Volkswagen Golf Variant 2015 Repair Manual - Suspension, Wheels, Steering PDF

Service
Repair Manual
Golf 2015 ➤
Golf Variant 2015 ➤
Suspension, Wheels, Steering
Edition 03.2016
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Service Department. Technical Information

Service
List of Workshop Manual Repair Groups
Repair Group
00 - Technical Data
40 - Front Suspension
42 - Rear Suspension
43 - Level Control System
44 - Wheels, Tires and Vehicle Alignment
48 - Steering AG. Volkswagen AG d
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Technical information should always be available to the foremen and mechanics, because their
careful and constant adherence to the instructions is essential to ensure vehicle road-worthiness and
safety. In addition, the normal basic safety precautions for working on motor vehicles must, as a
matter of course, be observed.
All rights reserved.

No reproduction without prior agreement from publisher.
Copyright © 2016 Volkswagen AG, Wolfsburg D4B80416633

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00 - Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
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1 Evaluating Vehicles in Collisions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
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1.1 Collision Vehicle Evaluation Checklist . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
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2 Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
2.1 Start/Stop System Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
2.2 Subframe Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
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3 Repair Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
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3.1 Shock Absorber Leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

3.2 Shock Absorber Noises . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
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3.3 Shock Absorbers, Checking when Removed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

3.4 Steering Gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
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3.5 Seals, Sealing Rings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
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3.6 Bolts and Nuts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
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3.7 Electrical Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
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3.8 Wheel Bearing in Curb Weight, Lifting Vehicles with Coil Spring . . . . . . . . . . . . . . . . . . . . 6
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4 Disposal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
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4.1 Front Shock Absorbers, Venting and Emptying . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
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4.2 Rear Shock Absorbers, Venting and Emptying . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
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5 Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
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40 - Front Suspension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
1 Front Axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
1.1 Overview - Front Axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
2 Subframe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
2.1 Overview - Subframe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
2.2 Subframe, Securing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
2.3 Subframe, Lowering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
2.4 Subframe without Steering Gear, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . 23
2.5 Subframe with Steering Gear, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
2.6 Subframe, Servicing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
2.7 Stabilizer Bar, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
2.8 Coupling Rod, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
2.9 Thread in Longitudinal Member, Servicing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
3 Suspension Strut and Upper Control Arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
3.1 Overview - Suspension Strut and Upper Control Arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
3.2 Suspension Strut, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
3.3 Suspension Strut, Servicing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
4 Lower Control Arm and Ball Joint . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
4.1 Overview - Lower Control Arm and Ball Joint . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
4.2 Lower Control Arm, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
4.3 Ball Joint, Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
4.4 Ball Joint, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
4.5 Front Lower Control Arm Bonded Rubber Bushing, Replacing . . . . . . . . . . . . . . . . . . . . . . 65
4.6 Lower Control Arm Rear Bonded Rubber Bushing, Replacing . . . . . . . . . . . . . . . . . . . . . . 67
5 Wheel Bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
5.1 Overview - Wheel Bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
5.2 Wheel Bearing Housing, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
5.3 Wheel Bearing Unit, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
6 Drive Axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
6.1 Overview - Drive Axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
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Golf 2015 ➤ , Golf Variant 2015 ➤
Suspension, Wheels, Steering - Edition 03.2016
6.3 Drive Axle, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85

6.4 Drive Axle Threaded Connection, Loosening and Tightening . . . . . . . . . . . . . . . . . . . . . . 101
6.5 Drive Axle Heat Shield, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
6.6 Drive Axle, Disassembling and Assembling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
6.7 Outer CV Joint, Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
6.8 Inner CV Joint, Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114
7 Special Tools . . . . . . . . . ..V.o.lk.sw
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1.2 Rear Axle, Lowering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 136

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1.3 Rear Axle, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 142
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2 Axle Beam . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150
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2.1 Overview - Axle Beam . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150
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2.2 Axle Beam Bonded Rubber Bushing, Replacing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150
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3 Subframe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 157
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3.1 Overview - Subframe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 157
3.2 Subframe, Securing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 158
3.3 Subframe, Servicing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 165
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4 Stabilizer Bar . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 177
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4.1 Overview - Stabilizer Bar . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 177

4.2 Stabilizer Bar, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 178
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4.3 Coupling Rod, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . orm 179

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5 Control Arm, Tie Rod . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 181

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5.1 Overview - Transverse Link . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 181

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5.2 Overview - Tie Rod . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 184

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5.3 Upper Transverse Link, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 185

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5.4 Lower Transverse Link, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 187

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5.5 Tie Rod, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 189
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6 Suspension Strut/Shock Absorber, Spring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 191
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6.1 Overview - Suspension Strut, Shock Absorber and Spring . . . . . . . . . . . . . . . . . . . . . . . . 191
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6.2 Shock Absorber, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 193
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6.3 Shock Absorber, Servicing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 200

6.4 Spring, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 202
7 Wheel Bearing and Trailing Arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 209
7.1 Overview - Wheel Bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 209
7.2 Overview - Trailing Arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 213
7.3 Wheel Bearing Housing, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 213
7.4 Wheel Bearing Unit, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 222
7.5 Wheel Bearing Housing Bonded Rubber Bushing, Replacing . . . . . . . . . . . . . . . . . . . . . . 229
7.6 Trailing Arm with Mounting Bracket, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . 234
7.7 Trailing Arm, Servicing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 237
8 Drive Axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 240
8.2 Drive Axle Threaded Connection, Loosening and Tightening . . . . . . . . . . . . . . . . . . . . . . 241
8.3 Drive Axle, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 242
8.4 Drive Axle, Disassembling and Assembling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 247
8.5 Outer CV Joint, Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 251
8.6 Inner CV Joint, Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 252
9 Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 255
43 - Level Control System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 267

1 Electronic Damping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 267
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1.1 Overview - Electronic Damping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 267

