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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
  • 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 Sedan / Polo

Original Volkswagen repair manual


15,89 €7% VAT incl.

Immediately available for download

Language: English

Digital PDF file

5.484 KB

190 Sites

Detailed technical data

Immediately readable

This repair manual contains: Appraisal of accident vehicles, Repairing front suspension, I - Assembly overview, subframe, anti-roll bar and suspension link, Specified torques for wheel bolts, Removing and fitting tyres with run-flat capability to wheel rims, Tyre Pressure Monitor Display (TPM), Wheel alignment, Protecting wheel centring seat against corrosion, Electrical/electronic components and fitting locations and Bleeding steering system, checking for leaks and checking fluid level. Show more
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Repair manual Polo Sedan / Polo Running gear, axles, steering PDF download has the following content:

Chapter overview

  • Technical data
    1
  • 1 Check list for assessing the running gear on accident vehicles
    1
  • 2 General notes
    3
  • Front suspension
    4
  • 1 Appraisal of accident vehicles
    4
  • 2 Repairing front suspension
    5
  • 2.1 Overview - front axle
    5
  • 2.2 Raising wheel suspension to unladen position
    6
  • 3 I - Assembly overview, subframe, anti-roll bar and suspension link
    8
  • 3.1 Repairing threads in longitudinal member
    10
  • 3.2 Fixing subframe in position
    10
  • 3.3 Checking swivel joint
    12
  • 3.4 Removing and installing swivel joint
    12
  • 3.5 Installation position of swivel joints
    15
  • 3.6 Removing and installing suspension link
    15
  • 3.7 Removing and installing bracket
    17
  • 3.8 Renewing bonded rubber bush for bracket
    19
  • 3.9 Removing and installing subframe
    21
  • 3.10 Removing and installing anti-roll bar, vehicles with power-assisted steering
    24
  • 4 II - Assembly overview - wheel bearing
    26
  • 5 III - Assembly overview - suspension strut
    38
  • 5.1 Vehicle data sticker
    39
  • 5.2 Removing and installing suspension strut
    39
  • 5.3 Repairing front coil spring suspension strut
    43
  • 6 Repairing drive shafts
    46
  • 6.1 Removing and installing drive shafts
    46
  • 7 IV - Repairing drive shaft with constant velocity joint
    49
  • 7.1 Checking outer constant velocity joint
    54
  • 7.2 Checking inner constant velocity joint
    55
  • 8 V - Repairing drive shaft with triple roller joint
    57
  • 8.1 Dismantling and assembling triple roller joint
    60
  • Rear suspension
    64
  • 1 Appraisal of accident vehicles
    64
  • 2 Repairing rear axle
    65
  • 2.1 Removing and installing rear axle
    65
  • 2.2 Assembly overview - rear axle beam, drum brake
    68
  • 2.3 Assembly overview - rear axle beam, disc brake
    71
  • 2.4 Removing and installing bonded rubber bush
    73
  • 2.5 Removing and installing spring
    76
  • 2.6 Removing and installing shock absorber
    77
  • 2.7 Assembly overview - shock absorber on vehicle with front wheel drive
    79
  • 3 Repairing wheel bearing, drum brake
    82
  • 3.1 Assembly overview - wheel bearing
    82
  • 3.2 Removing and installing wheel bearing/hub unit on vehicles with drum brakes
    83
  • 4 Repairing wheel bearing (disc brake)
    85
  • 4.1 Assembly overview - wheel bearing
    85
  • 4.2 Removing and installing wheel bearing/wheel hub on vehicles with disc brakes
    86
  • Wheels, tyres, vehicle geometry
    89
  • 1 Appraisal of accident vehicles
    89
  • 2 Specified torques for wheel bolts
    90
  • 3 Removing and fitting tyres with run-flat capability to wheel rims
    91
  • 3.1 Pressing tyre off wheel rim
    91
  • 3.2 Removing tyre from wheel
    92
  • 3.3 Fitting tyre to wheel rim
    93
  • 4 Tyre Pressure Monitor Display (TPM)
    95
  • 5 Wheel alignment
    97
  • 5.1 General
    97
  • 5.2 Test prerequisites
    98
  • 5.3 Test preparations
    99
  • 5.4 Vehicle data sticker
    99
  • 5.5 Wheel alignment specifications
    99
  • 5.6 Transverse vehicle inclination “zero position”
    101
  • 5.7 Overview - wheel alignment procedure
