Running gear, axles, steering

Chapter overview

• Technical data
  1
• 1 Checklist for evaluating running gear of accident vehicles
  1
• 2 General information
  3
• Front suspension
  4
• 1 Appraisal of accident vehicles
  4
• 2 Servicing 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 links
  11
• 3.1 Assembly overview: subframe, anti-roll bar, suspension links
  11
• 3.2 Assembly overview: front left vehicle level sender G78
  16
• 3.3 Removing and installing front left vehicle level sender G78
  16
• 3.4 Repairing thread in longitudinal member
  17
• 3.5 Fixing position of subframe and brackets
  18
• 3.6 Lowering subframe
  19
• 3.7 Removing and installing subframe without steering rack
  23
• 3.8 Removing and installing subframe with steering rack
  25
• 3.9 Repairing subframe
  30
• 3.10 Checking swivel joint
  38
• 3.11 Removing and installing swivel joint
  39
• 3.12 Removing and installing suspension link with mounting bracket
  43
• 3.15 Renewing bonded rubber bush for suspension link
  53
• 3.16 Renewing mounting bracket with suspension link bush
  55
• 3.17 Removing and installing anti-roll bar
  57
• 4 Assembly overview: wheel bearing
  63
• 4.1 Removing and installing wheel bearing housing (3-point mounting)
  65
• 4.2 Removing and installing wheel bearing housing (4-point mounting)
  67
• 4.3 Removing and installing wheel bearing housing
  68
• 5 Assembly overview: suspension strut
  74
• 5.1 Removing and installing suspension strut, Golf
  75
• 5.2 Removing and installing suspension strut, Golf Plus, CrossGolf
  82
• 5.3 Repairing suspension strut
  89
• 6 Removing and installing drive shafts
  92
• 6.1 Loosening and tightening drive shaft hexagon bolt
  92
• 6.2 Loosening and tightening twelve-point head bolt, with ribbing, securing drive shaft
  93
• 6.4 Removing and installing drive shaft with constant velocity joint
  96
• 6.6 Removing and installing right drive shaft with (push-on) constant velocity slip joint
  104
• 6.7 Removing and installing drive shafts with triple roller joint AAR2600i
  110
• 6.8 Removing and installing drive shafts with triple roller joint AAR3300i
  114
• 6.9 Removing and installing intermediate shaft
  118
• 7 Repairing drive shaft - overview of drive shafts
  120
• 7.1 Heat shields for drive shafts
  122
• 8 Assembly overview: drive shaft with VL90 or VL100 constant velocity joint
  123
• 8.1 Dismantling and assembling drive shaft with VL90 or VL100 constant velocity joint
  125
• 8.2 Checking outer constant velocity joint
  130
• 8.3 Checking inner constant velocity joint
  130
• 9 Assembly overview: drive shaft with VL107 constant velocity joint (bolt-on)
  133
• 9.1 Dismantling and assembling drive shaft with VL107 constant velocity joint
  136
• 9.2 Repairing intermediate shaft
  140
• 10 Assembly overview: drive shaft with VL107 constant velocity slip joint (push-on)
  143
• 10.1 Dismantling and assembling drive shaft with VL107 (push-on) constant velocity slip joint
  144
• 10.2 Checking outer constant velocity joint
  147
• 11 Assembly overview: drive shaft with triple roller joint AAR2600i
  149
• 11.1 Dismantling and assembling drive shaft with triple roller joint AAR2600i
  151
• 12 Assembly overview: drive shaft with triple roller joint AAR3300i
  156
• 12.1 Dismantling and assembling drive shaft with triple roller joint AAR3300i
  158
• Rear suspension
  164
• 1 Appraisal of accident vehicles
  164
• 2 Repairing rear suspension (front-wheel drive)
  165
• 2.1 Overview - rear axle
  165
• 2.2 Rear axle in unladen position, Golf
  166
• 2.3 Rear axle in unladen position, Golf Plus, CrossGolf
  168
• 3 Assembly overview: subframe, transverse link, track rod (front-wheel drive)
  170
• 3.1 Removing and installing rear axle
