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  • Examplepage for repair manual Running gear, axles, steering
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  • Examplepage for repair manual Running gear, axles, steering
  • Examplepage for repair manual 2 Running gear, axles, steering
  • Examplepage for repair manual 3 Running gear, axles, steering

Running gear, axles, steering

For Polo

Original Volkswagen repair manual


22,19 €7% VAT incl.

  • Deutsch
  • English

Immediately available for download

Language: English

Digital PDF file

7.116 KB

278 Sites

Detailed technical data

Immediately readable

This repair manual contains: Appraisal of accident vehicles, Servicing front suspension, Assembly overview: wheel bearing, Repairing drive shaft - overview of drive shafts, Specified torque for wheel bolts, Fitting wheel and tyre, Removing and fitting tyres with run-flat properties to wheel rims, Tyre Pressure Loss Indicator (TPLI), Vehicle alignment check, Instructions for changing or fitting wheels and Protecting wheel centring seat against corrosion. Show more
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Repair manual Polo Running gear, axles, steering PDF download has the following content:

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
  • 3.1 Repairing threads in longitudinal member
    11
  • 3.2 Fixing position of subframe
    12
  • 3.3 Checking swivel joint
    14
  • 3.4 Removing and installing swivel joint
    14
  • 3.5 Installation position of swivel joints
    17
  • 3.6 Removing and installing suspension link
    17
  • 3.7 Removing and installing suspension bracket
    19
  • 3.8 Renewing bonded rubber bush for suspension bracket
    21
  • 3.9 Removing and installing subframe
    24
  • 3.10 Removing and installing anti-roll bar, vehicles with power steering
    27
  • 3.11 Removing and installing rubber bush for anti-roll bar
    29
  • 4 Assembly overview: subframe made of steel, anti-roll bar, suspension links
    33
  • 4.1 Repairing threads in longitudinal member
    35
  • 4.2 Fixing position of subframe
    35
  • 4.3 Checking swivel joint
    37
  • 4.4 Removing and installing swivel joint
    38
  • 4.5 Installation position of swivel joints
    40
  • 4.6 Removing and installing suspension link
    41
  • 4.7 Renewing front bonded rubber bush for suspension link
    46
  • 4.8 Renewing rear bonded rubber bush for suspension link
    49
  • 4.9 Removing and installing subframe
    51
  • 4.10 Removing and installing anti-roll bar
    53
  • 4.11 Removing and installing rubber bush for anti-roll bar
    55
  • 5 Assembly overview: wheel bearing
    58
  • 6 Assembly overview: suspension strut
    71
  • 6.1 Vehicle data sticker
    72
  • 6.2 Removing and installing suspension strut
    72
  • 6.3 Repairing front coil spring suspension strut
    78
  • 7 Removing and installing drive shafts
    81
  • 7.1 Removing and installing drive shaft with constant velocity joint
    81
  • 7.2 Removing and installing drive shaft with triple roller joint AAR 2000 (bolted on)
    84
  • 7.3 Removing and installing drive shafts with triple roller joint AAR 2000i (inserted)
    86
  • 8 Repairing drive shaft - overview of drive shafts
    91
  • 8.1 Heat shields for drive shafts
    93
  • 9 Assembly overview: drive shaft with VL90 or VL100 constant velocity joint
    94
  • 9.1 Dismantling and assembling drive shaft with VL90 or VL100 constant velocity joint
    96
  • 9.2 Checking outer constant velocity joint
    100
  • 9.3 Checking inner constant velocity joint
    101
  • 10 Assembly overview: drive shaft with VL107 constant velocity joint
    104
