c
in t
or
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250
AG.
AG. Volkswagen AG d
agen oes
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Golf 2004 ➤ , Golf Plus 2005 ➤ eo
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un
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14 Assembly overview - wheel bearing housing, trailing link (four-wheel
rm
ab
pe
ility
drive, subframe made from steel and wheel bearing housing made
ot
wit
, is n
from aluminium)
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
2 - Cover
l purpos
3 - Bolt
❑ M12 x 1.5 x 80
nform
ercia
a
com
t
ion in
removing
r
te o
thi
s
4 - Coupling rod iva
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❑ Connects anti-roll bar to fo
en
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5 - Bolt cop Vo
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❑ 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”
tain parts have to be exchanged and/or installed in addition when replacing ⇒ page 235
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
lkswage es n
❑ 4 Nm byV
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16 - Brake disc utho tee
or
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17 - Bolt ss
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❑ Loosening and tightening hexagon bolt for drive shaft ⇒ page 274
erm
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ility
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❑ Loosening and tightening twelve-point bolt for drive shaft ⇒ page 275
h re
hole
spec
es, in part or in w
t to the co
Note
rrectness of i
l purpos

nf
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orm
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atio
This wheel bearing/hub unit is maintenance and adjustment free. Adjustments and repairs are not possible!
om
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19 - Bolt
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❑ M6 x 12
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❑ 12 Nm
en
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20 - Backplate
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housing

Removing
AG. Volkswagen AG d
– Remove coil spring ⇒ page 257 . agen oes
olksw not
byV gu
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– Loosen the outer drive shaft threaded connectionrised
nte
⇒ page 274 . aut
ho eo
ra
ss c
– Remove wheel.
ce
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un
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an
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itte
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erm
ab
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– Remove ABS speed sensor from wheel bearing housing.
wit
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t to the co
rrectness o
cial p
f inform
mer
atio
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n
c
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or
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– Unscrew bolts -arrows- and remove splash plate -1-.

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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
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operations. o
ir se
ran
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– Fit trailing arm to wheel bearing housing with bolts -arrows-
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but do not tighten yet.

an
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yet.
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hole

spec
es, in part or in w
– 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

l purpos
tightened only when the dimension between the centre of wheel

hub and lower edge of wheel housing has been attained
⇒ page 188 .
nf
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orm

m
atio
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Gr. 46 .
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Specified torques
o
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f
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t.
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op
C py
t. rig
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Upper transverse link to wheel bearing housing 130 Nm + 90° further
p by
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♦ 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.

AG. Volkswagen AG d
Brake disc to wheel bearing agen
ksw housing. 4 Nm
oes
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Drive shaft to wheel
rise hub “hexagon bolt”
d ara
nte 180 Nm +180° further
♦ Use new boltut
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un
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♦ Use new bolt

an
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ility
ot
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14.2 Renewing bonded rubber bush for

hole
spec
wheel bearing housing

es, in part or in w
t to the co
⇒ page 240
14.3 Removing and installing wheel bearing/

rrectness of i
wheel hub unit

l purpos

nform
ercia

m
a
com
tion in
r
te o
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Cop py
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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
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wire ⇒ Rep. Gr. 46 . ise
d b ran
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Note
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un
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Do not suspend the brake caliper from the brake hose.
erm
ab
ility
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– Remove bolt for brake disc and remove brake disc.
is n
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ole,
spec
– Pull wheel hub/wheel bearing unit out from wheel bearing
t to the co
housing.
Installing
rrectne
ing:
ss o
cial p
f
– Use a new hexagon bolt and tighten ⇒ page 274 .
inform
mer
atio
om
n
c
i
or
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sd
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Specified torques
i
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pr
cum
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fo
en
ng

t.
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Cop py
Wheel hub with wheel bearing to wheel bearing housing 70 Nm + 90° further
t. rig
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♦ Use new bolt p by
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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 byV
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❑ End of coil spring horisturned nte
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to stop s aut ra
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4 - Bolt
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itte
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❑ 180 Nm
ility
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5 - Bolt
is n
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spec
6 - Shock absorber
t to the co
⇒ page 259
rrectne
of running gear ss o
cial p
f in
data plate
form
mer
atio

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n
c

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⇒ page 217
te
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t.
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⇒ page 236 C py
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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
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db e ran
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– Use a spanner or a reversible ratchet ss
handle to compress
ce
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spring compressor.
un
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– Compress coil spring until it can be removed.
erm
ab
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ot p
– Remove spring.
wit
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1- Adapter -V.A.G 1752/9-
ole,
spec
t to the co
Installing
rrectne
ing:
ss o
cial p
f in
End of spring -arrow- must lie against stop on bottom spring seat.
form
mer
– Install spring together with spring seat.

atio
om
n
c
– The bottom spring seat has a pin.

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– 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
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Special toolsd band
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o
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♦ Torque
ut
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a ac
ss
ce
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du
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ility
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, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
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Removing
– Remove wheel.
nf
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– Remove wheel housing liner ⇒ Rep. Gr. 66 .

rm
m
atio
m

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– 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
a does
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d by ara
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Specified torques tho eo
au ra
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Shock absorber to body 50 Nm + 45° further

itte
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♦ Use new bolts
erm
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ility
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ole,
spec
t to the co
15.3 Repairing shock absorber
rrectne
1 - Shock absorber
ss
⇒ page 259
o
cial p
f in
❑ Note different versions form
mer
of running gear
atio

om
data plate
n
c
i
or
n thi
e
2 - Protective cap
t
sd
iva
o
pr
cum
3 - Protective tube
r
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ng
t.
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4 - Support ring
Co
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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-
AG. Volkswagen AG d
agen oes
olksw not
V gu
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or eo
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hole
spec
Loosening and tighten‐

es, in part or in w
ing threaded connection

t to the co
for shock absorber

mounting
rrectness of i
1 - Commercially availa‐
ble ratchet handle
l purpos
2 - Socket -T10001/9-
nform
ercia
3 - Ratchet handle -
T10001/11-
m
a
com
tio
4 - Socket -T10001/1-
n in
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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 ed by gu
ara
ris nte
❑ Renew each ut time after
ho eo
ra
removingss a c
ce
le
7 - Shock absorber
un
pt
an
d
itte

y li
erm
ab
⇒ page 262
ility
ot p

wit
is n
h re

ole,
spec
gear versions; see


t to the co
data sticker
8 - Washer
rrectne

ss o
cial p

inform

mer
atio
om
n
c
i
or
n thi
e

t
sd
iva
o
pr
cum
r
fo
⇒ page 257
en
ng
t.
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op
C py
t. rig
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ers
p by
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by c lksw
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Prote AG.

AG. Volkswagen AG d
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or eo
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pt
du
an
Removing
itte
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ab
– Remove wheel.
ility
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– Remove wheel housing liner ⇒ General body repairs, exterior;
h re
Rep. Gr. 66 .
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
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op
– Remove bolt -arrow-. C py
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– Remove shock absorber. op Vo
by c 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
AG. Volkswagen AG d
agen oes
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un
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ab
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spec
t to the co
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cial p
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mer
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c
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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.

lkswage es n
o ot g
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17 Assembly overview - anti-roll bar (four-wheel drive, subframe made d b ua
ran
ir se tee
o
from aluminium and wheel bearing housing made from cast steel)
th or
au ac
ss
ce
e
nl
pt
du
an
itte
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ab
1 - Anti-roll bar
ility
ot p
wit
, is n
h re
of running gear
hole
spec
es, in part or in w
data plate
t to the co
⇒ page 265
rrectness of i
2 - Bush
l purpos
❑ Always renew bushes

on both sides of the ve‐
hicle.
nform
ercia
3 - Clamp
m
at
om
io
4 - Bolt
n
c
in t
or
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at
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❑ Tighten evenly.
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moving t. Cop py
rig
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ht
pyri by
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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
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Vol ot g
– Remove nut -1- and pull couplingedrodb -2- out of
y anti-roll bar. ua
ran
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th or
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nl
pt
du
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itte
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ab
ility
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spec
es, in part or in w
t to the co
rrectness of i

l purpos
nf
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or

m
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or c
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t.
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Cop py
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by
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Prote AG.


AG. Volkswagen AG d
the vehicle using tensioning straps -T10038- . lksw
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ris tee
WARNING tho or
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itte
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ab
ility
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hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
– Remove anti-roll bar.
orm
m
atio
Installing
om
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– Evenly tighten bolts -arrows- for anti-roll bar clamp. t. Cop py
rig
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For the right side of the vehicle only (depending on equipment) p by
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by c lksw
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– 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
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aut ra
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nl
pt
du
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ab
ility
ot p
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spec
es, in part or in w
t to the co
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nform
mercia
at
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c
in t
or
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ate
do
priv
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for
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t.
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Cop py
t. rig
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pyri by
Vo
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by c lksw
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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
❑ Self-locking lkswage es n
o ot g
❑ Renew each time after byV ua
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removing ir se tee
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7 - Multi-point socket head bolt ss
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removing
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8 - Coupling rod
ility
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❑ Connects anti-roll bar to

is n
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ole,
spec
bearing housing
t to the co
9 - Subframe
rrectne

ss

o
cial p
f inform
mer
atio
om
n
c
i
or
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sd
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pr
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fo
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t.
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Cop py
t. rig
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Vo
co lksw
by
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
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rise nte
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Removing
pe
ility
ot
wit
, is n
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hole
spec
es, in part or in w
Note
t to the co
rrectness of i
l purpos
nform
ercia
Note
m
a
com
tion in
Do not loosen bolt -arrow- for track rod -3-.

r
te o
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s
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fo
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t.
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Cop py
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Prote AG.