    101
  • 5.8 Adjusting front axle camber
    101
  • 5.9 Check rear axle camber
    103
  • 5.10 Check rear axle toe
    103
  • 5.11 Adjusting front axle toe
    103
  • 5.12 Checking left and right wheel lock
    103
  • 6 Wheels, tyres
    105
  • 6.1 Vehicles with breakdown set
    105
  • 6.2 Tyre sealant
    105
  • 6.3 Removing a tyre
    105
  • 6.4 Fitting a new tyre
    106
  • 6.5 Disposal of tyre sealant
    106
  • 7 Protecting wheel centring seat against corrosion
    107
  • Steering
    108
  • 1 Appraisal of accident vehicles
    108
  • 2 Electrical/electronic components and fitting locations
    109
  • 3 Steering column
    110
  • 3.1 Removing and installing steering column
    110
  • 3.2 Checking steering column for damage
    114
  • 3.3 Removing and installing steering lock housing
    115
  • 3.4 Assembly overview - cross member for steering column
    116
  • 3.5 Removing and installing locking cable for ignition with key removal lock
    117
  • 3.6 Checking ignition key removal lock
    118
  • 3.7 Removing and installing mounting bracket
    118
  • 3.8 Removing and installing strut
    119
  • 4 Repairing mechanical (manual) steering box
    121
  • 4.1 Assembly overview - mechanical (manual) steering box
    121
  • 4.2 Removing and installing mechanical (manual) steering box
    122
  • 4.3 Dismantling and assembling mechanical (manual) steering box
    125
  • 4.4 Removing and installing track rod
    127
  • 4.5 Checking play, tightness and bellows of track rod ball joints
    128
  • 4.6 Checking and adjusting left track rod length
    128
  • 4.7 Allocation of track rod ball joints
    129
  • 4.8 Determining centre position of steering rack
    129
  • 4.9 Adjusting steering box
    129
  • 5 Repairing electrohydraulic power-assisted steering box (TRW)
    131
  • 5.1 Assembly overview - power-assisted steering box (TRW)
    131
  • 5.2 Removing and installing power-assisted steering box (TRW)
    132
  • 5.3 Removing and installing power steering sensor G250 (TRW)
    138
  • 5.4 Dismantling and assembling power-assisted steering box (TRW)
    141
  • 5.5 Removing and installing track rod (TRW)
    143
  • 5.6 Checking play, tightness and bellows of track rod ball joints (TRW)
    144
  • 5.7 Checking and adjusting left track rod length (TRW)
    144
  • 5.8 Allocation of track rod ball joints (TRW)
    145
  • 5.9 Determining centre position of rack (TRW)
    145
  • 5.10 Adjusting steering box (TRW)
    146
  • 5.11 Checking delivery pressure of motor/pump unit (TRW)
    146
  • 5.12 Removing and installing motor/pump unit (TRW)
    149
  • 5.13 Assembly overview - motor/pump unit (TRW)
    153
  • 5.14 Renewing reservoir of motor/pump unit (TRW)
    154
  • 6 Repairing electrohydraulic power-assisted steering box (Koyo)
    157
  • 6.1 Assembly overview - power-assisted steering box (Koyo)
    157
  • 6.2 Removing and installing power-assisted steering box (Koyo)
    158
  • 6.3 Removing and installing power steering sensor G250 ( Koyo)
    164
  • 6.4 Dismantling and assembling power-assisted steering box (Koyo)
    167
  • 6.5 Removing and installing track rod (Koyo)
    169
  • 6.6 Checking play, tightness and bellows of track rod ball joints (Koyo)
    170
  • 6.7 Checking and adjusting left track rod length (Koyo)
    170
  • 6.8 Allocation of track rod ball joints (Koyo)
    171
  • 6.9 Determining centre position of rack (Koyo)
    171
  • 6.10 Adjusting steering box (Koyo)
    171
  • 6.11 Checking delivery pressure of motor/pump unit (Koyo)
    172
  • 6.12 Removing and installing motor/pump unit (Koyo)
    174
  • 6.13 Assembly overview - motor/pump unit (Koyo)
    178
  • 6.14 Renewing reservoir of motor/pump unit (Koyo)
    179
  • 7 Bleeding steering system, checking for leaks and checking fluid level
    182
  • 7.1 Bleeding steering system
    182
  • 7.2 Checking steering system for leaks
    182
  • 7.3 Checking hydraulic fluid level of power-assisted steering
    183
Manufacturer's designation Running gear, axles, steering
Manufacturer Volkswagen
Suitable for Polo Sedan (2003 - 2005) / Polo (2005 - 2007)
Suitable car types 9N2, 9N4
Category Reparaturanleitung

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