1.2 Electronic Damping Control Module J250 , Removing and Installing . . . . . . . . . . . . . . . . . . 272
1.3 Left/Right Front Body Acceleration Sensor G341 / G342 , Removing and Installing . . . . . . 274
1.4 Left Rear Body Acceleration Sensor G699 , Removing and Installing . . . . . . . . . . . . . . . . 275
2 Level Control System Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 277
2.1 Overview - Front Level Control System Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 277
2.2 Overview - Rear Level Control System Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 278
2.3 Left/Right Front Level Control System Sensor G78 / G289 , Removing and Installing . . . . 280
2.4 Left/Right Rear Level Control System Sensor G76 / G77 , Removing and Installing . . . . . . 282
3 Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 285
44 - Wheels, Tires and Vehicle Alignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 286

1 Wheels and Tires . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 286
1.1 Wheel Bolt Tightening Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 286
1.2 Tires, Dismounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 286
1.3 Tires, Dismounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 287
1.4 Tires, Mounting . . . . . . . . . . . .w.ag. e.n.A.G.. V. o.lk. s.w.a.ge. n.A.G. d.o.es. . . . . . . . . . . . . . . . . . . . . . . . . . . . 287
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1.5 Wheel, Changing . . . . . b. y.V.o. . . . . . . . . . . . . . . . . . . . . . o.t .gu.a. . . . . . . . . . . . . . . . . . . . . . . 288
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1.6 Tire Sealant, Disposingho
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au Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . r.ac. . . . . . . . . . . . . . . . . . 292
s
2 Tire Pressure Monitoring System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 294
ce
le
un
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an
2.1 Tire Pressure Monitoring System Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 294
d
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3 Vehicle Alignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 296
pe
ility
3.1 Axle Alignment Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 296
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3.2 Test Prerequisites . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 296
h re
hole
spec
3.3 Measurement Preparations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 297
es, in part or in w
3.4 Axle Alignment Specified Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 298
t to the co
3.5 Axle Alignment Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 302
3.6 Evaluating Need for Axle Alignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 304
rrectness of i
3.7 Vehicle Data Label . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 306
3.8 Front Axle Camber, Adjusting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 306
l purpos
3.9 Rear Axle Camber, Adjusting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 307

3.10 Rear Axle Toe, Adjusting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 308
nform
ercia
3.11 Front Axle Toe, Adjusting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 309

m
3.12 Wheel Run-Out Compensation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 309

com
tion in
3.13 Maximum Steering Angle, Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 310

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4 Wheel/Tire Vibration, Causes and Solution . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 311

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4.1 Vibration Causes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 311

um
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4.2 Road Test, Performing Before Balancing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 311

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4.3 Wheel, Balancing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 312
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4.4 Vibration Control System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 316
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4.5 Tire and Wheel Radial and Lateral Run-Out, Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Prote
cted AG.
agen
316
4.6 Rim Radial and Lateral Run-Out, Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 317
4.7 Wheels and Tires, Matching . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 318
4.8 Flat Spots in Tires From Standing, Determining . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 319
5 Adaptive Cruise Control (ACC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 321
5.1 Adaptive Cruise Control (ACC), Calibrating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 321
6 Driver Assistance Systems Front Camera . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 327
6.1 Driver Assistance Systems Front Camera, Calibrating . . . . . . . . . . . . . . . . . . . . . . . . . . . . 327
7 Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 334
48 - Steering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 336
1 Steering Wheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 336
1.1 Overview - Steering Wheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 336
Contents iii
1.2 Steering Wheel, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 336

2 Steering Column . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 338
2.1 Overview - Steering Column . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 338
2.2 Steering Column, Checking agen for Damage A.G.d.oe. s. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
AG. Volkswagen 339
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2.3 Steering Column,byHandling
Vol and Transporting . n.o.t g. u.a . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 339
d r
2.4 Steering Column, ris
e Removing and Installing . . . . . . . .an.te.e . . . . . . . . . . . . . . . . . . . . . . . . . . 340
ho
2.5 Electronics auSteering Column Lock Control Module J764 , Removing
t or
ac and Installing . . . . . . 348
s
3 Steering Gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 350
ce
le
un
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3.1 Overview - Steering Gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 350
an
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3.2 Steering Gear, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 351
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3.3 Boot, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 357
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3.4 Tie Rod, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 359
h re
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3.5 Tie Rod End, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 362
spec
3.6 Steering Gear, Servicing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 363
es, in part or in w
t to the co
4 Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 365
4.1 Steering Angle Sensor G85 , Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . 365
rrectness of i
5 Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 366
l purpos
6 Revision History . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 369
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iv Contents
00 – Technical Data
1 Evaluating Vehicles in Collisions
(Edition 03.2016)
⇒ “1.1 Collision Vehicle Evaluation Checklist”, page 1
1.1 Collision
lksw
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AG. Volkswagen AG d
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Checklist
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When servicing
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b
load-bearing or wheel-supporting components
ara
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accidentth vehicles, damages on suspension could remain
o eo undis‐
au
covered. These undiscovered damages may lead to heavy
ra
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ss
ages in continued vehicle operation. Therefore, on accident
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vehicles, the listed components must be checked in the described
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manner and sequence, independent of performing an axle align‐
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ment. If no deviations from the specified values were determined
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during an axle alignment, then no deformations of the chassis are
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Visual and Function Check of Steering System
spec
es, in part or in w
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♦ Visual check for deformations and cracks
♦ Check for play in tie rod joints and steering gear
rrectness of i
♦ Visual inspection for faulty boots and grease boots
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♦ Check electric and hydraulic lines and hoses for chafe marks,
cuts and kinks.
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♦ Check of hydraulic lines, threaded connections and steering

gear for proper seal
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♦ Make sure the steering gear and lines are securely fastened.
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♦ Check proper function through entire steering angle by turning

at
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steering wheel from stop to stop. Steering wheel must be ro‐

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or
tary without hitching at equal force.

