Running gear

Chapter overview

• Technical data
  1
• 1 Technical data
  1
• 1.1 Running gear
  1
• 1.2 Wheels, tyres
  1
• 1.3 Steering
  1
• 1.4 Braking
  1
• Front suspension
  9
• 1 Repairing front suspension (basic running gear)
  9
• 1.1 Removing and installing subframe, anti-roll bar and suspension link (basic running gear)
  10
• 1.2 Allocation of anti-roll bar to Golf/Vento basic running gear
  13
• 1.3 Checking swivel joint
  14
• 1.4 Reworking cap nut in longitudinal member
  14
• 1.5 Removing and installing wheel bearing, suspension strut, drive shaft (basic running gear)
  15
• 1.6 Removing and installing drive shaft, vehicles with automatic gearbox
  19
• 1.7 Repairing front suspension strut (basic running gear)
  20
• 1.8 Allocation of suspension strut mounting to vehicle
  22
• 2 Repairing front suspension (Plus running gear)
  23
• 2.2 Removing and installing swivel joint
  26
• 2.3 Allocation of anti-roll bar to Golf/Vento Plus running gear
  27
• 2.4 Removing and installing wheel bearing, suspension strut (Plus running gear)
  27
• 2.5 Repairing front suspension strut (Plus running gear)
  31
• 2.6 Modified suspension strut from 06.93, vehicles with Plus running gear
  32
• 2.7 Removing and installing drive shaft (Plus running gear), vehicles with bonded drive shaft
  33
• 2.8 Removing and installing drive shaft with triple roller joint
  35
• 2.9 Wheel hubs with compressed splines, vehicles with Plus running gear
  36
• 2.10 Removing and installing drive shafts on vehicles with compressed splines in the wheel hub
  37
• 3 Repairing drive shaft
  39
• 3.1 Checking outer constant velocity joint
  44
• 3.2 Checking inner constant velocity joint
  45
• 3.3 Repairing drive shaft with triple roller joint
  47
• 3.4 Dismantling and assembling triple roller joint
  48
• Rear suspension
  52
• 1 Repairing rear axle (front-wheel drive vehicles)
  52
• 1.1 Repairing rear axle
  52
• 1.2 Removing and installing bonded rubber bush
  54
• 1.3 Track width change on Golf/Vento from 08.93 - model year 1994
  58
• 1.4 Modified weld studs on rear axle
  59
• 1.5 Reworking cap nut in longitudinal member, vehicles with front-wheel drive
  60
• 1.6 Allocation of rear axle assembly and anti-roll bar
  61
• 1.7 Dismantling and assembling suspension strut
  61
• 1.8 Removing and installing rear axle, Golf Variant
  63
• 1.9 Assembly overview: Rear axle, Golf Variant
  64
• 1.10 Removing and installing bonded rubber bush
  66
• 1.11 Modified weld studs on rear axle, Golf Variant
  71
• 1.12 Modified rear axle for Golf Variant
  73
• 1.13 Removing and installing rear shock absorber, Golf Variant
  74
• 1.14 Dismantling and assembling shock absorber, Golf Variant
  75
• 2 Repairing rear axle (vehicles with four-wheel drive)
  77
• 2.1 Assembly overview - rear axle, vehicles with four-wheel drive
  77
• 2.2 I - Assembly overview - rear axle assembly
  78
• 2.3 II - Assembly overview - suspension link
  81
• 2.4 Removing and installing rear axle
  83
• 2.5 Determining installation position with bonded rubber bush removed
  85
• 2.6 Reworking cap nut in longitudinal member, vehicles with four-wheel drive
  85
• 3 Repairing wheel bearing
  87
• 3.1 Repairing wheel bearing, vehicles with front-wheel drive - drum brakes
  87
• 3.2 Repairing wheel bearing, vehicles with front-wheel drive - disc brakes
  90
• 3.3 Repairing wheel bearings, vehicles with four-wheel drive - drum brakes
  94
• 3.4 Repairing wheel bearing, vehicles with four-wheel drive - disc brakes
  97
• Wheels, tyres, vehicle geometry
  101
• 1 Wheel alignment
  101
• 1.1 Test prerequisites:
  101
• 1.2 Specifications for wheel alignment, vehicles with front and four-wheel drive
  101
• 1.3 Adjusting front wheel camber
  103
• 1.4 Calculating the direction of travel:
  103
• Anti-lock brake system
  104
• 1.1 Notes for repairs on ABS, ABS/EDL
  104
• 1.2 Removing and installing control unit
  105
• 1.3 Removing and installing speed sensor and speed sensor rotor
  105
• 2.1 Assembly overview - hydraulic unit, brake servo/brake master cylinder, LHD
  107
• 2.2 Modified Teves 04 ABS/EDL units
  108
• 2.3 Removing and installing hydraulic unit, LHD
  109
• 2.4 Removing and installing brake pedal position sender, LHD
  110
• 3.1 Assembly overview - hydraulic unit, brake servo/brake master cylinder, RHD
  112
• 3.2 Removing and installing hydraulic unit, RHD
  115
• 3.3 Removing and installing brake pedal position sender, RHD
  116
• 4.1 General information on this ABS
  118
• 4.2 Notes for repairs on ABS, ABS/EDL
  118
• 4.3 Removing and installing control unit and hydraulic unit
  119
• 5 Assembly overview - hydraulic unit, brake servo/brake master cylinder Teves 20 GI - LHD
  122
• 5.1 Assembly overview - hydraulic unit, brake servo/brake master cylinder, LHD