WARNING


Continuation for both sides of vehicle: lkswage es n
o ot g
byV ua
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– Remove anti-roll bar. o
ir se tee
th or
u
Installing ss
a ac
ce
e
nl
pt
du
an
itte
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erm
ab
ility
ot p
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– Evenly tighten bolts -arrows- for anti-roll bar clamp.
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
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– Install wheel and tighten. ⇒ page 288

rp
cu
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m
f
en
ng
t.
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Cop py
t. rig
gh ht
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Vo
co lksw
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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.
AG. Volkswagen AG d
agen oes
olksw not
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d by ara
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or eo
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nl
pt
du
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ab
ility
ot p
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es, in part or in w
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nf
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Cop py
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Vo
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by c lksw
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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
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by ara
❑ Looseningrise
d and tighten‐ nte
ing
ut twelve-point bolt for
ho eo
ra
ss a
drive shaft ⇒ page 275 c
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nl
pt
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itte
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ility
Note
ot p
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hole
3 - Drive shaft
spec
es, in part or in w
t to the co

4 - Hose clip
rrectness of i

moving
l purpos

nf
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5 - Boot
orm
m

atio
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❑ Material: (polyester elastomer).

n in
or c
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6 - Hose clip
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7 - Dished spring
rig
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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
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17 - Dished spring orise nte
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❑ With inner splines aut ra
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ab
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19.1 Loosening and tightening drive shaft

ot p
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is n
hexagon bolt
h re
ole,
spec

t to the co

rrectness o
cial p
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mer
atio
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n
c
i
or
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sd
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fo
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t.
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op
C py
t. rig
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drive shaft to wheel hub has been loosened.
ht
pyri by
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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
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– Lower vehicle onto itsoriswheels. nte
eo
th
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– Turn hexagon bolt
ss 180° further. c
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un
pt
an
d
19.2 Loosening and tightening 12-point bolt

itte
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ab
for drive shaft

ility
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spec
♦ Socket AF 24 -T10361-
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
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pr
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fo
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t.
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Cop py
ht. rig
rig ht
py by
co Vo
by lksw
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Prote AG.

AG. Volkswagen AG d
agen oes
olksw not
V gu
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Wheel bearings must not ut be subjected to load after bolt securing
ho eo
ra
drive shaft to wheel hub
ss a
has been loosened. c
ce
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un
pt
an
d

itte
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ility
ot p
♦ Procedure for loosening 12-point flange bolt.
wit
is n
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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.
rrectne
– Tighten the outer joint to 120 Nm.
Loosening 12-point bolt
– With vehicle still standing on its wheels, loosen the twelve- ss o
cial p
f in
point bolt a maximum of 90°, as the wheel bearing will other‐
form
mer
wise be damaged.
atio
m

o
n
c
i
or
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t
sd
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– Remove 12-point bolt -arrow-.

um
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fo
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ng
t.
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Fitting 12-point bolt
Co
Cop py
t. rig
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– Renew 12-point bolt.
ht
pyri by
Vo
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by c 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
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ing: by
Vol not
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se nte
– Install wheel and tighten ⇒ page 288tho.ri e or
au ac
The threaded connections on the bearing housing may be wheel
ss
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nl
pt
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an
itte
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started has been attained ⇒ page 188 .
erm
ab
ility
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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

nform
ercia

m
♦ Use new bolt

at
om
ion
c
in t
r

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te
♦ Use new bolt

a
do
priv
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for
Drive shaft to flange shaft/gearbox 40 Nm

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

19.4 Dismantling and assembling drive shaft

equipment required
♦ Tube -VW 416 B-
♦ Thrust plate -VW 447 H-
AG. Volkswagen AG d
agen oes
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un
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spec
t to the co
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f inform
mer
atio
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n
c
i
or
n thi
te
sd
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pr
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fo
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ng
t.
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Cop py
t. rig
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pyri by
Vo
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by c lksw
cted agen
Prote AG.

♦ Circlip pliers -VW 161 A-

1331-
1332-
lkswage es n
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un
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pe
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wit
, is n
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spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tion in

r
te o
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s
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do
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fo
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ng
t.
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Cop py
t. rig
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pyri by
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co lksw
by
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Prote AG.

♦ Puller -T10382-

– Clamp drive shaft in vice using protective jaw covers. lkswage es n
o ot g
byV ua
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– Fold back boot. o
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th or
u
– Set puller -T10382- up so that smooth side of puller
ss
a plate - ac
ce
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nl
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VW 771- .
ab
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es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
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ate
do
priv
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for
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t.
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Cop py
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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
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t to the co
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1- Dished spring
nf
ercia
orm
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by lksw
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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- ). AG. Volkswagen AG d
agen oes
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♦ Make sure thread of spindle -A- on pliers moves freely. Lubri‐ by
Vol not
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♦ If the thread is tight (e.g. due to dirt), the requireds a clamping ra
c
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nl
is applied.
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Assembling
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
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orm
m
atio
m

o
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or c
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1- Dished spring
t
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Cop py
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pyri by
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by c lksw
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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
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♦ 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

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an
itte

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erm
ab
ility

ot p
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hole
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es, in part or in w
t to the co

rrectness of i
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nf
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orm
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om
n in
or c
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19.5 Checking outer constant velocity joint
Co
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p by
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lksw
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Prote
damage.
AG.

Removing
joint body.
G. Volkswagen
– Swing segment of hub into
lksw
square
agen
A
cage window.
AG do
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– Tip hub out of cage. ris
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tee
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The six balls fors aeach
u joint belong to a tolerance group. Check r ac
s
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e
nl
traces of seizing. Too much circumferential backlash in the joint

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

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

erm
ab
ility
are no reason to change the joint.

ot p
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, is n
Installing
h re
hole
spec

es, in part or in w
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.
l purpos

nform
ercia
– Checking function of constant velocity joint

m
at
om
The constant velocity joint is correctly assembled if the ball hub

ion
c
can be moved by hand backwards and forwards over its entire

in t
or
his
e
range of axial movement.

at
do
priv
cum
or
19.6 Checking inner constant velocity joint

f
en
ng
t.
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op py
Removing
t. C rig
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pyri by
Vo
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The joint is to be dismantled to renew the grease if it is heavily by c 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
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s Press balls into cage.
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The ball hub has two different distances between the ball tracks:
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– Insert hub complete with cage and balls into joint body, making
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– Also make sure that chamfer on inner circumference of ball

form
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hub is visible after swinging it into place.

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– 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.
AG. Volkswagen AG d
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44 – Wheels, tyres, vehicle geometry

AG. Volkswagen AG d
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1. Appraisal of accident vehicles 287

2 Torque settings for wheel bolts lksw

agen
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Wheel bolt to wheel hub for all vehicles d by ara
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Specified torque: 120 Nm. s aut ra
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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
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289
Prote AG.
3. Fitting wheel and tyre
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4 Removing and fitting tyres (wheels
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with tyre pressure monitoring)
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4.1 Notes on safety and conditions for re‐
spec
moving and fitting tyres (wheels with tyre
t to the co
pressure monitoring)
rrectne
• It is extremely important to adhere to the instructions and
warnings in the following descriptions.
ss
• Check whether the tyre pressure sensor should also be re‐
o
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placed ⇒ Vehicle diagnosis, testing and information system
inform
VAS 5051.
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Note
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♦ Ensure that the tyre does not contact the tyre pressure sensor
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during removal or fitting.
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♦ The tyre pressure sensor must not come into contact with wa‐ C py
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ter or be blown upon with compressed air when the wheel rim rig ht
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is cleaned.
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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 . Volkswagen AG

gen AG does
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If a vehicle is fitted with tyres requiring nominal tyre inflation pres‐y Volk not
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sures other than those specified on the tank flap sticker, these risedb ara
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tyres (second wheel set) can also be monitored with theut TPM ho eo
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system. ss a c
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information system -VAS 5051B- .
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not automatically detected and learned by the TPM system (unlike
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spec
proved wheel and tyre combinations).
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The following work has to be performed to switch to the second
wheel set:
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♦ Read ID numbers (IDs) of the wheel electronics (tyre pressure
sensors) prior to installation.
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♦ Switch the TPM to wheel set 2.
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♦ Enter the necessary nominal tyre pressures and the IDs of the
wheel electronics in the system.
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4.3 Pressing tyre off wheel rim
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♦ Comply with the notes on safety and conditions C py
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⇒ page 290
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– 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.
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– Run tyre fitting machine clockwise until upper bead lies com‐ kswagen AG does
not
pletely above wheel rim flange. by
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valve insert, the seal, the sealing washer and the valve cap
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with new parts from the repair set ⇒ Electronic parts catalogue
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“ETKA” .
t to the co
♦ If the tyre pressure sensor is damaged, then replace the com‐
plete item ⇒ page 304 .
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4.5 Fitting tyre to wheel rim

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Caution
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♦ Comply with the notes on safety and conditions

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⇒ page 290
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When a tyre is changed, it is recommended also to change the
agen
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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.
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– When the tyre bead does not lie completely against the Vol
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rim flange: deflate the tyre, press tyre bead off wheel
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– Then balance wheel.
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– Install wheel and tighten bolts to specified torque

⇒ page 288 .
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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 locatedVo lks on the flank of the tyreesfol‐
not
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lowing the tyre designation d bof the respective tyre manufactur‐ ara
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• It is extremely important
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warnings in the following descriptions.