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Visual and Function Check of Suspension C py
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• Observe the sequence of the following test steps!
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♦ Check all components shown in assembly overviews for de‐
Prote AG.
formation, cracks and other damages

♦ Replace damaged components
♦ Perform a vehicle alignment on a Volkswagen AG approved
alignment rack.
Visual and Function Check for Wheels, Tires
♦ Check for run-out and imbalance.
♦ Check tires for cuts and impact damage on tread and flanks.
♦ Check the tire pressure. Refer to the tire pressure label on the
driver side B-pillar or on the fuel filler door for the correct tire
pressure.
Replace the tire if the wheel rim and/or the tire are damaged. This
also applies when the course of the accident and damage on the
vehicle points to possible non-visible damages.
Another criteria is the age of the tires: the tires must not be older
than 6 years.
If in Doubt
• As soon as a safety risk cannot be ruled out, the tire(s) must
be replaced.
1. Evaluating Vehicles in Collisions 1

Entire Vehicle
Check other vehicle systems, for example: gen AG. Volkswagen AG
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♦ Brake system including ABS byV gu
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♦ Exhaust system and passenger
tho protection by visual and func‐ eo
tion check au ra
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Test values, adjustment values and notes can be found in re‐
un
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spective repair manuals/ELSA.

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Checking of accident vehicles described here, refers to suspen‐
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sion and does not lay claim to completeness for entire vehicle.
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Electronic Vehicle Systems
spec
Safety related systems, such as: ABS/EDS; Airbag; electronically
t to the co
controlled suspension systems; electromechanical; electrohy‐
draulic steering and other driver assist systems, must be checked
for possible stored fault messages using the Vehicle Diagnostic
rrectne
Tester . If a fault is stored in the Diagnostic Trouble Code (DTC)
memory, then perform the corresponding repair in the repair man‐
ual/ELSA. After the repair the corresponding system must be
ss o
checked again for stored faults to be sure that the function is es‐
cial p
f i
tablished again.
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2 Rep. Gr.00 - Technical Data

2 Safety Precautions
⇒ “2.1 Start/Stop System Safety Precautions”, page 3
⇒ “2.2 Subframe Safety Precautions”, page 3
2.1 Start/Stop System Safety Precautions
WARNING
If vehicle will be driven on the streets, all bolts and nuts must
be tightened properly!
WARNING
Risk of injury due to the engine automatically starting on vehi‐

cles with a Start/Stop system.
♦ For vehicles with an active start/stop system, the engine
can automatically start if necessary.
♦ Make sure the start/stop system is off whenever working
on the vehicle. Turn off the ignition and turn it back on only
when necessary.
2.2 Subframe Safety Precautions

♦ Welding and straightening work on supporting or wheel car‐
rying components of the suspension is not permitted.
♦ Always replace corroded bolts/nuts.
♦ Bonded rubber bushings can only n Abe turned
G. Volkswagto
enaAG
limited extent.
Therefore, the threadedVconnections
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the components not with
o
bonded rubber bushings ed
by should only be tightened whenguthe ara
wheel bearing housing
thoris is lifted (curb weight position). Refer to nte
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⇒ “3.8.1 Wheel s a Bearing in Curb Weight, Lifting Vehicles with
u ra
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Coil Spring, Front Axle”, page 6 .
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2. Safety Precautions 3
3 Repair Information
⇒ “3.1 Shock Absorber Leaks”, page 4
⇒ “3.2 Shock Absorber Noises”, page 4
⇒ “3.3 Shock Absorbers, Checking when Removed”, page 5
⇒ “3.4 Steering Gear”, page 5
⇒ “3.5 Seals, Sealing Rings”, page 6
⇒ “3.6 Bolts and Nuts”, page 6
⇒ “3.7 Electrical Components”, page 6
⇒ “3.8 Wheel Bearing in Curb Weight, Lifting Vehicles with Coil
Spring”, page 6
3.1 Shock Absorber Leaks

Shock absorbers are frequently rejected and exchanged because
of leaks. Examinations on the test stand and on the vehicle have
shown that the replacement of a large number of rejected shock
absorbers was not justified.
Slight leaking of oil (“sweating”) at piston rod seal is no reason to
replace a shock absorber. A shock absorber damp with oil is OK
under the following circumstances:
♦ Oil leakage (shaded in illustration) is visible, but dull, matte
and possibly dry due to dust.
♦ Oil excretion extends from upper shock absorber connection
(piston rod oil seal) no further than lower spring plate -arrow-
AG. Volkswagen AG d
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3.2 Shock Absorber Noises

rrectness of i
Shock absorbers are frequently rejected and exchanged because

l purpos
of rumbling noises. Examinations on the test stand and vehicle

have shown that there was not complaint with approximately 70%
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of the rejected shock absorbers and the replacement was not

justified.
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With complaints that are interpreted as rumbling or knocking

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sounds, proceed as follows.

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– Determine where, when and how the sounds change during a

p
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or
road test on a dry stretch of road with irregularities.

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Only in the rarest of cases shock absorbers
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3.3 Shock Absorbers, Checking when Re‐
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Defective shock absorbers are noticeable when driving due to
h re
loud rumbling noises - a result of wheel hopping - especially on
ole,
spec
poor stretches of road. Moreover, they can be recognized by a
large loss of oil.
t to the co
Note
rrectne
Shock absorbers are maintenance-free, shock absorber oil can‐
ss
not be topped off.
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A removed shock absorber can be checked by hand as follows:
mer
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– Push the shock absorber together by hand.

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• Piston rod must move with even resistance throughout entire
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stroke and without jerking.

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– Release piston rods.
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• For shock absorbers with sufficient gas pressure, piston rod
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Note
♦ If this is not the case, the shock absorber must be replaced.

