Running gear, axles, steering

Chapter overview

• Technical data
  1
• 1 Technical data
  1
• 1.1 Technical data
  1
• 1.2 Running gear
  1
• 1.3 Steering
  1
• 1.4 Wheels, tyres
  1
• 2 General notes:
  3
• 2.1 General notes:
  3
• 3 Fastening subframe to body
  3
• 3.1 Fastening subframe to body
  3
• 3.2 Repair of damaged threads
  3
• 4 Environmentally-friendly disposal of fluid-filled components
  4
• 4.1 Environmentally-friendly disposal of fluid-filled components
  4
• 4.2 Releasing gas from front gas-filled shock absorber
  4
• 4.3 Releasing gas in rear gas-filled shock absorber
  5
• 4.4 Draining the power-assisted steering box
  7
• 5 Checking the shock absorber
  8
• 5.1 Checking the shock absorber
  8
• 5.2 Leaks in shock absorbers
  8
• 5.3 Noises from shock absorbers
  9
• 5.4 Checking the shock absorber when removed
  9
• 5.5 Testing the shock absorber on the shock tester
  9
• Front suspension
  12
• 1 Assembly overview of subframe
  12
• 1.1 Assembly overview of subframe
  12
• 1.2 Repairing thread in longitudinal member
  12
• 1.3 Overview of components
  13
• 1.4 Removing and installing anti-roll bar
  22
• 1.5 Vehicle levelling sender in vehicles with automatic headlight range control
  27
• 1.6 Checking lower ball joint
  31
• 1.7 Removing and installing ball joint
  32
• 1.8 Removing and installing wishbone
  35
• 1.9 Replacing bonded rubber bushes for wishbone
  36
• 1.10 Removing and installing subframe
  41
• 1.11 Replacing subframe bushes
  45
• 2 Assembly overview: Wheel bearing
  48
• 2.1 Assembly overview: Wheel bearing
  48
• 2.2 Drive shaft/wheel hub splines
  49
• 2.4 Removing and installing wheel bearing housing
  64
• 3 Assembly overview: Suspension strut
  73
• 3.1 Assembly overview: Suspension strut
  73
• 3.2 Removing and installing suspension strut/coil spring
  77
• 4 Drive shafts
  83
• 4.1 Drive shafts
  83
• 4.2 Removing and installing drive shaft
  83
• 4.3 Servicing drive shaft with constant velocity joint
  85
• 4.4 Checking outer constant velocity joint
  95
• 4.5 Checking inner constant velocity joint
  96
• 4.6 Repairing drive shaft with inner tripod joint
  101
• 4.7 Dismantling and assembling inner tripod joint
  110
• Rear suspension
  114
• 1 Servicing rear axle (front-wheel drive vehicles)
  114
• 1.1 Servicing rear axle (front-wheel drive vehicles)
  114
• 1.2 Removing and installing rear axle
  114
• 1.3 Assembly overview rear axle beam
  117
• 1.4 Removing and installing bonded rubber bush
  125
• 1.5 Removing and installing shock absorber/spring
  127
• 1.6 Assembly overview of shock absorber on FWD vehicles
  131
• 1.7 Vehicle levelling sender in vehicles with automatic headlight range control
  133
• 2 Servicing wheel bearing
  134
• 2.1 Servicing wheel bearing
  134
• 2.2 Servicing wheel bearing, front-wheel drive vehicles
  134
• 2.3 Removing and installing wheel bearing/wheel hub unit
  136
• 3 Servicing rear axle (vehicles with four-wheel drive)
  139
• 3.1 Servicing rear axle (vehicles with four-wheel drive)
  139
• 3.2 Overview for rear axle with four-wheel drive
  140
• 3.3 Removing and installing spring
  142
• 3.4 Removing and installing shock absorber
  147
• 3.5 Removing and installing anti-roll bar
  149
• 3.6 Checking exhaust system for leaks
  153
• 4 Assembly overview of longitudinal and transverse link
  156
• 4.1 Assembly overview of longitudinal and transverse link
  156
• 4.2 Vehicle levelling sender in vehicles with automatic headlight range control
  162
• 4.3 Pressing in and pressing out wheel bearing
  163
• 4.4 Removing and installing bearing for longitudinal link
  169
• 4.5 Removing and installing ball bearings
  172
• 4.6 Removing and installing longitudinal link
  175
• 4.7 Removing and installing transverse link
  179
• 5 Assembly overview of subframe with axle drive
  187
• 5.1 Assembly overview of subframe with axle drive
  187
• 5.2 Removing and installing subframe
  190
• 5.3 Removing and installing bonded rubber bush for subframe
  194
• 5.4 Removing and installing bonded rubber bush for final drive
  197
• 6 Servicing drive shaft
  200
• 6.1 Servicing drive shaft
  200
• 6.2 Removing and installing drive shaft
  200
• 6.3 Servicing drive shaft with constant velocity joint
  203
• Wheels, Tyres, Wheel alignment
  212
• 1 Wheels and tyres
  212
• 1.1 Wheels and tyres
  212
• 1.2 Balancing wheels on the vehicle
  212
• 1.3 Instructions for changing/fitting wheels
  213
• 2 Vehicle alignment
  214
• 2.1 Vehicle alignment
  214
• 2.2 General notes
  214
• 2.3 Specified values for vehicle alignment, standard running gear
  215
• 2.4 Specified values for vehicle alignment, sports running gear (PQZ)
  216
• 2.5 Specified values for vehicle alignment for the New Beetle RSi
  218
• 2.6 Test requirements:
  218
• 2.7 Measuring procedure
  219
• 2.8 Checking rear axle camber (FWD vehicles)
  221
• 2.9 Adjusting rear axle camber (vehicles with four-wheel drive)
  221
• 2.10 Centring rear axle toe (vehicles with front-wheel drive)
  221
• 2.11 Adjusting toe at rear axle for vehicles with four-wheel drive
  222
• 2.12 Adjusting front axle camber
  222
• 2.13 Adjusting toe at front axle
  223
• Steering
  224
• 1 Airbag, steering wheel, steering column
  224
• 1.1 Airbag, steering wheel, steering column
  224
• 1.2 Removing and installing driver's airbag unit
  224
• 1.3 Servicing steering wheel
  229
• 1.4 Removing and installing steering column
  230
• 1.5 Removing and installing steering lock housing
  238
• 1.6 Checking steering column for damage
  239
• 1.7 Assembly overview, cross member for steering column
  241
• 1.8 Differing steering columns
  243
• 2 Servicing power assisted steering
  247
• 2.1 Servicing power assisted steering
  247
• 2.2 Removing and installing power assisted steering box
  247
• 2.3 Assembly overview, power steering box (LHD)
  252
• 2.4 Assembly overview, power steering box (RHD)
  256
• 2.6 Removing and installing track rod
  260
• 2.7 Modified track rod ball joints
  262
• 2.8 Modified track rods
  263
• 2.9 Checking play, security and boots on tie rod ends
  264
• 2.10 Determining central position on rack
  264
• 2.11 Adjusting steering box
  264
• 3 Vane pump, reservoir, hydraulic pipes
  265
• 3.1 Vane pump, reservoir, hydraulic pipes
  265
• 3.2 Checking vane pump delivery pressure
  265
• 3.3 Removing and installing vane pump; models with low mounted vane pumps
  272
• 3.4 Assembly overview: Vane pump with hydraulic pipes/hoses
  276
• 3.5 Assembly overview for low-mounted vane pump
  282