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• Check whether the tyre pressure sensor should also be re‐

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♦ Ensure that the tyre does not contact the tyre pressure sensor
during removal or fitting.
rrectne
♦ The tyre pressure sensor must not come into contact with wa‐
ter or be blown upon with compressed air when the wheel rim
s
is cleaned.
s o
cial p
f inform
5.2 Installation conditions

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Warming cold tyres to minimum installation temperature

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

the temperature in the core of the tyreeshould not be more than
30 °C. olks
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To install tyres without
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warm the upper parts of the sidewall and the inside of the upper
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bead to at least 15 °C.
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• This internal temperature is referred to as the core tempera‐
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• Rubber is a poor conductor of heat, therefore a cold tyre must
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be left in an area with the correct temperature for a sufficiently
hole
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long period so the inner rubber layers can warm up to at least
es, in part or in w
15 °C.
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• The surface temperature of the tyre during the warming up
phase is no indication of its internal temperature.
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• To enable cold tyres to absorb heat from the ambient air as
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quickly as possible, they should not be stacked on top of one

another but instead stored individually in order to allow the
warm air to “flow” around them effectively.
nf
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• Tyres must never be placed in front of a radiator or hot air
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blower for warming, since this can very quickly lead to critical
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surface temperatures.
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• Except for warming with warm water or warm ambient air

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• When cold tyres (below 0 °C) are transferred to a warm envi‐
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ronment (above 0 °C), a layer of condensation immediately
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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

lkswage es n
o ot g
– When pressing off a tyre using tyre fitting equipment by V with a ua
ed ran
press-off plate, always ensure that the tyre valve/
horis tyre pres‐ tee
sure sensor -arrow- is directly opposite theaubead breaker -1-.
t or
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The bead breaker must be positioned no more than 2 cm from
ce
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wheel rim flange.
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– Remove balance weights and excessive dirt from wheel.
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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
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5.4 Removing tyre from wheel

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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
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head. This allows it to be removed easily. Volks not
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sensor -2- is directly in front of assembly head -1-.
Caution
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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 .
nform
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– Position assembly head -1- near tyre valve/ tyre pressure sen‐
n
c
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sor so that an assembly lever can be inserted approx. 30° next

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

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– Additionally insert a plastic assembly lever -4-.
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– Remove assembly lever -3-.
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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
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– Run tyre fitting machine
ss clockwise. c
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– Stop the fitting of lower bead before reaching tyre valve/ tyre
pressure sensor -arrow- to prevent damage to tyre pressure
l purpos
sensor .
nform
ercia
rim may only be turned until the assembly head is just before the
tyre valve/ tyre pressure sensor -arrow-.
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ion
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ate
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rig ht
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by lksw
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
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– Stop the fitting of upper bead before reaching tyre valve/ tyre
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pressure sensor -arrow- to prevent damage to tyre pressure
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sensor .
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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
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– Remove depressor from wheel rim.
rrectness of i
sure)
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Caution
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ercia
Never increase the inflation pressure when the tyre bead does
m
at
not lie completely against the wheel rim flange.
om
ion
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This would lead to damage to the tyre and/or the wheel rim.
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– When the tyre bead does not lie completely against the wheel
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ng
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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
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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
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A tyre's rolling circumference may change as a result of: Volksw not
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♦ Insufficient tyre inflation pressure. oris tee
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♦ Structural tyre damage. ss
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♦ One-sided loading of vehicle.
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♦ Increased load on one axle, e.g. due to towing a trailer.
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♦ Use of snow chains.
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♦ Spare wheel installed.
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spec
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♦ Wheel renewal.
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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
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also light up. However, no fault will be stored in the system for the
tyre monitor display.
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The warning lamp cannot be extinguished by pressing the TPM
rm
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atio
button -E492- . In this case, please carry out the following steps:
om
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– Connect vehicle diagnosis, testing and information system -

or
thi
e
VAS 5051- and select “Guided fault finding” ⇒ Vehicle diag‐

t
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nosis, testing and information system VAS 5051.

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Anti-lock brake system ABS/TCS Mark 70 or anti-lock
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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
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6. Tyre monitor display 301

7 Tyre pressure monitor (TPM)

AG. Volkswagen AG d
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For detailed information on the tyre pressure monitor (TPM), refer Vol
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to ⇒ Self-study programme No. 347 ; Tyre Pressure Monitoringsed by ara
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The tyre pressure monitor system includes wheel electronics
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mounted on each wheel.
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At regular intervals, the wheel electronics transmit data which the
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central locking and anti-theft alarm system aerial receives and
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forwards to the tyre pressure monitor control unit -J502- .
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This control unit is integrated with its own diagnostic address into
hole
spec
the convenience system central control unit -J393- .
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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.
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The nominal tyre pressures for this set of wheels are specified for
the partially and fully laden vehicle and must not be changed.
nform
ercia
The driver can switch between partial and full load, poll the status
m
and switch the TPM system on or off via a SET button -2- in the
a
com
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centre console.
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Caution
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This button is not available for the North American region
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(NAR). Therefore, the function described above is omitted in t. C rig
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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
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pressure sensor swa
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2 - Valve core ed
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❑ Allocation ⇒autElectronic
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parts catalogue
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❑ Always renew when

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Note
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3 - Sealing washer
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4 - Sealing ring
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❑ Will be slightly deformed

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

is tightened
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5 - Wheel
❑ Fitting tyres of wheels
nform
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with tyre pressure mon‐

m
itoring ⇒ page 290

com
tion in
❑ Fitting tyres with run-flat

r
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capabilities ⇒ page 294

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

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Golf 2004 ➤ , Golf Plus ir se2005 ➤
d ran
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th or
ac
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❑ Do not use convenience valve caps or metal valve caps.
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7.3 Removing and installing tyre pressure ot p
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sensor
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Removing
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– Unscrew union nut -1-.
– Remove tyre pressure sensor -2- from bed of wheel rim.
rrectness of i
Installing
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Caution
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♦ Before installing tyre pressure sensor , clean valve hole.
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– Install tyre pressure sensor -2- along with a new seal and Cop py
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sealing washer and push it into wheel rim at the points marked
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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

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8 Wheel alignment d b ua
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ir se tee
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ss
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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
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computer
ole,
spec
♦ Brake pedal actuator -
t to the co
V.A.G 1869/2-
♦ Tool insert 18 mm -T10179-
rrectne
T10001-
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f inform
mer
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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 AG. VolkswagenXAG d Shock absorber X
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Subframe bracket olksw X Anti-roll
not bar X
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ise
X 1) Trailingntarm
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1) Prerequisite:
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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
hole
spec
moved and reinstalled moved and reinstalled

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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

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Track rod/track rod ball X Track rod X

joint
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Steering box X Wheel bearing housing X

orm
Subframe X 1) Subframe X
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Suspension strut X Coil spring X

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Subframe bracket X 1) Shock absorber X

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Anti-roll bar X 1) Anti-roll bar X

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Trailing arm X
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Rep. Gr.44 - Wheels, tyres, vehicle geometry
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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 ir se
d b ua
ran
tee
tho
or
• Check suspension, wheel
au bearing, steering and steering link‐ ac
ss
age for excessive play and damage.
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le
un
pt
• Tread depth difference of no more than 2 mm on one axle.
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itte
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• Tyres inflated to correct pressure.
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ility
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• Vehicle unladen.
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hole
• Fuel tank must be full.
spec
es, in part or in w
• 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
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and turn tables are not touching end stop.

Please note!
nform
ercia
• The test equipment must be properly adjusted and attached

m
a
to the vehicle; observe device manufacturer's operating in‐
com
tion in
structions.
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If necessary, contact the manufacturer for familiarisation with the
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proper use of the wheel alignment equipment.

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Wheel alignment platforms and wheel alignment units and com‐

t.
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puters can lose their calibration over a period of time. C py
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Wheel alignment platforms and alignment units and computers cop Vo
by lksw
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-aheadkswage n AG
-30′ ± 30′ does -41′ ± 30′ -41′ ± 30′ -14′ ± 30′
position) byV
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ed
Maximum permissible
thoris differ‐ max. 30′ max. 30′
nte
eo max. 30′ max. 30′
ence betweens a sides
u ra
c
s
1)
Toe-out on turns at 20° left 1°38′ ± 20′ 1°40′ ± 20′ 1°40′ ± 20′ 1°38′ ± 20′
ce
le
un
pt
and right lock

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

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

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hole
Ride height 382 ± 10 mm 367 ± 10 mm 367 ± 10 mm 402 ± 10 mm

spec
es, in part or in w
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
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Front axle Sports running Sports running Sports running BlueMotion

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

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Total toe (wheels not press‐ 10' ± 10′ 10' ± 10′ 10' ± 10′ 10' ± 10′
n in
r
te o
ed)
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Camber (in straight-ahead -44′ ± 30′ -30′ ± 30′ -43′ ± 30′ -41′ ± 30′
r
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position)
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ence between sides t. C rig
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Toe-out on turns 1) at 20° left 1°22′ ± 20′ 1°38′ ± 20′ 1°20′ ± 20′ 1°40′ ± 20′
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and right lock
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Prote AG.
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.
d b 30′
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max. 30′ max.
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ara 30′ max. 30′
ence between sides rise nte
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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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8.5 Wheel alignment specifications, Golf

t to the co
Plus, CrossGolf
rrectne

ss o
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f inform
mer
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or
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fo
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Cop py
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Prote AG.