As long as there is no large loss of oil, the mode of operation
corresponds to that of a conventional shock absorber.
♦ The damping function is also completely available without gas
pressure, as long as there is no large loss of oil. However,
noise may increase.
3.4 Steering Gear

To perform a problem-free and successful steering gear repair,
extreme caution and cleanliness, as well as properly functioning
tools are an important requirement. Understandably, general
safety guidelines apply when performing repairs.
A series of applicable general notes for individual repair proce‐
dures - otherwise listed several times at many points in the repair
manual - has been collected here. They apply for this repair man‐
ual.
♦ Thoroughly clean connecting points and their surrounding
areas before loosening.
♦ When installing steering gear, make sure centering sleeves
are correctly seated between console and steering gear.
♦ Place removed parts on a clean surface and cover to prevent
contamination. Use foils and paper. Only use lint-free cloths!
♦ Install clean parts only: remove the replacement part from its
packaging just before installing it.
♦ Use exclusively lubricants and sealants marked with part num‐
bers.
3. Repair Information 5
♦ Carefully cover or seal open components, if repairs are not

carried out immediately.
3.5 Seals, Sealing Rings

♦ Always replace the gaskets and seals.
♦ After removing seals, inspect contact surface on housings and
shafts for burrs and damage and repair if necessary.
♦ Remove all residual sealant of fluid seals from sealing surfa‐
ces, no sealant residue must enter the steering gear housing
when doing this.
3.6 Bolts and Nuts

♦ Loosen and tighten the bolt and nut from the covers and hous‐
ings diagonally.
♦ Do not cant but loosen and tighten especially sensitive parts
in diagonal manner in stages, for example servo motor with
control module.
♦ Tightening specifications for non-lubricated bolts and nuts are
given.
♦ Always replace self-locking nuts and bolts.
3.7 Electrical Components

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en AG
does when
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coming into contact with a metal y Vol object. The reason for thisnois
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build-up of static electricityed bin the human body. This charge can ran
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lead to malfunctionsuby th touching the electrical components of
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steering gear and ssteering
s a
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– Touch a grounded object, for example a water pipe or a vehicle

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hoist, before working on electrical components. Do not make

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direct contact on connector terminals.

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3.8 Wheel Bearing in Curb Weight, Lifting

om
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Vehicles with Coil Spring

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⇒ “3.8.1 Wheel Bearing in Curb Weight, Lifting Vehicles with Coil

i
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Spring, Front Axle”, page 6

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⇒ “3.8.2 Wheel Bearing in Curb Weight, Rear Axle, Lifting Vehi‐ . Cop py
cles with Coil Spring”, page 8
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3.8.1 Wheel Bearing in Curb Weight, Lifting

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Vehicles with Coil Spring, Front Axle

Special tools and workshop equipment required
♦ Engine and Gearbox Jack - VAS6931-

♦ Tensioning Strap - T10038-

♦ Engine/Gearbox Jack Adapter - Wheel Hub Support - T10149-
Caution
All bolts at suspension parts with bonded rubber bushings must

always be tightened in curb weight position (unloaded condi‐
tion).
Bonded rubber bushings have a limited range of motion.
Axle components with bonded rubber bushings must be
brought into the position they will be in during driving before
tightening (curb weight position).
Otherwise, the bonded rubber bushing will be stressed result‐
ing in a shortened service life.
By raising appropriate suspension using Engine and Gearbox

Jack - VAS6931- and Engine/Gearbox Jack Adapter - Wheel Hub
Support - T10149- , this position can be simulated on the hoist.
Note
Before appropriate suspension is raised, vehicle must be strap‐

ped to lift arms of hoist using Tensioning Strap
en AG. V
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WARNING thor eo
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The vehicle could fall off the hoist if it is not secured.
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– Turn the wheel hub until one of the holes for the wheel bolts
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– Install Engine/Gearbox Jack Adapter - Wheel Hub Support -

hole
spec
T10149- with wheel bolt on wheel hub.

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Note
Tightening of the respective bolts/nuts must then only occur after

dimension -a- between the wheel hub center and the lower edge
of wheel housing has been attained.
Dimension -a- is dependent on standing height of installed sus‐

pension:
Chassis 1) Standing Height -a- in mm

Basic (G01+2UA/G02+2UA/ 383 ± 10 mm
G07+2UA/G18/G22)
Sport (G01+2UC+GM1/G01 368 ± 10 mm
+2UP/G02+2UC+GM1/G07
+2UC/G21/G26)
Raised (G01+2UF/G02+2UF/ 398 ± 10 mm
G24/G25/G27)
DCC (G03+2UQ/G03+2UH) 373 ± 10 mm
GTI (G06+2UC/G06+2UC 368 ± 10 mm
+GM1+A8H/G06+2UC+GM3
+A8G/G06+2UJ/G04+2UM/
G29)
AG. Volkswagen AG d
GTI heavy duty suspension 383 ± 10lkmm
swa
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not
(G06+2UN) db
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ho
1) The suspension that the vehicle is equipped eo
aut with is indicated ra
on the vehicle data plate. The suspension
ss is indicated
by a PR c
ce
e
number. Allocation of the PR number according to the suspen‐

nl
pt
du
sion.
an
itte
y li
erm
ab
– Lift the wheel bearing housing using the Engine and Gearbox
ility
ot p
Jack - VAS6931- until dimension -a- is reached.

wit
, is n
h re
hole
WARNING spec
es, in part or in w
t to the co
♦ Do not lift or lower the vehicle when the Engine and Gear‐
box Jack - VAS6931- is below the vehicle.
rrectness of i
♦ Do not leave the Engine and Gearbox Jack - VAS6931-

under the vehicle any longer than necessary.
l purpos
nform
ercia
– Tighten the bolts and nuts.

m
– Lower the wheel bearing housing.

at
om
ion
c
– Remove the Engine and Gearbox Jack - VAS6931- from under

in t
or
his
e
the vehicle.
at
do
priv
– Remove Engine/Gearbox Jack Adapter - Wheel Hub Support

um
for
en
- T10149- .
ng
t.
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Cop py
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gh
3.8.2 Wheel Bearing in Curb Weight, Rear
ht
pyri by
Vo
co lksw
by
Axle, Lifting Vehicles with Coil Spring cted agen
Prote AG.


