Running gear, axles, steering

Chapter overview

• Technical data
  1
• 1 Technical data
  1
• 1.1 Running gear
  1
• 1.2 Wheels, tyres
  1
• Front suspension
  2
• 1 Electrical/electronic components and locations
  2
• 1.2 Front left vehicle level sender G78 on front axle
  3
• 1.3 Rear left vehicle level sender G76 on rear axle
  4
• 2 Torque settings for front axle
  6
• 3 Repairing front suspension
  9
• 3.1 Overview - front axle
  9
• 3.2 I: Assembly overview: subframe, anti-roll bar and suspension link
  10
• 3.3 Checking swivel joint
  12
• 3.4 Removing and installing swivel joint
  13
• 3.5 Removing and installing suspension link
  15
• 3.6 Renewing bonded rubber bush for suspension link
  17
• 3.7 Removing and installing subframe
  20
• 3.8 Renewing bonded rubber bushes in subframe
  23
• 3.9 Repairing threads in longitudinal member
  24
• 3.10 II: Assembly overview: wheel bearing
  25
• 3.12 III: Assembly overview: coil spring strut
  35
• 3.13 Removing and installing suspension strut
  36
• 3.14 Repairing front suspension strut
  38
• 4 Repairing drive shafts
  41
• 4.1 Overview - drive shafts
  41
• 4.3 Removing and installing triple roller joint drive shaft AAR 3300i
  45
• 4.4 I - Repairing front drive shaft with constant velocity joint
  49
• 4.5 Removing, checking and installing outer constant velocity joint
  55
• 4.6 Removing, checking and installing inner constant velocity joint
  56
• 4.7 II - Repairing front drive shaft with triple roller joint AAR 2000
  58
• 4.8 Dismantling and assembling triple roller joint
  61
• 4.9 IV - Repairing front drive shaft with triple roller joint AAR 2900
  63
• 4.10 Dismantling and assembling triple roller joint AAR 2900
  67
• 4.11 IV - Repairing drive shaft with triple roller joint AAR 3300i
  71
• 4.12 Dismantling and assembling triple roller joint AAR 3300i
  75
• Rear suspension
  77
• 1 Rear axle in unladen position
  77
• 2 Torque settings for rear axle
  79
• 3 Repairing rear axle
  80
• 3.1 Removing and installing rear axle
  80
• 3.2 Assembly overview - rear axle beam
  83
• 3.3 Removing and installing bonded rubber bush
  86
• 3.4 Removing and installing hydraulic bonded rubber bush
  90
• 3.5 Removing and installing spring/shock absorber
  96
• 3.6 Assembly overview - shock absorber on vehicle with front-wheel drive
  98
• 4 Repairing wheel bearing
  100
• 4.1 Repairing wheel bearing, front-wheel drive vehicles
  100
• 4.2 Removing and installing wheel bearing/wheel hub on vehicles with disc brakes
  101
• Wheels, tyres, vehicle geometry
  104
• 1 Specified torque for wheel bolts
  104
• 2 Protecting wheel centring seat against corrosion
  105
• 3 Wheels, tyres
  106
• 3.1 Models with breakdown set
  106
• 3.2 Removing a tyre
  106
• 4 Wheel alignment
  108
• 4.1 General
  108
• 4.2 Test prerequisites:
  109
• 4.3 Test preparations
  109
• 4.4 Vehicle data sticker
  110
• 4.5 Wheel alignment specifications
  111
• 4.6 Adjusting camber at front axle
  113
• 4.7 Adjusting camber on rear axle
  114
• 4.8 Adjusting toe setting on rear axle (front-wheel drive vehicles)
  114
• 4.9 Adjusting front axle toe
  115
• 4.10 Checking left and right-hand wheel lock
  115
• Steering
  117
• 1 Connecting VAS 5051 A and selecting functions
  117
• 2 Torque settings for steering system
  119
• 2.1 Torque settings for steering column
  119
• 2.2 Torque settings for steering rack
  120
• 2.3 Torque settings for vane pump
  120
• 2.4 Torque settings for pressure line/suction hose to engine
  121
• 3 Steering column
  126
• 3.1 Removing and installing steering column
  126
• 3.2 Checking steering column for damage
  133
• 3.3 Removing and installing steering lock housing
  134
• 3.4 Assembly overview - steering column cross member for New Beetle saloon . . . .
  135
• 3.6 Steering column variations
  137
• 3.7 Removing and installing locking cable for ignition with key removal lock
  139
• 3.8 Checking ignition key removal lock
  140
• 4 Repairing power steering
  141
• 4.1 Removing and installing power-assisted steering rack
  141
• 4.2 Assembly overview - power steering rack (LHD)
  145
• 4.3 Assembly overview - power steering rack (RHD)
  147
• 4.4 Removing and installing track rod
  149
• 4.5 Revised track rod ball joints
  150
• 4.6 Revised track rods
  151
• 4.7 Checking play, tightness and bellows of track rod ball joints
  151
• 4.8 Determining centre position of steering rack
  152
• 4.9 Adjusting steering rack
  152
• 5 Bottom-mounted vane pump
  153
• 5.1 Assembly overview
  153
• 5.2 Checking delivery pressure of vane pump
  154
• 5.3 Removing and installing vane pump
  156
• 6 Top-mounted vane pump
  160
• 6.1 Assembly overview
  160
• 6.2 Checking delivery pressure of vane pump
  161
• 6.3 Removing and installing vane pump
  164
• 7 Top-mounted vane pump (vehicles with 2.5 l 5-cylinder engine)
  168
• 7.1 Assembly overview
  168
• 7.2 Checking delivery pressure of vane pump
  169
• 7.3 Removing and installing vane pump
  171
• 8 Vane pump, reservoir, hydraulic lines (vehicles with 1.4 l engine)
  174
• 8.1 Assembly overview
  174
• 9.1 Assembly overview
  178
• 10 Vane pump, reservoir, hydraulic lines (vehicles with 2.3 l V5 engine)
  185
• 10.1 Assembly overview
  185
• 11 Vane pump, reservoir, hydraulic lines (vehicles with 2.5 l 5-cyl. engine)
  188
• 11.1 Assembly overview
  188
• 12 Securing pressure line on manual and automatic gearboxes
  191
• 12.1 Securing pressure line on 5-speed manual gearbox 02T
  191
• 12.2 Securing pressure line on 5-speed manual gearbox 02J
  192
• 12.3 Securing pressure line on 5-speed manual gearbox 0A4
  194
• 12.4 Securing pressure line on 6-speed manual gearbox 02M
  196
• 12.5 Securing pressure line on automatic gearbox 01M
  197
• 13 Bleeding steering system, checking for leaks and checking fluid level
  206
• 13.1 Bleeding steering system
  206
• 13.2 Checking steering system for leaks
  206
• 13.3 Checking power steering fluid level
  207