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′db
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10' ± 10′ 10' ± u10′
ara
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Camber (in straight-ahead -30′ ± 30′ -41′tho± 30′ -41′ ± 30′ -14′ ± 30′ e or a
au
position) ss c
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pt
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ence between sides
itte
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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′
hole
spec
es, in part or in w
ence between sides
t to the co
rrectness of i
1)
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atio
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Front axle CrossGolf Golf Plus BlueMotion thi

te
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PR numbers 2UB G06

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Total toe (wheels not pressed) 10' ± 10′ 10' ± 10′

t.
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Camber (in straight-ahead position) -14′ ± 30′ -37′ ± 30′
t. C rig
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Maximum permissible difference between sides max. 30′ max. 30′
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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 wgear
agen AG gear
. Volkswagen AG
does no
gear ning gear
Volks except 18' t g with 18' wheels
by ua
ris
ed wheels ran
t ee
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)
ot p
wit
, is n
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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
at
Max. permissible deviation from direction of max. 20′ max. 20′
om
io
travel
n
c
in t
or
his
Ride height 395 ± 10 mm 370 ± 10 mm
ate
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8.6 Overview - wheel alignment procedure Cop py
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Always adhere to the following procedure!
co Vo
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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 .
↓ ↓
↓ ← ← ← ← ←

AG. Volkswagen AG d
agen oes
olksw not
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d by ara
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h
Golf 2004 ➤ , Golf Plus 2005 ➤ aut ra
c
s
Running gear, axles, steering - Edition 08.2009 s
ce
le
un
pt
an
d
itte
↓
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erm
ab
→ →
ility
Check rear axle camber Is actual value within toler‐ No
ot p
ance?
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is n
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ole,
↓ ↓
spec
↓ ← ← Yes Adjust ⇒ page 314 .
t to the co
↓ ↓
↓ ← ← ← ← ←
rrectne
↓
Check rear axle toe → Is actual value within toler‐ → No
ss
ance?
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f i
↓ ↓
nform
↓ ← ← Yes mer Adjust ⇒ page 315 .
atio
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↓
o
↓
n
c
i
or
n thi
↓ ← ← ← ← ←
te
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Check front axle caster. → Is actual value within toler‐ → No
en
ng
t.
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ance? t. Cop py
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↓ ↓
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↓ ← ← Yes Prote
cted Inspect axle components and
AG.
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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


AG. Volkswagen AG d
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olksw not
V
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rise nte
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♦ Camber correction is necessary only aafter body repairs. The
u ra
ss c
camber is not adjustable, but can be equalized by moving the
ce
le
un
brackets and/or the subframe.
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♦ Move subframe only to left or right, but never in or opposite to
rm
ab
pe
direction of normal travel!
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ot
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, is n
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– Remove noise insulation. hole
spec
es, in part or in w
– 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
l purpos
must be inspected ⇒ page 1 .

– Specification for camber may be adjusted by moving subframe
nform
ercia
at brackets.
m
a
– Tighten bolts for subframe and brackets to body to specified
com
tio
torque plus extra turn angle.
n in
r
te o
thi
Following the movement of the subframe and, consequently, the
s
iva
do
steering box, clearance between the steering column universal
r
rp
cum
joint and the notch in the bulkhead must be checked.
fo
en
ng
t.
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Cop py
– Remove securing nuts -arrows- and remove footwell trim.
t. rig
gh ht
pyri by
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co lksw
by
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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-

AG. Volkswagen AG d
agen oes
olksw not
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ed
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aut 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
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wit
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h re
hole
spec
es, in part or in w
t to the co
– Loosen upper transverse link nut -A- on subframe.
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
– Adjust camber by turning eccentric bolt -B- with 18 mm socket

t.
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op
-T10001- .
C py
ht. rig
rig ht
py by
co Vo
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cted agen
Note
Prote AG.
The maximum adjustment range is 90° to the left or right of centre.

AG. Volkswagen AG d
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d by ara
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or eo
h
aut Golf 2004 ➤ , Golf Plus 2005 ➤ ra
c
s
s Running gear, axles, steering - Edition 08.2009
ce
le
un
pt
an
d
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 o
cial p
f inform
– Use socket (18 mm) -T10179-
mer
atio
m
– Check camber value again after tightening nut -A-.
o
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
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Cop py
t. rig
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pyri by
Vo
o
by c 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.
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss
ce
le
un
pt
an
d
itte
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ab
pe
ility
ot
wit
, is n
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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
nform
ercia

m
a
com
tion in
r
te o
thi
s
iva
do
r
rp
8.10 Adjusting front axle toe

um
fo
en
ng
t.
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Special tools and workshop equipment required t. Cop py
rig
gh ht
♦ Torque wrench -V.A.G 1332- pyri by
Vo
co lksw
by
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- olkswage
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
e
nl
pt
du
an
Select “Select function/component” by pressing Go to button.

itte
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erm
ab
ility
8.12 Vehicle data sticker

ot p
wit
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Explanation of “PR numbers” on vehicle data sticker

hole
spec
Various types of running gear are installed depending on engine

es, in part or in w
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

l purpos
vehicle data sticker by the PR number for the front axle.

The vehicle data sticker can be found in the spare wheel well and
nform
ercia
in the service booklet.

m
at
om
Example of a vehicle data sticker

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

his
ate
gear G02 -arrow-.

do
priv
cum
for
en
ng
t.
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Cop py
t. rig
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pyri by
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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
ho eo
The bottle therefore has an expiry date -arrow-. aut ra
ss c
ce
le
In this example, the expiry date of 05/2003 has been exceeded

un
pt
and the bottle must be renewed.
an
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itte
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erm
ab
If the bottle has been opened, e.g. to repair a tyre, then it must
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also be renewed.
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is n
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ole,
spec
t to the co
rrectne
9.3 Removing a tyre
ss o
cial p
f in
Tyres which have been filled or sealed using tyre sealant must be
form
mer
drained before removal. atio

om
n
c
WARNING
or
n thi
te
sd
iva
o
r
♦ Avoid eye and skin contact with tyre sealant.

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

t.
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op
lergies. C py
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♦ Wear eye protection and protective gloves whilst working co Vo
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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. AG. Volkswagen AG d
agen oes
lksw not
– Inflate tyre to approx. 3 bar . . . 4 bar. The bead of the tyre mustd by
Vo gu
ara
slip audibly over the hump of the rim. orise nte
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– Screw in valve insert. ss a c
ce
le
– Correct inflation pressure to prescribed pressure.

un
pt
an
d
itte
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– Balance wheel.
erm
ab
ility
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9.5 Tyre sealant disposal
t to the co
♦ Tyre sealant or residue must not be mixed or disposed of with
other fluids.
rrectne
♦ Excess tyre sealant must be collected and stored in a plastic
container. The plastic container can be disposed of through
ss o
the disposal system along with the breakdown set (when the
cial p
f in
expiry date is exceeded).
form
mer
♦ The items can be returned or disposed of through the existing
atio
m
workshop disposal system.

o
n
c
i
or
n thi
♦ Request information through your service provider or the dis‐
te
sd
va
posal representative at your distribution centre or importer.

i
o
pr
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fo
9.6 Alloy wheels with metal valves

en
ng
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Cop py
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As of model year 2005, hollow-chamber wheels have been fitted
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as part of certain equipment variants. These hollow-chamber op 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
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d by ara
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or eo
h
aut ra
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ce
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un
pt
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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
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nform
mercia
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com
tion in
r
te o
thi
s
iva
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cum
fo
en
ng
t.
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Cop py
t. rig
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pyri by
Vo
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cted agen
Prote AG.