Caution
All bolts at suspension parts with bonded rubber bushings must

always be tightened in curb weight position (unloaded condi‐
tion).
Bonded rubber bushings have a limited range of motion.
Axle components with bonded rubber bushings must be
brought into the position they will be in during driving before
tightening (curb weight position).
Otherwise, the bonded rubber bushing will be stressed result‐
ing in a shortened service life.
By raising the axle on one side using the Engine and Gearbox
Jack - VAS6931- and Engine/Gearbox Jack Adapter - Wheel Hub
Support - T10149- , this position can be simulated on the hoist.
Note
Before lifting the axle on one side, the vehicle must be secured
on both sides to the lift arms of the lift using Tensioning Strap -
T10038- .
1- Tensioning Strap - T10038-
WARNING
lkswage es n
Vo ot g
The vehicle could fall off the hoist d if it is not secured.
by ua
ran
ir se tee
tho
u or
a ac
ss
– Turn the wheel hub until one of the holes for the wheel bolts
ce
e
nl
is on top.
pt
du
an
itte
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– Install Engine/Gearbox Jack Adapter - Wheel Hub Support -

erm
ab
T10149- with wheel bolt.

ility
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wit
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hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
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or
his
ate
do
priv
cum
for
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Cop py
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AG. Volkswagen AG d
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th
Tightening of the respective bolts/nuts must
s au then only occur after ra
c
dimension -a- between the wheel hub center and the lower edge s
ce
e
of wheel housing has been attained.
nl
pt
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itte
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ab
Dimension -a- is dependent on standing height of installed sus‐
ility
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pension:
wit
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Chassis 1) Standing Height -a- in mm
hole
spec
es, in part or in w
Basic (G01/G02/G07/G18/G22 385 ± 10 mm
t to the co
+2UA)
Sport (G01/G02/G07 +2UC, 370 ± 10 mm
G21)
rrectness of i
Raised (G01/G02 +2UF) 400 ± 10 mm
l purpos
DCC (G03) 375 ± 10 mm

GTI (G06+2UC/ G06 + 2UJ/ 370 ± 10 mm
nf
ercia
o
G04 + 2UM)
rm
m
atio
m
GTI heavy duty suspension 385 ± 10 mm

o
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c
(G06 + 2UN)
or
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te
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a
1)
iv
The suspension that the vehicle is equipped with is indicated
o
r
rp
cu
on the vehicle data plate. The suspension is indicated by a PR
o
m
f
en
ng
number. Allocation of the PR number according to the suspen‐

t.
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op
sion. C py
ht. rig
rig ht
– Lift the wheel bearing housing using the engine/gearbox jack
py by
co Vo
by lksw
until dimension -a- is reached. Prote
cted AG.
agen
WARNING
♦ Do not lift or lower the vehicle when the Engine and Gear‐
box Jack - VAS6931- is below the vehicle.
♦ Do not leave the engine/gearbox jack under the vehicle
any longer than necessary.
– Tighten the bolts and nuts.

– Lower the wheel bearing housing.
– Remove the Engine and Gearbox Jack - VAS6931- from under
the vehicle.
– Remove the Engine/Gearbox Jack Adapter - Wheel Hub Sup‐
port - T10149-

4 Disposal
⇒ “4.1 Front Shock Absorbers, Venting and Emptying”,
page 11
⇒ “4.2 Rear Shock Absorbers, Venting and Emptying”,
page 12
4.1 Front Shock Absorbers, Venting and

Emptying
⇒ “4.1.1 Front Shock Absorbers, Venting and Emptying, Standard
Shock Absorber”, page 11
⇒ “4.1.2 Front Shock Absorbers, Venting and Emptying, DCC
4.1.1 Front Shock Absorbers, Venting and

Emptying, Standard Shock Absorber
– Secure the gas-filled shock absorber vertically in vise, with
piston rod facing down.
WARNING
AG. Volkswagen AG d
agen oes
olksw not
yV gu
Wear protective eyewearrised while drilling.
b ara
nte
ho eo
aut ra
ss c
– Drill a 3 mm hole -A- through the shock absorber outer tube.
ce
le
un
pt
an
d
itte
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erm
ab
Note
ility
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wit
is n
Gas escapes when drilling.

h re
ole,
spec
– Continue drilling until the tube inside is drilled through (ap‐

t to the co
proximately 25 mm deep).
– Drill a second 6 mm hole -B- through the outer and inner shock
rrectne
absorber tubes.
– Hold the shock absorber over an appropriate container for
ss
catching oil and move the piston rod repeatedly through the
o
cial p
entire stroke until no more oil flows out.

inform
mer
atio
om
n
c
i
or
n thi
te
sd
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o
pr
cum
r
fo
en
ng
t.
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Cop py
ht. rig
rig ht
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co Vo
by lksw
cted agen
Prote AG.
4. Disposal 11
4.1.2 Front Shock Absorbers, Venting and

Emptying, DCC Shock Absorber
– Tension the gas-filled shock absorber vertically in the vise.
AG. Volkswagen AG d
WARNING agen oes
olksw not
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d by ara
e nte
Wear protective eyewear while drilling. horis
eo
aut ra
ss c
ce
e
nl
pt
– Drill a 3 mm hole -A- through the shock absorber outer tube. du
an
itte
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erm
ab
ility
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Note
wit
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hole
spec
es, in part or in w
t to the co
rrectness of i
absorber tubes.
l purpos

nform
ercia

m
at
om
io
4.2 Rear Shock Absorbers, Venting and
n
c
in t
or
Emptying
his
ate
do
priv
cum
⇒ “4.2.1 Rear Shock Absorbers, Venting and Emptying, Standard
for
en
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n
t.
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Cop py
⇒ “4.2.2 Rear Shock Absorbers, Venting and Emptying, DCC
t. rig
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Prote
4.2.1 Rear Shock Absorbers, Venting and
AG.
Emptying, Standard Shock Absorber

WARNING
Wear protective eyewear while drilling.
– Drill a 3 mm hole -A- through the shock absorber outer tube.
Note

absorber tubes.