  • 10.1 Dismantling and assembling drive shaft with VL107 constant velocity joint
    106
  • 11 Assembly overview: drive shaft with triple roller joint AAR 2000/100 (bolted-on)
    111
  • 11.1 Dismantling and assembling drive shaft with triple roller joint
    113
  • 12 Assembly overview: drive shaft with triple roller joint AAR 2000/108 (bolted-on)
    119
  • 12.1 Dismantling and assembling drive shaft with triple roller joint
    120
  • 13 Assembly overview: drive shaft with triple roller joint AAR 2000i (inserted)
    121
  • 13.1 Dismantling and assembling drive shaft with triple roller joint AAR2000i
    123
  • Rear suspension
    128
  • 1 Appraisal of accident vehicles
    128
  • 2 Repairing rear axle
    129
  • 2.1 Rear axle in unladen position
    129
  • 2.2 Removing and installing rear axle
    131
  • 2.3 Assembly overview - rear axle beam, drum brake
    135
  • 2.4 Assembly overview - axle beam (disc brakes)
    138
  • 2.5 Removing and installing bonded rubber bush
    140
  • 2.6 Removing and installing spring
    143
  • 2.7 Removing and installing shock absorber
    144
  • 2.8 Assembly overview - shock absorber on vehicle with front-wheel drive
    145
  • 3 Repairing wheel bearing, drum brake
    148
  • 3.1 Assembly overview - wheel bearing
    148
  • 3.2 Removing and installing wheel bearing/hub unit on vehicles with drum brakes
    149
  • 4 Repairing wheel bearing (disc brake)
    152
  • 4.1 Assembly overview - wheel bearing
    152
  • 4.2 Removing and installing wheel bearing/wheel hub on vehicles with disc brakes
    153
  • Wheels, tyres, vehicle geometry
    156
  • 1 Appraisal of accident vehicles
    156
  • 2 Specified torque for wheel bolts
    157
  • 3 Fitting wheel and tyre
    158
  • 3.1 General information
    158
  • 3.2 Fittings instructions
    158
  • 4 Removing and fitting tyres with run-flat properties to wheel rims
    160
  • 4.1 Notes on safety and prerequisites
    160
  • 4.2 Fittings instructions
    160
  • 4.3 Pressing tyre off wheel rim
    161
  • 4.4 Removing tyre from wheel
    162
  • 4.5 Fitting tyre to wheel rim
    163
  • 5 Tyre Pressure Loss Indicator (TPLI)
    166
  • 6 Vehicle alignment check
    168
  • 6.1 General information
    168
  • 6.2 Conditions for testing
    169
  • 6.3 Test preparations
    170
  • 6.4 Vehicle data sticker
    170
  • 6.5 Wheel alignment specifications
    170
  • 6.6 Transverse vehicle inclination “zero position”
    172
  • 6.7 Overview - wheel alignment procedure
    172
  • 6.8 Adjusting camber at front wheels, subframe made of aluminium
    173
  • 6.9 Correcting front axle camber, subframe made of steel
    174
  • 6.10 Check rear axle camber
    176
  • 6.11 Check rear axle toe
    176
  • 6.12 Adjusting front axle toe
    176
  • 6.13 Checking left and right-hand wheel lock
    176
  • 7 Wheels, tyres
    178
  • 7.1 Models with breakdown set
    178
  • 7.2 Tyre sealant
    178
  • 7.3 Removing a tyre
    178
  • 7.4 Fitting a new tyre
    179
  • 7.5 Tyre sealant disposal
    179
  • 8 Instructions for changing or fitting wheels
    180
  • 8.1 Fitting wheels
    181
  • 9 Protecting wheel centring seat against corrosion
    182
  • 10 Vibration due to wheels/tyres - causes and rectification
    183
  • 10.1 Causes of rough running
    183
  • 10.2 Balancing wheels
    183
  • 10.3 Conducting a road test before balancing wheels
    183
  • 10.4 Balancing wheels on stationary wheel balancing machine
    184
  • 10.5 Vibration control system VAS 6230
    186
  • 10.6 Finish balancer
    186
  • 10.7 Radial and lateral runout of wheels and tyres
    187
  • 10.9 Checking radial and lateral run-out on wheel rim
    188
  • 10.10 Matching
    189