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
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ed
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ut
– Check to ensure sthat
s a contact surface -arrow- on inner side of ra
c
wheel (rim) and also centring seat of rim are free of corrosion
ce
le
un
and dirt.
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– The spherical caps * in the holes for the wheel bolts and the
rm
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ility
threads of the wheel bolts must also be free of corrosion and

ot
dirt, oil or grease.

wit
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hole
*A spherical cap is the curved surface of a section of a sphere

spec
cut by a plane.
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
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fo
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Prote AG.
10. Instructions for changing or fitting wheels
AG. Volkswagen AG d
agen oes
ksw not
Golf 2004 ➤ , Golf Plus 2005 ➤ by Vol
gu
ara
d
Running gear, axles, steering - Edition
orise 08.2009 nte
eo
th
au ra
s c
– Check whether the wheel bolts cans be easily screwed in by
ce
le
hand. The thread of the wheel bolts must not come into contact
un
pt
an
d
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
rrectne
Damaged, badly corroded or difficult to remove wheel bolts
must be renewed.
ss o
cial p
f inform
mer
10.1 Fitting wheels
atio
om
n
– Preserve wheel centring seat ⇒ page 323 .
c
i
or
n thi
te
sd
1- When fitting the wheel, screw in all wheel bolts uniformly by
iva
o
r
hand.
p
cum
r
fo
en
ng
2- Tighten the wheel bolts in diagonal sequence to approx. 30

t.
yi Co
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
ris
Ensure that only centring ring -arrow- but not contact
tho surface of eo
au ra
wheel rim has been waxed. Otherwise, the brakes
ss will be soiled, c
which would reduce the braking efficiency.
ce
le
un
pt
an
d
itte
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rm
WARNING
ab
pe
ility
ot
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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
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
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Cop py
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rig ht
py by
co Vo
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cted agen
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 en Ais
G.not
Volkalways
swagen AG
evenly spread across the entire running surface
lkswagof the tyre. This does not
Vo
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
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nl
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tyre and thus reduce the tyre service life.

an
itte
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erm
ab
Recommendation
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To ensure
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h re
hole
• optimal safety,
spec
es, in part or in w
• 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.
l purpos
12.2 Balancing wheels

nform
ercia
Before you start balancing the wheels, the following requirements

must be met.
m
at
om
ion
• The tyre pressure must be OK.

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

lkswage es n
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d ran
ir se
tho tee
or Golf 2004 ➤ , Golf Plus 2005 ➤
u
ss
a
Running gear, ac
axles, steering - Edition 08.2009
ce
e
nl
pt
du
12.3 Conducting a road test before balancing
an
itte
y li
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.
nf
ercia
orm
m
Tyre position Marked with ...
atio
om
n in
c
Front left tyre FL

or
thi
te
sd
a
Front right tyre FR

iv
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Rear left tyre RL
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Rear right tyre RR
Co
Cop py
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– Remove wheels from vehicle. pyri by
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by
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
. Volkswrunout
agen AG
⇒
doepage
s
328 .
k not
Vol g
– 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
ss
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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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♦ 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

hole
spec
⇒ page 330 .
es, in part or in w
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
l purpos
– Bolt the wheel to the vehicle.

– First hand-tighten the lowest wheel bolt to about 30 Nm.
nf
ercia
or
– Then tighten the remaining wheel bolts diagonally to about

m
m
atio
30 Nm. This process centres the wheel on the hub.

om
n in
or c

thi
te
sd
iva
– Now use a torque wrench to tighten the wheel bolts to the

o
r
rp
cu
specified torque in diagonal sequence.

o
m
f
en
ng
t.
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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
n AG.system
Volkswag-VAS
en AG 6230- you can perform
more functionsVthan wage does
olks just stationary balancing.not
g
y ua
db r
A specialorifeature
se of this system is the testing of theanradial
tee force of
the wheel
au
th
and tyre while rolling. or
a
ss c
A roller presses against the wheel with a force of about 635 kg.
ce
e
nl
pt
This simulates the vertical tyre force against the road surface
du
an
itte
during travel.
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erm
ab
ility
Radial and lateral runout in the wheel and tyre and differences in
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the stiffness of the tyre cause the vertical force of the wheel to
, is n
h re
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
nform
ercia
12.6 Finish balancer

m
at
om
ion
c
in t
or
his
ate
Note
do
priv
cum
for
en
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♦ Before working with a finish balancer , the mechanic needs to

n
t.
yi Co
op
have been instructed by the manufacturer of the balancer.
C py
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rig ht
♦ To balance the wheels, set the wheels of the driven axle on
py by
co Vo
by lksw
the sensor platforms (only the front wheels of a front-wheel
Prote
cted AG.
agen
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
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Note ut
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The imbalance should always be less than 20 grams before you
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change the balance weight.
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– If necessary, remove the wheel bolts again.
ot p
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– 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.
nform
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– Balance the wheels until the imbalance is less than 5 grams.

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– Tighten wheel bolts to specified torque if you have not already
n
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Always tighten wheel bolts to specified torque using a torque
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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 . lksw
agen oes
n o ot g
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ir se
12.9 Checking radial and lateral runout on
tee
ho
aut or
ac
ss wheel
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an
– Mount the wheel on the wheel balancer .

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– Use the wheel balancing machine centring system -VAS

ility
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5271- .
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S - Lateral runout
rrectness of i
H - Radial runout
l purpos
– Compare the measured values with the specifications in the

table ⇒ page 329 .
nf
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Note
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Extreme values on the tyre gauge due to small irregularities may

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be disregarded.
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Specifications for radial and lateral runout on wheel
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Wheel Radial runout (mm) Lateral runout (mm)
by lksw
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Steel wheel 0.5 0.5

Wheel Radial runout (mm) Lateral runout (mm)

Alloy wheel 0.5 0.8
Note
AG. Volkswagen AG d
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If the measured value
ised exceeds the specification, acceptably
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smooth running ut
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12.10 Matching
erm
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When radial or lateral runout of the wheel and tyre coincide, the
hole
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imbalance of the wheel is amplified by the tyre.
es, in part or in w
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
l purpos
caused by storage or handling, ⇒ page 331 .

Procedure for match mounting
nf
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– Deflate the tyre. orm

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– Press the tyre beads off the rim flanges.

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– Coat the tyre bead all round with tyre fitting paste .
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– Rotate the tyre 180° relative to the wheel.

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– Inflate the tyre to approx. 4 bar.
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– Mount the wheel with tyre on the wheel balancer. rig ht
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– 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

agen oes
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Flat spots caused by hard bybraking cannot be repaired. Suchgtyres
V ua
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must be renewed. thoris tee
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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.

ab
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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
spec
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.
nform
ercia
♦ Flat spots caused by storage or handling can be removed only

m
by running the tyres warm.

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

te o
thi
wintry weather.
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Requirements and conditions:

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– Check and, if necessary, correct inflation pressures. t. 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 yV
o following the road test.
lks ot g
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ed ran
– Remove the wheels fromhoris the vehicle. tee
ut or
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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 n AG do
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Volks ot g
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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
wage oe
♦ From model year 2009, a new, 3rd Volgeneration, steering box is ot gu
ks sn
d by
being used. Notes on differentiating between 2nd and 3rd ara
ise nte
generations ⇒ page 399 u.thor eo
a ra
ss c
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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found.
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hole
spec
♦ Completely remove all residue from liquid sealants from the

es, in part or in w
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‐
l purpos
ings diagonally.
♦ Avoid canting sensitive parts such as servo motor with control
nf
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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,
lksw
age touch anGearthed
does
not
object, such as a water pipe
d by or a lifting platform. Do not touch
V gu
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the contact pins of the
or electrical connectors with bare hands.
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au ac
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es, in part or in w
t to the co
rrectness of i
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2.5 Guided fault-finding, vehicle self-diag‐

nosis and test instruments
nf
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or
♦ Before performing repair work on the electromechanical steer‐
m
m
atio
ing box, determine the cause of damage as precisely as
om
n in
possible using the vehicle diagnosis, testing and information
or c
system -VAS 5051- in “guided fault finding”, “vehicle self-di‐

thi
te
sd
a
agnosis” and “test instruments” operating modes.

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2. General repair instructions 335

3 Steering wheel
AG. Volkswagen AG d
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lksw not
3.1 Removing and installing steering wheel Vo gu
by ara
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rise nte
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auth
equipment required ra
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ility
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spec
es, in part or in w
t to the co
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Removing
nform
ercia
– Remove driver side airbag unit ⇒ Rep. Gr. 69 ; Airbag; Re‐

m
at
om
moving and installing driver side airbag unit .
ion
c
in t
or
– Separate connections -1 and 2- for coil connector.

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AG. Volkswagen AG d
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or eo
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un
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erm
ab
ility
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is n
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spec
t to the co
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cial p
f inform
mer
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om
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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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Installing C py
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– Set steering wheel onto steering column. op Vo
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– Centre markings of steering wheel and steering column
AG.
-arrows- must align.
3. Steering wheel 337

AG. Volkswagen AG d
agen oes
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un
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ab
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is n
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t to the co
rrectness o
cial p
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mer
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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

AG. Volkswagen AG d Golf 2004 ➤ , Golf Plus 2005 ➤
agen oes
Volksw Running
not g gear, axles, steering - Edition 08.2009
by ua
ed ran
ris tee
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ut or
4 Steering column, Golf
ss
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4.1 Assembly overview: steering column
erm
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Note
spec
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ss o
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1 - Bolt
inform
mer
❑ 20 Nm
atio
m
2 - Cross member for steering

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column
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⇒ page 346
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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

AG. Volkswagen AG d
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Removing
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a
Only the complete steering column is supplied as a replacement
com
tion in
part. Repair is not possible.
r
te o
thi
The steering lock housing can be transferred ⇒ Electrical system;
s
iva
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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 c 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
agen oes
olksw not
V gu
d by ara
ise nt
– Unscrew securing
ut
hor
nuts -arrows- and remove footwell trim -1-.ee or
a ac
ss
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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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es, in part or in w
t to the co
rrectness of i
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tion in
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– Remove earth cable -arrow- and cable g-1- Afrom

G. Volsteering
kswagen Acol‐
a en G do
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– Remove bolts -2-. rise tee
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au
Vehicles with crash bars ss ac
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un
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ility
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, is n
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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
a
com
tion in
r
te o
thi
s
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op py
– Remove bolt -1- and remove crash bar for clutch pedal -2-. t. C rig
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– Remove bolt -3- and remove crash bar for brake pedal -4-.
o Vo
by c lksw
cted agen
Prote AG.
– Lower steering column slightly and carefully pull out upwards.
Installing
– Hook steering column into installation aid on mounting brack‐
et.
– Align steering column to mounting bracket.