  173
• 3.2 Vehicle level sender for vehicles with automatic headlight range control
  177
• 3.3 Renew vehicle level sender in vehicle
  178
• 3.4 Removing and installing upper transverse link
  179
• 3.5 Removing and installing lower transverse link
  181
• 3.6 Removing and installing track rod
  182
• 4 Assembly overview: wheel bearing housing, trailing arm (front-wheel drive)
  185
• 4.1 Removing and installing wheel bearing housing
  186
• 4.2 Renewing bonded rubber bush for wheel bearing housing
  189
• 4.3 Removing and installing wheel bearing/wheel hub unit
  192
• 4.4 Removing and installing trailing arm with mounting bracket
  195
• 4.5 Repairing trailing arm
  199
• 5 Assembly overview: shock absorber, coil spring (front-wheel drive)
  203
• 5.1 Removing and installing coil spring
  203
• 5.2 Removing and installing shock absorbers
  205
• 5.3 Repairing shock absorber
  206
• 6 Assembly overview: anti-roll bar (front-wheel drive)
  209
• 6.1 Removing and installing anti-roll bar
  209
• 8 Repairing rear suspension (four-wheel drive)
  213
• 8.1 Overview of rear axle (aluminium)
  213
• 8.2 Overview of rear axle (steel)
  215
• 8.3 Rear axle in unladen state (aluminium and steel)
  217
• 9 Assembly overview: subframe made from aluminium, final drive (four-wheel drive)
  219
• 9.1 Removing and installing rear axle
  219
• 9.2 Repairing subframe
  224
• 10 Assembly overview: subframe made from steel, final drive (four-wheel drive)
  229
• 10.1 Removing and installing rear axle
  229
• 10.2 Repairing subframe
  234
• 11.1 Overview - rear left vehicle level sender G76
  245
• 11.2 Renew vehicle level sender in vehicle
  245
• 11.3 Removing and installing upper transverse link
  246
• 11.4 Removing and installing lower transverse link
  247
• 11.5 Removing and installing track rod
  249
• 12.1 Overview - rear left vehicle level sender G76
  256
• 12.2 Renew vehicle level sender in vehicle
  256
• 12.3 Removing and installing upper transverse link
  257
• 12.4 Removing and installing lower transverse link
  259
• 12.5 Removing and installing track rod
  261
• 13.2 Removing and installing wheel bearing housing
  266
• 13.3 Renewing bonded rubber bush for wheel bearing housing
  270
• 13.4 Removing and installing wheel bearing/wheel hub unit
  273
• 13.5 Removing and installing trailing arm with mounting bracket
  274
• 13.6 Repairing trailing arm
  278
• 14.1 Removing and installing wheel bearing housing
  284
• 14.2 Renewing bonded rubber bush for wheel bearing housing
  287
• 14.3 Removing and installing wheel bearing/wheel hub unit
  287
• 15.1 Removing and installing coil spring
  289
• 15.2 Removing and installing shock absorbers
  291
• 15.3 Repairing shock absorber
  292
• 16.1 Removing and installing coil spring
  294
• 16.2 Removing and installing shock absorbers
  294
• 16.3 Repairing shock absorber
  296
• 17.1 Removing and installing anti-roll bar
  297
• 18.1 Removing and installing anti-roll bar
  300
• 19 Assembly overview: drive shaft
  303
• 19.1 Loosening and tightening drive shaft hexagon bolt
  305
• 19.2 Loosening and tightening twelve-point head bolt, with ribbing, securing drive shaft
  306
• 19.4 Removing and installing drive shaft
  309
• 19.5 Dismantling and assembling drive shaft
  313
• 19.6 Checking outer constant velocity joint
  319
• 19.7 Checking inner constant velocity joint
  320
• Wheels, tyres, vehicle geometry
  323
• 1 Appraisal of accident vehicles
  323
• 2 Specified torques for wheel bolts
  324
• 3 Fitting wheel and tyre
  325
• 3.1 General information
  325
• 3.2 Fittings instructions
  325
• 4 Removing and fitting tyres (wheels with tyre pressure monitoring)
  327
• 4.2 Wheel change
  327
• 4.3 Pressing tyre off wheel rim
  328
• 4.4 Removing tyre from wheel