  • 10.11 Flat spots caused by storage or handling
    190
  • Steering
    192
  • 1 Appraisal of accident vehicles
    192
  • 2 Electrical/electronic components and locations
    193
  • 3 Steering column
    194
  • 3.1 Removing and installing steering column
    194
  • 3.2 Checking steering column for damage
    198
  • 3.3 Removing and installing steering lock housing
    199
  • 3.4 Assembly overview - cross member for steering column
    200
  • 3.5 Removing and installing locking cable for ignition with key removal lock
    201
  • 3.6 Checking ignition key removal lock
    202
  • 3.7 Removing and installing mounting bracket
    202
  • 3.8 Removing and installing strut
    203
  • 4 Repairing mechanical (manual) steering rack
    205
  • 4.1 Assembly overview - mechanical (manual) steering rack
    205
  • 4.2 Removing and installing mechanical (manual) steering rack
    206
  • 4.3 Dismantling and assembling mechanical steering rack
    210
  • 4.4 Removing and installing track rod
    212
  • 4.5 Checking play, security and boots of track rod ends
    213
  • 4.6 Checking and adjusting left track rod length
    213
  • 4.7 Allocation of track rod ball joints
    214
  • 4.8 Determining centre position of steering rack
    214
  • 4.9 Adjusting steering rack
    214
  • 5 Repairing electrohydraulic power steering (TRW)
    216
  • 5.1 Assembly overview - power steering rack (TRW)
    216
  • 5.2 Removing and installing power steering rack (TRW)
    217
  • 5.3 Removing and installing power steering sensor G250 (TRW)
    224
  • 5.4 Dismantling and assembling power steering rack (TRW)
    227
  • 5.5 Removing and installing track rod (TRW)
    229
  • 5.6 Checking play, tightness and bellows of track rod ball joints (TRW)
    230
  • 5.7 Checking and adjusting length of left track rod (TRW)
    230
  • 5.8 Allocation of track rod ball joints (TRW)
    231
  • 5.9 Determining centre position of rack (TRW)
    231
  • 5.10 Adjusting steering rack (TRW)
    232
  • 5.11 Checking delivery pressure of motor/pump unit (TRW)
    232
  • 5.12 Removing and installing motor/pump unit (TRW)
    235
  • 5.13 Assembly overview - motor/pump unit (TRW)
    239
  • 5.14 Renewing reservoir of motor/pump unit (TRW)
    240
  • 6 Repairing electrohydraulic power steering (Koyo)
    244
  • 6.1 Assembly overview - power steering rack (Koyo)
    244
  • 6.2 Removing and installing power steering rack (Koyo)
    245
  • 6.3 Removing and installing power steering sensor G250 ( Koyo)
    251
  • 6.4 Dismantling and assembling power steering rack (Koyo)
    254
  • 6.5 Removing and installing track rod (Koyo)
    256
  • 6.6 Checking play, tightness and bellows of track rod ball joints (Koyo)
    257
  • 6.7 Checking and adjusting length of left track rod (Koyo)
    257
  • 6.8 Allocation of track rod ball joints (Koyo)
    258
  • 6.9 Determining centre position of rack (Koyo)
    258
  • 6.10 Adjusting steering rack (Koyo)
    259
  • 6.11 Checking delivery pressure of motor/pump unit (Koyo)
    259
  • 6.12 Removing and installing motor/pump unit (Koyo)
    261
  • 6.13 Assembly overview - motor/pump unit (Koyo)
    265
  • 6.14 Renewing reservoir of motor/pump unit (Koyo)
    266
  • 7 Bleeding steering system, checking for leaks and checking fluid level
    270
  • 7.1 Bleeding steering system
    270
  • 7.2 Checking steering system for leaks
    270
  • 7.3 Checking hydraulic fluid level of power steering
    271
Manufacturer's designation Running gear, axles, steering
Manufacturer Volkswagen
Suitable for Polo (2002 - 2005) / Polo (2005 - 2007)
Suitable car types 9N1, 9N3
Category Reparaturanleitung

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