4.2.2 Rear Shock Absorbers, Venting and

Emptying, DCC Shock Absorber
WARNING
Wear protective eyewear while drilling. agen

AG. Volkswagen AG d
oes
olksw not
V gu
d by ara
ise nte
r
– Drill a 3 mm hole -A- through the shock
aut
ho
absorber outer tube. eo
ra
ss c
ce
le
un
pt
Note
an
d
itte
y li
erm
ab
ility
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wit
is n
h re
ole,
spec
t to the co
absorber tubes.
rrectne
ss o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
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Cop py
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Prote AG.
4. Disposal 13
5 Special Tools
Special tools and workshop

equipment required
♦ Engine and Gearbox Jack -
VAS6931-
♦ Engine/Gearbox Jack
Adapter - Wheel Hub Sup‐
port - T10149-
AG. Volkswagen AG d
agen oes
olksw not
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d b ara
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tho eo
au ra
ss c
ce
le
un
pt
an
d
itte
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erm
ab
ility
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wit
is n
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ole,
spec
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
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te
sd
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pr
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40 – Front Suspension
1 Front Axle
⇒ “1.1 Overview - Front Axle”, page 15
1.1 Overview - Front Axle
I - Refer to
⇒ “2 Subframe”, page 16
II - Refer to
⇒ “3 Suspension Strut and Up‐
per Control Arm”, page 44
III - Refer to
⇒ “4 Lower Control Arm and
Ball Joint”, page 54 n AG. Volkswagen AG do
swage es n
IV - Refer to byV
olk ot g
ua
⇒ “5 Wheel Bearing”, ir se
d ran
tee
page 70 utho
or
a ac
ss
ce
le
un
pt
an
d
itte
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erm
ab
ility
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wit
is n
h re
ole,
spec
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
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o
pr
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t.
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by
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Prote AG.
1. Front Axle 15
2 Subframe
⇒ “2.1 Overview - Subframe”, page 16
⇒ “2.2 Subframe, Securing”, page 17
⇒ “2.3 Subframe, Lowering”, page 20
⇒ “2.4 Subframe without Steering Gear, Removing and Installing”,
page 23
⇒ “2.5 Subframe with Steering Gear, Removing and Installing”,
page 27
⇒ “2.6 Subframe, Servicing”, page 32
⇒ “2.7 Stabilizer Bar, Removing and Installing”, page 38
⇒ “2.8 Coupling Rod, Removing and Installing”, page 42
⇒ “2.9 Thread in Longitudinal Member, Servicing”, page 43
2.1 Overview - Subframe

. Volkswagen AG
gen AG does
swa
1 - Stabilizer Bar with the yRub‐Volk not
gu
ber Bushings risedb ara
nte
o eo
❑ Removing and aut instal‐
h
ra
ling. Refers to
s c
ce
e
⇒ “2.7 Stabilizer Bar,

nl
pt
du
Removing and Instal‐

an
itte
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ling”, page 38
erm
ab
ility
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2 - Nut
wit
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❑ 65 Nm
h re
hole
spec
❑ Replace after removal

es, in part or in w
❑ Counterhold at socket
t to the co
head of joint bolt when

tightening
rrectness of i
3 - Suspension Strut
l purpos
4 - Coupling Rod
❑ Removing and instal‐
nform
ercia
ling. Refer to
⇒ “2.8 Coupling Rod,
m
at

om
ion
ling”, page 42
c
in t
or
his
te
5 - Subframe
a
do
priv
❑ Securing. Refer to
um
for
en
g
⇒ “2.2 Subframe, Secur‐

n
t.
yi Co
ing”, page 17 . Cop py
t. rig
gh
❑ Lowering. Refer to
ht
pyri by
Vo
o
⇒ “2.3 Subframe, Low‐ by c lksw
cted agen
ering”, page 20 . Prote AG.
❑ Removing and installing

without steering gear.
Refer to
⇒ “2.4 Subframe without
Steering Gear, Remov‐
ing and Installing”, page
23 .
❑ Removing and installing
with steering gear. Refer to ⇒ “2.5 Subframe with Steering Gear, Removing and Installing”, page 27
6 - Bolt
❑ 70 Nm + 180° turn
16 Rep. Gr.40 - Front Suspension

7 - Bolt
❑ 20 Nm + 180° turn
8 - Left Support
9 - Bolt
❑ 50 Nm +90°
10 - Bolt
❑ 70 Nm + 180° turn
11 - Right Support
12 - Lower Bonded Rubber Bushing for Pendulum Support
❑ Replacing. Refer to ⇒ “2.6 Subframe, Servicing”, page 32
13 - Upper Bonded Rubber Bushing for Pendulum Support
❑ Replacing. Refer to ⇒ “2.6 Subframe, Servicing”, page 32
14 - Nut
❑ 65 Nm
❑ Counterhold at socket head of joint bolt when tightening
2.2 Subframe, Securingn AG. Volkswagen A

ge G do
swa es n
Special tools and workshop bequipment
yV
olk required ot g
ua
d ran
se
♦ Assembly Tool, Sub-frame
tho
ri Alignment - T10486A- tee
or
au ac
♦ Four Locating Pins
ss - T10486/1-
ce
e
nl
pt
du
♦ Locating Pins - T10486/2-

an
itte
y li
erm
ab
♦ Engine and Gearbox Jack - VAS6931- with Universal Support

ility
ot p
Plate - VAG1359/2-
wit
, is n
h re
♦ Torque Wrench 1332 40-200Nm - VAG1332-

hole
spec
es, in part or in w
Caution
t to the co
This procedure contains mandatory replaceable parts. Refer

rrectness of i
to component overview prior to starting procedure.