In the process, the pins -arrows A- of mounting bracket must be
aligned with and inserted into the holes -arrows B- of the steering
column
The steering column's correct installation position to the mounting
bracket is guaranteed only in this way.

– 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-.
lkswage es n
o ot g
byV ua
d ran
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u or
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un
pt
an
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erm
ab
ility
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is n
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– Attach ground cable -arrow- and cable -1- to steering column.

ole,
spec

t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
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te
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Prote AG.

– Fit universal joint -2- onto steering box pinion and tighten bolt
-1-.
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byV ua
d ran
ir se tee
o
– Install footwell trim -1- and secure with nuts -arrows-. auth or
ac
ss
ce
le
un
pt
an
d
itte
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erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
rrectne
– Install cable duct -1- below steering column.
ss o
The lugs -arrow- must engage in the guide on both sides.
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
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o
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fo
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ng
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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 .
– 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
agen oes
ksw
Proper steering column handling and transport by
Vol not
gu
ara
ed
is nte
♦ Use both hands to transport steering column. hor eo
aut ra
s c
♦ Hold steering column upper jacket tubesand in area of upper
ce
e
universal joint.
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
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, is n
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hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
orm
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345
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Prote
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
AG. Volkswagen AG d
agen oes
olksw not
y V gu
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au ra
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ce
e
nl
pt
du
an
itte
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erm
ab
ility
ot p
wit
, is n
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hole
spec
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°.
nf
ercia
orm
m
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Cop py
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by
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Prote AG.
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
Volksw and installing dash panel
not
g
insert .
y ua
db ran
– Remove bolts
ho
ri-arrows-
se under bracket. tee
t or
au ac
ss
ce
e
nl
pt
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erm
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ility
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, is n
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hole
spec
es, in part or in w
t to the co
rrectness of i
– Push connector -1- in -direction of arrow- and remove from

l purpos
support in mounting bracket.

– Unscrew bolt -arrow A-.
nform
ercia
– Remove bolts -arrows B- securing bracket to body.

m
at
om
ion
c
in t
or
Note
his
ate
do
priv
Bolts -arrows B- are screwed in from cross member.

um
for
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cted
– 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

AG. Volkswagen AG d
oes
olksw not
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Note utho eo
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s
ce
Bolts -arrows B- are screwed in from cross member.
le
un
pt
an
d
itte
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rm
– Screw in bolt -arrow A-.
ab
pe
ility
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– Insert connector -1- into support in mounting bracket and push
wit
, is n
to stop opposite -direction of arrow-.
h re
hole
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
a
5051B- .
com
tion in
r
te o
thi
s
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Specified torques
t. C rig
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co
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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
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byV ua
d ran
ir se tee
tho
or
Removings au ac
s
ce
le
– Remove plenum chamber bulkhead ⇒ General body repairs,

un
pt
exterior; Rep. Gr. 50 ; Assembly overview - plenum chamber
an
d
itte
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bulkhead .
rm
ab
pe
ility
– Remove bolt -arrow- in plenum chamber.
ot
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
com
tion in

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

iva
do
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Installing
fo
en
ng
t.
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Cop py
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pyri by
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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- .
Specified torques olkswage es n
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byV ua
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Component o
ir se Specified torque tee
th or
u
Strut to mounting bracket ss
a 20 Nm ac
ce
e
Strut to body nl 20 Nm
pt
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itte
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erm
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ility
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es, in part or in w
t to the co
rrectness of i
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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
e
nl
pt
du
an

itte
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⇒ page 351
erm
ab
ility
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6 - Handle
wit
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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
nform
ercia
moving
m
at
11 - Strut
om
ion
c

in t
or
his
e
⇒ page 360
at
do
priv
12 - Bolt
um
for
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❑ 20 Nm
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❑ 20 Nm
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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
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un
pt
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ility
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is n
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spec
t to the co
Removing
rrectne
Only the complete steering column is supplied as a replacement
part. Repair is not possible.
ss
The steering lock housing can be transferred ⇒ Electrical system;
o
cial p
f i
Rep. Gr. 94 ; Ignition switch and lock cylinder .
nform
mer
atio
m
WARNING
o
n
c
i
or
n thi
e
The following are prerequisites before starting work on the

t
sd
iva
electrical system and removing the steering wheel:

pr
cum
r
fo
en
ng
♦ Disconnect earth strap from battery ⇒ Electrical system;

t.
yi Co
op
Rep. Gr. 27 ; Battery; Disconnecting and reconnecting C py
t. rig
battery gh ht
pyri by
Vo
o
by c 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 .
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c
ce
le
un
pt
an
d
itte
y li
erm
ab
– Remove cable duct -1- below steering column. To do this,
ility
ot p
raise lugs -arrow- slightly on both sides and pull cable duct out
wit
is n
from guide on steering column.
h re
ole,
spec
t to the co
rrectness o
cial p
f inform
mer
atio
– Unscrew securing nuts -arrows- and remove footwell trim -1-.

om
n
c
i
or
n thi
te
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fo
en
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t.
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Cop py
t. rig
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by
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Prote AG.

– Remove earth cable -arrow- and cable -1- from steering col‐
umn.
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
– Remove ground cableuth-arrow- and cable -1- from steering col‐
o eo
ra
umn. ss a c
ce
e
nl
pt
du
an
itte
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erm
ab
ility
ot p
wit
, is n
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hole
spec
es, in part or in w
t to the co
rrectness of i
– Remove bolt -1- and remove crash bar for clutch pedal -2-.
l purpos
– Remove bolt -3- and remove crash bar for brake pedal -4-.
nform
ercia

m
at
– Lower steering column slightly and carefully pull out upwards.

om
ion
c
in t
r
Installing
o
his
ate
do
riv
– Hook steering column into installation aid on mounting brack‐

p
cum
or
et.
f
en
ng
t.
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Cop py
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rig ht
py by
co Vo
by lksw
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-.
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
– Attach ground cable -arrow- and cable -1- to steering column.

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
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
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Cop py
ht. rig
rig ht
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co Vo
by lksw
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
ise nte
or eo
h
aut ra
– Install footwell trim
ss -1- and secure with nuts -arrows-. 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
– Install cable duct -1- below steering column.

nf
ercia
The lugs -arrow- must engage in the guide on both sides.

orm
m
atio
om
n in
or c
thi
te
sd
iva
o
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cu
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Cop py
t. rig
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pyri by
Vo
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by c lksw
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
lks wage es n
o ot g
yV
Universal joint to steering
ir se
d b box ua
ran 30 Nm
♦ Use new boltth o tee
or
au ac
ss
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
5.3 Basic setting for steering angle sensor
ot
wit
, is n
G85 steering angle sender must be
h re
hole
spec
checked after the following repair work:
es, in part or in w
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;
l purpos
♦ If steering lock housing with steering column switch was re‐

moved or renewed;
nform
ercia
♦ If steering box was removed or renewed;

m
a
♦ If steering wheel was repositioned.
com
tion in
r
5.4 Handling and transporting steering col‐

te o
thi
s
iva
do
umn
r
rp
cum
fo
en
ng
t.
yi Co
op
WARNING C py
t. rig
gh ht
pyri by
Vo
o
♦ Adherence to proper steering column handling is essen‐
c by 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
y V gu
d b ara
rise nte
tho eo
au ra
ss c
ce
le
un
pt
an
d
itte
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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
rrectne
– Check that steering column turns smoothly and easily.

s
– Check that steering column can be adjusted in reach and

s o
height.
cial p
f inform
5.6 Removing and installing mounting

mer
atio
m
bracket
o
n
c
i
or
n thi
e

t
sd
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o
pr
cum
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fo
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ng
t.
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Cop py
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co lksw
by
cted agen
Prote AG.

AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut 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
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
– Push connector -1- in -direction of arrow- and remove from

te
sd
iva
support in mounting bracket.

o
r
rp
cu
o
m
f
– Remove bolts -arrows- from bracket to body.

en
ng
t.
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Cop py
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rig ht
by
Note copy Vo
by 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.

swage es n
– Insert connector -1- into support in mounting byV
o bracket and push
lk ot g
ua
to stop opposite -direction of arrow-. ir se
d ran
tee
tho
u or
a ac
ss
ce
e
nl
pt
du
an
itte
y li
erm
ab
– Install bolts -arrows- under bracket.
ility
ot p
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
nf
ercia
orm
m
atio
m
Specified torques
o
n in
or c
thi

te
sd
iva
o
r
Mounting bracket to body 20 Nm

rp
cu
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en
ng

t.
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op py
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pyri by
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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
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au ra
c
ss
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le
un
pt
an
d
itte
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erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co

– Remove strut -2-.
rrectne
Installing
ss o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi
– Secure strut to body by tightening bolt -arrow-.
Co
Cop py
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pyri by
Vo
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by c lksw
cted agen
Prote AG.

swage es n
– Install securing bolt -1- and tighten. byV
olk ot g
ua
d ran
ir se
– Install steering column ⇒ page 354 . tho tee
or
au ac
– Install plenum chamber bulkhead ⇒ General body repairs,
ss
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
nf
ercia
Strut to body 20 Nm
orm
m
atio
om
n in
or c
thi
te
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iva
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en
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Cop py
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Vo
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by
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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
byV gu
ara
ed
and 2nd generations) up to model year 2008 ris nte
ho eo
aut ra
ss c
ce
le
un
pt
Note
an
d
itte
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rm
ab
♦ There are no 2nd generation steering boxes available as spare parts.
pe
ility
ot
wit
, is n
♦ If the steering box has to be replaced, a new 3rd generation steering box will have to be fitted.
h re
hole
spec
♦ In addition, the electrical wiring harness from the E-box to the steering box will then also have to be renewed.
es, in part or in w
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” .
l purpos
1 - Universal joint
nform
mercia
2 - Hexagon bolt
a
com
tio
❑ 30 Nm
n in
r
te o
thi
s
iva
do
moving
r
rp
cum
fo
3 - Wiring
en
ng
t.
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op py
4 - Power steering box
. C rig
ht ht
rig by
❑ With power steering copy 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
lkswage es n
o ot g
byV ua
d ran
ir se 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
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
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 aut
h eo
ra
ss c
3 - Wiring
ce
le
un
pt
an
d
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
rrectne
7 - Rubber mounting
ss o
❑ With power steering

cial p
f in
control unit -J500-

form
mer
atio
m

o
n
c
V187-
or
n thi
te
sd
❑ With steering torque

iva
o
r
sender -G269-
p
cum
r
fo
en
ng
❑ Can be checked in gui‐

t.
yi Co
ded fault finding of the Cop py
t. rig
vehicle diagnosis, test‐ yri
gh by
ht
ing and information sys‐
op Vo
by c 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
swage es n
1332- byV
olk ot g
ua
d ran
ir se
♦ Engine and gearbox jack - tho tee
or
V.A.G 1383 A- ss
au ac
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
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
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
V gu
d by ara
ise nte
or eo
h
aut ra
ss c
ce
e
nl
pt
du
an
itte
y li

erm
ab
ility
ot p
wit
, is n
ly.
h re
hole
spec
es, in part or in w
Caution
t to the co

rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.

– Press track rod ball joint off wheel bearing housing with
-3287A-.

-14-.
– Remove exhaust system retainer on subframe.
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
d
– Remove bolts -arrows- on heatoris shield.
e nte
eo
h
ut ra
– Remove heat shield from
s subframe.
s a c
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
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 a16-
gen Afor
G. steering boxdand
gen AG
oes anti-
ksw
roll bar. by Vol not
gu
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
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
frame.
n in
or c
thi
e
– Place a wooden block -1- or similar between V.A.G 1383 A

t
sd
iva
and subframe.
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c 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
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co 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
If steering wheel is not in straight-ahead position or if a new steer‐

hole
spec
ing box was installed, front axle tracking must be checked and if
es, in part or in w
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
l purpos
system -VAS 5051- .

– Carry out basic setting for power steering control unit -J500-
nf
ercia
using vehicle diagnosis, testing and information system -VAS

orm
5051- ⇒ Vehicle diagnosis, testing and information system

m
atio
m
VAS 5051.
o
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
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 d by ara
ise nte
or eo
h
ut ra
Universal joint to steering box ss a 30 Nm c
♦ 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 o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted
372
agen
Prote AG.
Rep. Gr.48 - Steering
Caution
⇒ Rep. Gr. 34 .
boxes.

♦ Use new bolt AG. Volkswagen AG d
agen oes
olksw not
V
M10 x 35 strength class 10.9 d by gu
ara 50 Nm + 90° further
♦ Use new bolt rise nte
tho eo
au ra
ss c
ce
le
♦ Use new bolt

un
pt
an
d
itte
y li
erm
ab
ility
ot p
♦ Use new bolt
wit
is n
h re
ole,
spec
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
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-
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
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
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.

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
le
un
pt
for the service interval display.
an
d
itte
y li
erm
♦ In vehicles without a service interval display, the unused 3-pin
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 o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
– Remove bolt -1- for universal joint and pull universal joint -2- py by
co 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
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
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
-13-.
fo
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.


– Remove bolts -arrows- on heat shield.

– Remove bolts -5- and -6- for steering box.
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
– Remove bolts -7- and -8- for anti-roll bar. h re

hole
spec
es, in part or in w
t to the co

rrectness of i
l purpos
nform
mercia
at
om
ion
c
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.

– 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
ir se tee
tho
u or
a ac
ss
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co

– Unclip all remaining cable clips on steering box.
rrectne
– Disconnect connectors from steering box.

ss
– Lower subframe carefully with engine/gearbox jack -V.A.G

o
cial p
1383 A- .
inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
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.
lkswage es n
o ot g
byV ua
d ran
ir se 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
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
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
e
nl
pt
du
an

itte
y li
system -VAS 5051- .

erm
ab
ility
ot p
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.
nform
mercia
Specified torques
at
om
ion
c
in t
r

o
his
ate
do
riv

p
cum
♦ Use new bolts

for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c 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
Vo lksw
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
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
Caution
rrectness of i

⇒ Rep. Gr. 34 .
l purpos
boxes.
nform
ercia

m
a
com

ion in
r
te o
thi
s
iva
do
r

rp
cum
fo
en
g

n
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

AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss 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
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
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
a oes d
ksw
y Vol t gu
generation) after model year 2009
d b ara
ise n
or tee
th or
s au ac
s
1 - Wiring
ce
e
nl
pt
du
an
itte
2 - Universal joint
y li
erm
ab
ility
3 - Bolt
ot p
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
nform
ercia

m
at
om
ion
c
control unit -J500-
in t
or
his
e
at
do
riv

p
cum
or
V187-
f
en
ng
t.
yi Co
❑ With steering angle Cop py
sender -G85-
t. rig
gh ht
pyri 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‐
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-
AG. Volkswagen AG d
❑ With steering torque agen oes
olksw not
sender -G269- d by V gu
ara
ise nte
❑ Can be checked in gui‐ thor eo
ded fault finding ofssthe
au ra
c
vehicle diagnosis, test‐
ce
e
nl

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

hole
spec
8 - Nut
es, in part or in w
t to the co
❑ M12 x 1.5
rrectness of i
❑ Self-locking
l purpos

9 - Bolt
nf
ercia
orm
m

atio
om
n in
c
10 - Subframe
or
thi
te
sd
a
11 - Wheel bearing housing right

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Running
gen AG. gear,
Volkswaaxles,
gen AGsteering - Edition 08.2009
d
wa oes
olks not
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7.3 Removing and installing steering box, left-hand drive (3rd generation) after
b ara
ed nte
ris
ho eo
model year 2009
t
au ra
c
ss
ce
e
nl
pt
du
an
itte
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erm
equipment required
ab
ility
ot p
wit
, is n
1331-
h re
hole
spec
♦ Torque wrench -V.A.G es, in part or in w
1332-
t to the co
V.A.G 1383 A-
rrectness of i
l purpos
nf
ercia
orm
m
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n in
or c
thi
te
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t.
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Cop py
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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-.
AG. Volkswagen AG d
agen oes
– Remove exhaust system retainer on subframe. Volksw not
gu
by ara
d
rise nte
tho eo
au ra
ss c
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
rrectness of i
l purpos

nf
ercia
orm

m
atio
om
n in
or c
thi
te
sd
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t.
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Cop py
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pyri by
Vo
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by
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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
AG. Volkswagen AG d
agen oes
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or eo
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nl
pt
du
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itte
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ab
ility
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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
frame.
– Place a wooden block -1- or similar between V.A.G 1383 A
nform
ercia
and subframe.
m
at
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ion
c
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or
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ate
do
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for
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AG. Volkswagen AG d
agen oes
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– Remove cable guide from subframe -arrow-. ss c
ce
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nl
pt
du
an
itte
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– Disconnect all electrical connections on steering box.
erm
ab
ility
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– 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
nf
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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
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by
Vol
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ua
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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
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erm
ab
ility
ot p
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, is n
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hole
spec
Note
es, in part or in w
t to the co
rrectness of i
– Bolt universal joint to steering box.
l purpos
– Connect battery. ⇒ Rep. Gr. 27 ; Battery; Disconnecting and

reconnecting battery.
nform
ercia
– Carry out basic setting for -G85-Geber für Lenkwinkel- using

m
at

om
ion
5051.
c
in t
or
his
te

a
do
riv
ing road test.