  329
• 4.5 Fitting tyre to wheel rim
  329
• 5 Removing and fitting tyres with run-flat properties to wheel rims
  331
• 5.1 Safety information
  331
• 5.2 Pressing tyre off wheel rim
  331
• 5.3 Removing tyre from wheel
  332
• 5.4 Fitting tyre to wheel rim
  333
• 6 Tyre pressure monitor display
  336
• 7 Tyre pressure monitoring system (TPMS)
  338
• 7.1 Button behaviour
  338
• 7.2 Assembly overview: tyre pressure sensor
  339
• 7.3 Removing and installing tyre pressure sensor
  340
• 8 Vehicle alignment check
  342
• 8.1 General information
  342
• 8.2 Test conditions
  344
• 8.3 Test preparations
  344
• 8.4 Wheel alignment specifications, Golf
  345
• 8.5 Wheel alignment specifications, Golf Plus, CrossGolf
  347
• 8.6 Overview - wheel alignment procedure
  348
• 8.7 Correcting front axle camber
  350
• 8.8 Adjusting camber on rear axle
  351
• 8.9 Adjusting toe at rear axle
  353
• 8.10 Adjusting front axle toe
  353
• 8.11 Basic setting of steering angle sensor G85
  354
• 8.12 Vehicle data sticker
  355
• 9 Wheels, tyres
  356
• 9.1 Models with breakdown set
  356
• 9.2 Tyre sealant
  356
• 9.3 Removing a tyre
  356
• 9.4 Fitting a new tyre
  357
• 9.5 Tyre sealant disposal
  357
• 9.6 Alloy wheels with metal valves
  357
• 10 Instructions for changing or fitting wheels
  359
• 10.1 Fitting wheels
  360
• 11 Protecting wheel centring seat against corrosion
  361
• 12 Vibration due to wheels/tyres - causes and rectification
  362
• 12.1 Causes of rough running
  362
• 12.2 Balancing wheels
  362
• 12.3 Conducting a road test before balancing wheels
  362
• 12.4 Balancing wheels on stationary wheel balancing machine
  363
• 12.5 Vibration control system VAS 6230 A
  365
• 12.6 Finish balancer
  365
• 12.7 Radial and lateral runout of wheels and tyres
  366
• 12.9 Checking radial and lateral run-out on wheel rim
  367
• 12.10 Matching
  368
• 12.11 Flat spots caused by storage or handling
  369
• Steering
  371
• 1 Appraisal of accident vehicles
  371
• 2 General repair instructions
  372
• 2.1 Steering rack
  372
• 2.2 Gaskets and seals
  372
• 2.3 Nuts and bolts
  372
• 2.4 Electrical components
  373
• 2.5 Guided Fault Finding, vehicle self-diagnosis and test instruments
  373
• 3 Steering wheel
  374
• 3.1 Removing and installing steering wheel
  374
• 4 Steering column, Golf
  377
• 4.1 Assembly overview: steering column
  377
• 4.2 Removing and installing steering column
  377
• 4.4 Handling and transporting steering column
  383
• 4.5 Checking steering column for damage
  385
• 4.6 Removing and installing mounting bracket
  385
• 4.7 Removing and installing strut
  387
• 5 Steering column, Golf Plus, CrossGolf
  389
• 5.1 Assembly overview: steering column
  389
• 5.2 Removing and installing steering column
  389
• 5.4 Handling and transporting steering column
  395
• 5.5 Checking steering column for damage
  397
• 5.6 Removing and installing mounting bracket
  397
• 5.7 Removing and installing strut
  399
• 6 Electromechanical steering rack up to model year 2008
  401
• 7 Electromechanical steering rack from model year 2009
  421
• 8 Distinguishing between steering racks (1st and 2nd generations), Golf
  439
• 9 Differentiating between 2nd and 3rd generation steering racks
  440
• 10 Exchanging 1st generation steering rack for 2nd generation steering rack, Golf
  441
• 11 Repairing electromechanical steering rack (1st generation), Golf
  442
• 11.1 Removing and installing bellows
  442
• 11.2 Removing and installing track rod
  444
• 12 Repairing electromechanical steering rack (2nd and 3rd generation)
  448
• 12.1 Assembly overview: electromechanical steering rack
  448
• 12.2 Removing and installing bellows
  449
• 12.3 Removing and installing track rod
  451