l purpos
Mandatory Replacement Parts

nform
ercia
♦ Bolts - Subframe to Body

m
at
om
♦ Bolts - Pendulum Support to Transmission

ion
c
in t
or
♦ Bolts - Right Support to Subframe

his
ate
do
riv
♦ Bolts - Left Support to Subframe

p
cum
for
en
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Cop py
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Prote AG.
2. Subframe 17
Note
♦ For certain assemblies on the vehicle, subframe or complete

front axle must be removed.
♦ The original position of the subframe to the body is ensured
by using four Locating Pins - T10486/1- .
♦ Two Locating Pins - T10486/1- are a component of the As‐
sembly Tool, Sub-frame Alignment - T10486A- . If the Assem‐
bly Tool, Sub-frame Alignment - T10486A- is already in the
service operation, then only the addition of the two Locating
Pins - T10486/1- is required.
♦ If the Assembly Tool, Sub-frame Alignment - T10486A- is not
already in the service operation, then the Assembly Tool, Sub-
frame Alignment - T10486A- is to be used. It contains four
Locating Pins - T10486/1- and two Locating Pins - T10486/2- .
The Locating Pins - T10486/2- are not needed for the following
procedure.
AG. Volkswagen
– Remove the front and wrear
agennoise insulation. Refer
AG do
es n to ⇒ Body
olks
Exterior; Rep. Gr.
d by V66 ; Noise Insulation; Overview ot g
-uaNoise In‐
sulation . orise ran
te
h eo
ut r
– Removessthe
a pendulum support bolts -1- from the transmission.
ac
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
– Place the Engine and Gearbox Jack - VAS6931- -1- under the
subframe.
nf
ercia
– If necessary, clean the threads of the Locating Pins -

rm
m
T10486/1- .
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
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f
en
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t.
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by c lksw
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Prote AG.

AG. Volkswagen AG d
agen oes
olksw not
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d b ara
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autho eo Golf 2015 ➤ , Golf Variant 2015 ➤
ra
ss Suspension, Wheels, Steering - Edition 03.2016
c
ce
le
un
pt
an
d
• itte
To secure the subframe, the Locating Pins - T10486/1- must
y li
be installed at the positions -3, 5, 7 and 8- one after the other.
rm
ab
pe
ility
ot
wit
, is n
h re
Note
hole
spec
es, in part or in w
The Locating Pins - T10486/1- may only be tightened to a maxi‐
t to the co
mum of 20 Nm, since otherwise the locating pin threads will be
damaged.
rrectness of i
Secure the Rear Subframe
l purpos
nform
ercia
– Remove the bolts -1-.

m
a
com
t
– Remove the bolt -3- and the support -4-.
ion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
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co lksw
by
cted agen
Prote AG.
– Insert the Locating Pin - T10486/1- -1- and tighten to 20 Nm.

– Remove the bolt -5- and the support -6-.
– Insert the Locating Pin - T10486/1- and tighten to 20 Nm.
Front Subframe, Securing
2. Subframe 19
. Volkswagen AG
swa
gen AG- Edition 03.2016does
k not
Vol gu
d by ara
– Remove the bolt -8-. ris
e nte
utho eo
ra
a c
ss
ce
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un
pt
an
d
itte
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rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
– Insert the Locating Pin - T10486/1- -1- and tighten to 20 Nm.
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
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Cop py
t. rig
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by
– Remove the bolt -7-.
cted agen
Prote AG.
– Insert the Locating Pin - T10486/1- and tighten to 20 Nm.

• Securing the subframe is completed when all above men‐
tioned bolts are replaced with Locating Pins - T10486/1- one
after the other.
• The subframe position is now secured.
Locating Pins - T10486/1- , Removing
The removal is reverse of installation, noting the following:
– Only remove one locating pin and replace this with a bolt.
– For vehicles with a vehicle level sensor, perform the basic set‐
ting for the wheel damping electronics. Refer to Vehicle Diag‐
nostic Tester .
Tightening Specifications
♦ Refer to ⇒ “2.1 Overview - Subframe”, page 16
♦ Refer to ⇒ Engine Mechanical, Fuel Injection and Ignition;
Rep. Gr. 10 ; Subframe Mount; Overview - Subframe Mount
or ⇒ Engine Mechanical, Fuel Injection and Glow Plug; Rep.
Gr. 10 ; Subframe Mount; Overview - Subframe Mount .
♦ Refer to ⇒ Body Exterior; Rep. Gr. 66 ; Noise Insulation;
Overview - Noise Insulation .
If the steering wheel is found to be crooked during a road test
despite using the Locating Pins - T10486/1- , then an axle align‐
ment is necessary. In this case, put the axle alignment log in the
vehicle files.
2.3 Subframe, Lowering



♦ Vehicle Diagnostic Tester
Caution


♦ Bolt - Universal Joint to Steering Gear
♦ Bolts - Pendulum Support to Transmission
♦ Nut - Coupling Rod to Stabilizer Bar
Removing
– Turn the steering wheel to the straight-ahead position and re‐
move the ignition key so that the steering wheel lock engages.
Vehicle with “Keyless Access” Keyless Locking and Starting Sys‐
tem
– Switch the ignition off and open the driver door so the steering
wheel lock locks.
– Remove the bolt -1- and fold the footwell trim panel -2- in di‐
rection of -arrow- into the vehicle interior.
AG. Volkswagen AG d
agen oes
olksw not
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d b ara
rise nte
tho eo
au ra
– Remove the bolt -1- from the universals joint -2-. Then remove
s c
ce
the universal joint in direction of -arrow-.

e
nl
pt
du
an
itte
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erm
ab
Caution
ility
ot p
wit
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If the universal joint is separated from the steering gear, the

h re
following work cannot be performed:

hole
spec
es, in part or in w
♦ Connect the battery.

t to the co
♦ Switch on the ignition.