p
cum
for
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If steering wheel is not in straight-ahead position or if a new steer‐

t.
yi Co
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ing box was installed, front axle tracking must be checked and if C py
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– 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

lkswage es n
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byV ua
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ir se
Golf 2004 ➤ , Golf Plus
th 2005 ➤
o tee
or
u
ss steering - Edition 08.2009
a ac
ce
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un
pt
an
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ab
ility
ot p
♦ Use new bolts
wit
is n
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ole,
spec
♦ Use new nut
t to the co
rrectne
♦ Use new nuts
ss
o
cial p
f
link
inform
♦ Use new nuts
mer
atio
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c
i
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♦ Use new bolts
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♦ Use new bolt p by
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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

AG. Volkswagen AG d
agen oes
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7.4 Removing and installing steering box, right-hand drive (3rd generation) after d by
Vol not
gu
ara
model year 2009 ise nte
or eo
h
aut ra
ss c
ce
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nl
pt
du
an
equipment required
itte
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erm
ab
ility
ot p
1331-
wit
, is n
h re
hole
spec
1332- es, in part or in w
t to the co
V.A.G 1383 A-
rrectness of i
l purpos
nform
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at
om
ion
c
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ate
do
priv
cum
for
en
ng
t.
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Cop py
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cted agen
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.
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
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aut ra
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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
-14-.
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
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ate
do
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t.
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. Volkswagen AG
gen AG d
– Remove bolts
Vol
-5-
ksw and -6- for steering box.
a oes
not
by gu
ara
ed nte
oris eo
th
au ra
c
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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
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
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t.
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Cop py
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by
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Prote AG.

olkswagen AG
Running gear, axles, steering - Edition 08.2009swagen AG. V does
k not
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d by ara
– Remove bolts -11- and -16- for anti-roll bar.orise nte
h eo
ut ra
– Fix position of subframe ⇒ page 16 . ss a c
ce
le
un
pt
an
d
itte
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erm
ab
ility
ot p
wit
is n
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ole,
spec
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n
– Position
thi
te
sd
a
engine and gearbox jack -V.A.G 1383 A- under subframe.

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Co
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Prote AG.
– 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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byV ua
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ir se tee
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un
pt
– Now lift anti-roll bar -1- forwards over subframe -2- and down
an
d
itte
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while turning anti-roll bar slightly.

erm
ab
ility
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– Unbolt steering box from subframe.

wit
is n
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spec
t to the co
rrectness o
cial p
f inform
mer
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c
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or
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t.
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Cop py
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395
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
e
nl
pt
– Connect battery ⇒ Rep. Gr. 27 ; Battery; Disconnecting and

du
an
itte
reconnecting battery .
y li
erm
ab
ility
ot p
wit

, is n
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hole
5051.
spec
es, in part or in w
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.

l purpos

nf
ercia

rm
m
system -VAS 5051- .

atio
om
n in
c
or
thi

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VAS 5051.
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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
agen
Component olksw
oes
not Specified torque
byV gu
ara
Anti-roll bar to subframe orised
20nteNm + 90°
♦ Use new bolts aut
h eo
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ss c
ce
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nl
pt
du
♦ Use new nut
an
itte
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ab
ility
ot p
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♦ Use new nuts
spec
es, in part or in w
t to the co
link
♦ Use new nuts
rrectness of i
l purpos
nf
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o
♦ Use new bolts
rm
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atio
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♦ Use new bolt
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♦ Use new nut
co Vo
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Prote AG.

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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ara
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th or
au
8 Distinguishing between steering box‐c
a
ss
ce
e
es (1st and 2nd generations), Golf

nl
pt
du
an
itte
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ab
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
om
ion
The figure shows a 1st generation steering box.
c
in t
or
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te
Continuation with 1st generation steering box ⇒ page 401 .

a
do
priv
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or
Continuation with 2nd generation steering box ⇒ page 406 .

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Prote AG.

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
y V gu
d b ara
rise 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
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
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Cop py
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9. Differentiating between 2nd and 3rd generation steering boxes 399

10 Exchanging 1st generation ysteering Vol
ksw
age es n
ot g
box for 2nd generation osteering box,
b ua
ed ran
ris tee
Golf
th or
au ac
ss
ce
e
nl
pt
du
an
itte
Note
y li
erm
ab
ility
♦ There are no new 1st generation steering boxes available as ot p
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:
nform
ercia
♦ The wiring harness generally must be exchanged.

m
♦ Subframes from Part No. 1K0.199.369 through and including
at
om
io
1K0.199.369.E. must be exchanged. Subframes from Part No.
n
c
in t
r
1K0.199.369.F need not be exchanged. To order parts via the

o
his
e
⇒ Electronic parts catalogue “ETKA” , the assembly

at
do
riv
1K0.199.313 must be ordered with the respective index.

p
cum
for
en
g
♦ For left-hand-drive vehicles, the right bracket from Part No.

n
t.
yi Co
op
1K0.199.296 through and including 1K0.199.296.C must be C py
t. rig
exchanged. Brackets from Part No. 1K0.199.296.D need not
gh ht
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be exchanged.
cop Vo
by lksw
cted agen
Prote AG.
♦ 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- 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
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
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Cop py
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ht
Removing
rig by
copy Vo
by lksw
cted agen
Prote AG.
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
Note lksw
agen oes
not
Vo gu
by ara
ed
♦ If the steering rack shows horissigns of corrosion, damage, wear or nte
eo
soiling, renew the complete
s aut
steering box. ra
c
s
♦ Likewise, if there is no film of grease on the steering rack, the
ce
le
un
pt
steering box must be renewed.
an
d
itte
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rm
ab
pe
ility
Installing
ot
wit
, is n
h re
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.
nform
mercia
– Tighten lock nut -3- to specified torque while counterholding

a
com
tio
track rod ball joint -2-.

n in
r
te o
thi
– Lightly lubricate seal point between boot and track rod with
s
iva
do
grease -G 052 168 A1- (from repair kit Fuchs Renolit JP1619).
r
rp
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ng
t.
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Cop py
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co lksw
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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 .
swage es n
– Carry out basic setting for steering angle sender -G85- yV
o using
lk ot g
ua
⇒ vehicle diagnostic, testing and information rsystem
ise
d b
-VAS ran
tee
5051B- , “guided fault finding” . utho
or
a ac
ss
– Then carry out basic setting for steering using ⇒ vehicle di‐
ce
le
agnostic, testing and information system -VAS 5051B- , “gui‐
un
pt
an
d
ded fault finding” . itte
y li
rm
ab
pe
ility
Specified torques
ot
wit
, is n
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hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
ercia
equipment required
m
a
com
tion in
r
te o
thi
1275-
s
iva
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r
rp
c
um
fo
en
1332-
ng
t.
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♦ Open jaw insert, 38 mm - t. C rig
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V.A.G 1923- pyri by
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cted agen
♦ 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
ran
ris tee
utho or
a ac
ss
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
joint puller -3287 A- and now remove nut.
spec
es, in part or in w
– 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
l purpos
nform
mercia
at
om
ion
c
in t
or
his
e
– Unscrew track rod from steering rack using open jaw insert,
at
do
riv
38 mm -V.A.G 1923- .
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cum
for
en
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t.
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op
Note C py
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Vo
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♦ If the steering rack shows signs of corrosion, damage, wear or
c by 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 -
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Removing boot
Note
If boot is defective, moisture and dirt will enter steering box. There
must be a palpable film of grease in the area of the teeth on the
steering rack. If there is no film of grease, the steering box must
be renewed. The steering box must also be renewed if corrosion,
damage or wear to the steering rack is present.

– Remove wheel.
– Clean outside of steering box in vicinity of boots.

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

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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” .
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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- .
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12. Repairing electromechanical steering box (2nd and 3rd generations) 409
– Screw track rod into track rod ball joint until dimension -a- is
attained.
Dimension -a- = 371 ± 1 mm
– Turn track rod into steering rack and tighten to specified tor‐
que.
– Position boot -2- on track rod -1-.

V.A.G 1275- .

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Running Gear Axles Steering

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Running Gear Axles Steering

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Service

Service Department. Technical Information

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Copyright © 2010 Volkswagen AG, Wolfsburg K0058991120

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

8.2 Checking outer constant velocity joint . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103

42 - Rear suspension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134

5 Assembly overview: shock absorber, coil spring (front-wheel drive) . . . . . . . . . . . . . . . . . . 173 pt

5.1 Removing and installing coil spring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 173 y li

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

8.2 Overview of rear axle (steel) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 185

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

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

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

8.12 Vehicle data sticker . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . f inform 317

9 Wheels, tyres . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 318

9.1 Models with breakdown set . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 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

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

5 Steering column, Golf Plus, CrossGolf . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 351

5.1 Assembly overview: steering column . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 351

5.2 Removing and installing steering column . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 351

generations) up to model year 2008 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 363

to model year 2008 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 365

year 2008 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 366

the following parts of accident vehicles must be examined in the

Visual and functional examination of steering system

♦ Visual examination for tears in boots

♦ Examine electrical and hydraulic lines and hoses for chafing,

♦ Examine hydraulic lines, threaded connections and steering

steering from stop to stop. In the process, the steering wheel

1. Checklist for evaluating running gear of accident vehicles 1

A checklist for evaluating running gear of accident vehicles can

4 Rep. Gr.40 - Front suspension

I - Assembly overview - sub‐

frame, anti-roll bar, suspen‐

2. Repairing front suspension 5

The chapter “Removing and installing drive shafts” can be found