  122
• 6 Assembly overview - hydraulic unit Teves 20 Gl, RHD
  123
• 6.1 Assembly overview - hydraulic unit Teves 20 Gl, RHD
  123
• 7 Initiating basic setting, vehicles with ABS/EDL
  125
• Brakes - mechanism
  126
• 1 Repairing front brakes
  126
• 1.1 Repairing front brakes, brake caliper VW II
  126
• 1.2 Removing and installing brake pads/brake calipers
  128
• 1.3 Removing and installing brake pads/brake calipers as of model year 1996 (T)
  129
• 1.4 Repairing front brakes, Girling brake caliper
  130
• 1.5 Removing and installing brake pads or linings
  132
• 1.6 Repairing front brakes, Teves/ATE
  133
• 1.7 Removing and installing brake pads or linings
  135
• 2 Repairing rear brakes (drum brakes)
  138
• 2.1 Removing and installing rear brakes
  138
• 2.2 Removing and installing impulse rotor
  139
• 2.3 Repairing rear brakes
  139
• 2.4 Removing and installing brake shoes
  141
• 2.5 Adjusting handbrake
  142
• 3 Repairing rear brakes (disc brakes)
  144
• 3.1 Repairing rear brakes (disc brakes)
  144
• 3.2 Modified brake caliper
  146
• 3.3 Removing and installing brake pads or linings
  146
• 3.4 Adjusting handbrake
  148
• 4 Assembly overview - handbrake lever
  149
• Brakes - hydraulics
  150
• 1 Assembly overview - brake servo/brake master cylinder
  150
• 1.1 Ecomatic vacuum supply
  151
• 1.2 Assembly overview: pedal cluster, brake pedal
  152
• 1.3 Separating brake pedal from, and clipping to, brake servo
  153
• 1.4 Removing and installing brake pedal
  154
• 2 Removing and installing brake servo/brake master cylinder, RHD
  155
• 2.1 Removing and installing brake servo/brake master cylinder, RHD
  155
• 3 Repairing front brake caliper, brake caliper VW II
  156
• 3.1 Removing and installing front brake caliper piston
  157
• 4 Repairing Girling front brake calipers
  159
• 4.1 Assembly overview - Girling front brake calipers
  159
• 4.2 Removing and installing front brake caliper piston
  160
• 5 Repairing rear brake caliper
  162
• 5.1 Removing and installing rear brake caliper piston
  163
• 6 Checking and adjusting brake pressure regulator
  165
• 6.1 Checking and adjusting brake pressure regulator, load-dependent
  165
• 6.2 Specifications for load dependent brake pressure regulator
  165
• 6.3 Checking brake pressure regulator, pressure-dependent
  166
• 7 Bleeding brake system on vehicles with and without ABS or ABS/EDL
  168
• 7.1 Bleeding brake system
  168
• 7.2 Bleeding brake system without brake filling and bleeding unit
  169
• Steering
  170
• 1.1 Modified teeth on steering rack steering pinion and steering column drive shaft
  172
• 1.2 Assembly overview: Steering wheel with airbag
  173
• 1.3 Removing and installing airbag module
  174
• 1.4 Removing and installing steering wheel with airbag
  175
• 1.5 Removing and installing coil connector with slip ring
  176
• 1.6 Removing and installing column tube for height adjustable steering wheel
  177
• 2 Assembly overview: mechanical steering rack
  178
• 2.1 Adjusting steering rack
  179
• 2.2 Removing and installing mechanical (manual) steering rack
  180
• 2.3 Bolting track rod onto steering rack
  181
• 3 Repairing power steering
  183
• 3.1 Checking pump delivery pressure
  183
• 3.2 Checking function of steering hydraulics pump V119 , Ecomatic
  184
• 3.3 Checking delivery pressure of steering hydraulics pump V119 , Ecomatic
  184
• 3.4 Removing and installing steering hydraulics pump V119 , Ecomatic
  185
• 3.5 Removing and installing power steering rack
  186
• 3.6 Assembly overview - power steering rack (TRW)
  188
• 3.7 Modified teeth on steering rack steering pinion and steering column drive shaft
  190
• 3.8 Modified track rod ball joint for Golf Variant, Golf convertible
  190
• 3.9 Removing and installing track rod (TRW and ZF power steering rack)
  191
• 3.10 Checking and/or adjusting left-hand track rod length
  192
• 3.11 Repairing TRW power steering
  193
• 3.12 Dismantling and assembling power steering rack (TRW)
  196
• 3.13 Adjusting power steering rack when installed
  205
• 3.14 Adjusting power steering rack with new steering rack (TRW)
  206
• 3.15 Assembly overview - power steering rack (ZF)
  207
• 3.16 Repairing ZF power assisted steering rack
  210
• 3.17 Dismantling and assembling power assisted steering rack (ZF)
  212
• 3.18 Adjusting power steering rack (ZF)
  222
• 4 Assembly overview: vane pump, reservoir and hydraulic lines
  223
• 4.1 Assembly overview: steering hydraulics pump V119 , hydraulic lines, Ecomatic
  224
• 4.3 Removing and installing poly-V belt
  228
• 4.5 Installing vane pump
  230
• 4.6 Tensioning V-belt
  231
• 4.7 Removing and installing power-assisted steering vane pump, vehicles with 128 kW engine
  232