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
  6
• 3 Subframe, anti-roll bar, suspension links
  9
• 3.1 Assembly overview: subframe, anti-roll bar, suspension links
  9
• 3.2 Assembly overview: front left vehicle level sender G78
  14
• 3.3 Removing and installing front left vehicle level sender G78
  14
• 3.4 Repairing thread in longitudinal member
  15
• 3.5 Fixing position of subframe and brackets
  16
• 3.6 Lowering subframe
  17
• 3.7 Removing and installing subframe without steering rack
  21
• 3.8 Removing and installing subframe with steering rack
  23
• 3.9 Repairing subframe
  28
• 3.10 Checking swivel joint
  37
• 3.11 Removing and installing swivel joint
  37
• 3.12 Removing and installing suspension link with mounting bracket
  41
• 3.14 Renewing bonded rubber bush for suspension link
  48
• 3.15 Renewing mounting bracket with suspension link bush
  50
• 3.16 Removing and installing anti-roll bar
  51
• 4 Assembly overview: wheel bearing
  57
• 4.1 Removing and installing wheel bearing unit
  59
• 4.2 Removing and installing wheel bearing housing
  61
• 5 Assembly overview: suspension strut
  66
• 5.1 Removing and installing suspension strut
  67
• 5.2 Repairing suspension strut
  72
• 6 Removing and installing drive shafts
  75
• 6.1 Loosening and tightening drive shaft hexagon bolt
  75
• 6.2 Loosening and tightening twelve-point head bolt, with ribbing, securing drive shaft
  76
• 6.4 Removing and installing drive shaft with constant velocity joint
  79
• 6.6 Removing and installing right drive shaft with (push-on) constant velocity slip joint
  85
• 6.7 Removing and installing drive shafts with triple roller joint AAR2600i
  89
• 6.8 Removing and installing drive shafts with triple roller joint AAR3300i
  92
• 6.9 Removing and installing intermediate shaft
  95
• 7 Repairing drive shaft - overview of drive shafts
  97
• 7.1 Heat shields for drive shafts
  99
• 8 Assembly overview: drive shaft with VL90 or VL100 constant velocity joint
  100
• 8.1 Dismantling and assembling drive shaft with VL90 or VL100 constant velocity joint
  102
• 8.2 Checking outer constant velocity joint
  107
• 8.3 Checking inner constant velocity joint
  107
• 9 Assembly overview: drive shaft with VL107 constant velocity joint (bolt-on)
  110
• 9.1 Dismantling and assembling drive shaft with VL107 constant velocity joint
  113
• 9.2 Repairing intermediate shaft
  117
• 10 Assembly overview: drive shaft with VL107 constant velocity slip joint (push-on)
  120
• 10.1 Dismantling and assembling drive shaft with VL107 (push-on) constant velocity slip joint
  121
• 10.2 Checking outer constant velocity joint
  124
• 11 Assembly overview: drive shaft with triple roller joint AAR2600i
  126
• 11.1 Dismantling and assembling drive shaft with triple roller joint AAR2600i
  128
• 12 Assembly overview: drive shaft with triple roller joint AAR3300i
  133
• 12.1 Dismantling and assembling drive shaft with triple roller joint AAR3300i
  135
• Rear suspension
  140
• 1 Appraisal of accident vehicles
  140
• 2 Repairing rear suspension (front-wheel drive)
  141
• 2.1 Overview - rear axle
  141
• 2.2 Rear axle in unladen position
  142
• 3 Assembly overview: subframe, transverse link, track rod (front-wheel drive)
  145
• 3.1 Removing and installing rear axle
  147
• 3.2 Vehicle level sender for vehicles with automatic headlight range control
  151
• 3.3 Renew vehicle level sender in vehicle
  152
• 3.4 Removing and installing upper transverse link
  153
• 3.5 Removing and installing lower transverse link
  155
• 3.6 Removing and installing track rod
  156
• 4 Assembly overview: wheel bearing housing, trailing arm (front-wheel drive)
  159
• 4.1 Removing and installing wheel bearing housing
  160
• 4.2 Renewing bonded rubber bush for wheel bearing housing
  163
• 4.3 Removing and installing wheel bearing/wheel hub unit
  166
• 4.4 Removing and installing trailing arm with mounting bracket
  169
• 4.5 Repairing trailing arm
  173
• 5 Assembly overview: shock absorber, coil spring
  176
• 5.1 Removing and installing coil spring
  176
• 5.2 Removing and installing shock absorbers
  178
• 5.3 Repairing shock absorber
  179
• 6 Assembly overview: anti-roll bar
  182
• 6.1 Removing and installing anti-roll bar
  182
• 7.1 Removing and installing shield
  186
• 8 Repairing rear suspension (four-wheel drive)
  188
• 8.1 Overview - rear axle
  188
• 8.2 Rear axle in unladen position
  190
• 9 Assembly overview: subframe, final drive (four-wheel drive)
  192
• 9.1 Removing and installing rear axle
  192
• 9.2 Repairing subframe
  197
• 10 Assembly overview: transverse link, track rod (four-wheel drive)
  205
• 10.1 Overview - rear left vehicle level sender G76
  208
• 10.2 Renew vehicle level sender in vehicle
  208
• 10.3 Removing and installing upper transverse link
  209
• 10.4 Removing and installing lower transverse link
  211
• 10.5 Removing and installing track rod
  213
• 11 Assembly overview: wheel bearing housing, trailing arm (four-wheel drive)
  216
• 11.1 Removing and installing wheel bearing housing
  218
• 11.2 Renewing bonded rubber bush for wheel bearing housing
  221
• 11.3 Removing and installing wheel bearing/wheel hub unit
  224
• 11.4 Removing and installing trailing arm with mounting bracket
  226
• 11.5 Repairing trailing arm
  229
• 12 Assembly overview: shock absorber, coil spring (four-wheel drive)
  232
• 12.1 Removing and installing coil spring
  232
• 12.2 Removing and installing shock absorbers
  234
• 12.3 Repairing shock absorber
  236
• 13 Assembly overview: anti-roll bar (four-wheel drive)
  239
• 13.1 Removing and installing anti-roll bar
  239
• 14 Assembly overview: drive shaft
  242
• 14.1 Loosening and tightening twelve-point head bolt, with ribbing, securing drive shaft
  243
• 14.3 Removing and installing drive shaft
  246
• 14.4 Dismantling and assembling drive shaft
  249
• 14.5 Checking outer constant velocity joint
  254
• 14.6 Checking inner constant velocity joint
  255
• Wheels, tyres, vehicle geometry
  257
• 1 Appraisal of accident vehicles
  257
• 2 Torque settings for wheels
  258
• 3 Fitting wheel and tyre
  259
• 3.1 General information
  259
• 3.2 Fittings instructions
  259
• 4 Removing and fitting tyres (wheels with tyre pressure monitoring)
  261
• 4.2 Wheel change
  261
• 4.3 Pressing tyre off wheel rim
  262
• 4.4 Removing tyre from wheel
  263
• 4.5 Fitting tyre to wheel rim
  263
• 5 Removing and fitting tyres with run-flat properties to wheel rims
  265
• 5.1 Safety information
  265
• 5.2 Fittings instructions
  265
• 5.3 Pressing tyre off wheel rim
  266
• 5.4 Removing tyre from wheel
  267
• 5.5 Fitting tyre to wheel rim
  268
• 6 Tyre pressure monitor display
  271
• 6.1 General information
  271
• 6.2 System fault in the ABS system
  272
• 6.3 Perform basic settings
  272
• 7 Tyre pressure monitor
  274
• 7.1 Button behaviour
  274
• 7.2 Assembly overview: tyre pressure sensor
  275
• 7.3 Removing and installing tyre pressure sensor
  276
• 8 Vehicle alignment check
  278
• 8.1 General information
  278
• 8.2 Conditions for testing
  280
• 8.3 Test preparations
  280
• 8.4 Specifications for wheel alignment Jetta from 2006, Golf Variant from 2007
  281
• 8.6 Specifications for wheel alignment Bora from 2006 (Mexico)
  284
• 8.7 Specifications for wheel alignment, Jetta from 2006 (India)
  285
• 8.8 Overview - wheel alignment procedure
  286
• 8.9 Correcting front axle camber
  287
• 8.10 Adjusting camber on rear axle
  288
• 8.11 Adjusting toe at rear axle
  290
• 8.12 Adjusting front axle toe
  291
• 8.13 Basic setting of steering angle sensor G85
  292
• 8.14 Vehicle data sticker
  292
• 9 Wheels, tyres
  293
• 9.1 Models with breakdown set
  293
• 9.2 Tyre sealant
  293
• 9.3 Removing a tyre
  293
• 9.4 Fitting a new tyre
  294
• 9.5 Tyre sealant disposal
  294
• 9.6 Alloy wheels with metal valves
  294
• 10 Instructions for changing or fitting wheels
  296
• 10.1 Fitting wheels
  297
• 11 Protecting wheel centring seat against corrosion
  298
• 12 Vibration due to wheels/tyres - causes and rectification
  299
• 12.1 Causes of rough running
  299
• 12.2 Balancing wheels
  299
• 12.3 Conducting a road test before balancing wheels
  299
• 12.4 Balancing wheels on stationary wheel balancing machine
  300
• 12.5 Vibration control system VAS 6230 A
  303
• 12.6 Finish balancer
  303
• 12.7 Radial and lateral runout of wheels and tyres
  304
• 12.9 Checking radial and lateral run-out on wheel rim
  305
• 12.10 Matching
  306
• 12.11 Flat spots caused by storage or handling
  307
• Steering
  309
• 1 Appraisal of accident vehicles
  309
• 2 General repair instructions
  310
• 2.1 Steering rack
  310
• 2.2 Gaskets and seals
  310
• 2.3 Nuts and bolts
  310
• 2.4 Electrical components
  311
• 2.5 Guided Fault Finding, vehicle self-diagnosis and Test Instruments
  311
• 3 Steering wheel, steering column
  312
• 3.1 Removing and installing steering wheel
  312
• 3.4 Assembly overview - steering column, left-hand drive, Jetta as of model year 2009
  321
• 3.10 Handling and transporting steering column, Jetta as of model year 2009
  338
• 3.11 Checking steering column for damage
  339
• 4 Electromechanical steering rack up to model year 2008
  343
• 5 Electromechanical steering rack from model year 2009
  364
• 6 Differentiating between 2nd and 3rd generation steering racks
  382
• 7 Repairing electromechanical 2nd and 3rd generation steering racks
  383
• 7.1 Removing and installing boot
  383
• 7.2 Removing and installing track rod
  385