♦ Turning the steering gear
rrectness of i
♦ Turning the steering column

l purpos
These points must be observed, because otherwise it can

cause irreparable damage.
nf
ercia
orm
m
atio
om
n in
– Remove the lower noise insulation. Refer to ⇒ Body Exterior;

or c
Rep. Gr. 66 ; Noise Insulation; Overview - Noise Insulation .

thi
te
sd
iva
o
r
rp
cu
o
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f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
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21
cop Vo
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Prote
cted AG.
agen 2. Subframe
– Remove the exhaust system bracket from the subframe

-arrows-.
– Remove the pendulum support bolts -1-.
AG. Volkswagen AG d
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olksw not
V gu
d by ara
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or eo
h
aut ra
ss c
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nl
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du
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erm
ab
– Remove the hex nut -1- from the right and left coupling rod
ility
ot p
-3-.
wit
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h re
– Remove the coupling rod -3- from the stabilizer bar -2- on the
hole
spec
left and right sides.

es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
orm
m
atio
m
Vehicles with a Vehicle Level Sensor

o
n in
or c
thi
– Disconnect the connector -1- from the Left Front Level Control
te
sd
a
System Sensor - G78- or Right Front Level Control Sensor -

iv
o
r
rp
cu
G289- .
o
m
f
en
ng
t.
yi
Continuation for All Vehicles
Co
Cop py
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Prote AG.

subframe.
– Secure the subframe and lower it approximately 10 cm. Refer
to ⇒ “2.2 Subframe, Securing”, page 17 .
Note
Be careful not to overstretch the wire for the steering and the Oil
Level Thermal Sensor - G266- .
Installing
Install in reverse order of removal. Note the following:
AG. Volkswagen AG d
agen oes
ksw
Note by Vol not
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ara
d
rise nte
o
t the steering gear with lubricant such as soft e or
♦ Coat the seal on
au
h
ac
soap before installing
ss the steering gear.
ce
le
un
pt
♦ After attaching the steering gear to universal joint, make sure
an
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Rep. Gr. 26 ; Exhaust Pipes/Mufflers; Overview - Muffler or

⇒ Engine Mechanical, Fuel Injection and Glow Plug; Rep. Gr.
26 ; Exhaust Pipes/Mufflers; Overview - Muffler .
If the steering wheel is found to be crooked during a road test
despite using the Locating Pins - T10486/1- , then an axle align‐
ment is necessary. In this case, put the axle alignment log in the
vehicle files.
2.4 Subframe without Steering Gear, Re‐

moving and Installing
2. Subframe 23
Removing
Note
Subframe is removed together with control arms.
– Loosen the wheel bolts.

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-3-.

– Remove the nuts -arrows- on the left and right side of the ve‐
hicle.
Vehicles with Level Control System Sensor

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– Remove the clips -1 and 2- for the wiring harness -3- from the
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2. Subframe 25
– Place the -VAS6931- -1- under the subframe.

– Secure the subframe (refer to
⇒ “2.2 Subframe, Securing”, page 17 ) and lower it approxi‐
mately 10 cm.
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– For vehicles with a level control system sensor, perform the
basic setting for the wheel damping electronics using the
⇒ Vehicle diagnostic tester.
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♦ Pendulum support bolts. Refer to ⇒ Rep. Gr. 10 ; Subframe
tion in
Mount; Overview - Subframe Mount .
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♦ Noise insulation bolts. Refer to ⇒ Body Exterior; Rep. Gr. 66 ;
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If the steering wheel is still crooked after using the -T10486/1-
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then an axle alignment is necessary. In this case the record it in

the vehicles axle alignment log.
2.5 Subframe with Steering Gear, Remov‐

ing and Installing
♦ Puller - Ball Joint - T10187-
Removing
– Turn the steering wheel in the straight position and remove the
ignition key so that the steering wheel lock engages.
Vehicles with “Keyless Access” Keyless Locking and Starting
System
wheel lock engages.
Continuation for all Vehicles.
– Remove the bolts -1- and fold the footwell trim panel -2- in the
direction of the -arrow- into the vehicle interior.
2. Subframe 27
– Remove the bolt -1- from the universal joint -2-. Then remove
Caution

♦ Switching on the ignition
♦ Turning the steering column.
These points must be observed since performing these actions
could cause irreparable damage.

– Raise the vehicle.
– Remove the wheels.

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– Remove the control arm from the ball joint.
– Loosen the nut from the tie rod end, but do not unscrew yet.
Caution
To protect the thread, screw the nut on the pin a few turns.
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Continuation for all Vehicles

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2. Subframe 29
– Disconnect the connector -1- for the Oil Level Thermal Sensor
- G266- .
– If equipped, disconnect the connector -2- from the After-Run
Coolant Pump - V51- . To do so, open the catch -3- in the
direction of the -arrow- and release the connector.
– Remove the clips -1- and -2- for the wiring harness -3- from
the subframe and the steering gear.
– Place the -VAS6931- -1- under the subframe. AG. Volkswagen AG d

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– Remove the bolts -arrows- and remove the heat shield -1- from
the steering gear.
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Note
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Different heat shields -1- are installed depending on the engine.

On some engine versions, the connectors for the steering gear
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– Disconnect the connectors -1 and 2- from the steering gear.
– Unclip the wiring harness -1- from the steering gear -2-
-arrows-.
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Installing
2. Subframe 31
Note
♦ Tighten the nuts -arrows- in curb weight position. Refer to

⇒ “3.8.1 Wheel Bearing in Curb Weight, Lifting Vehicles with
♦ Coat the seal on the steering gear with lubricant such as soft
soap before installing the steering gear.
♦ After attaching steering gear to the universal joint, make sure
that seal on steering gear is positioned on the mounting plate
without and kinks and is sealed correctly. The opening to the
footwell must be sealed correctly. Ingress of water and/or
noises may be the result.

basic setting for the wheel damping electronics using the Ve‐
hicle Diagnostic Tester.
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♦ ⇒ “1.1 Wheel Bolt Tightening Specifications”, page 286
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♦ Bearing Installer - Wheel Hub/Bearing Kit - T10205-

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♦ Hydraulic Press - Bushing Tool Kit - VAS6779-
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♦ Threaded Rod - VAS6779/2-
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♦ Hexagon Nut - VAS6779/3-

♦ Tube - VAS6779/4-
♦ Thrust Piece - VAS6779/5-
♦ Funnel - VAS6779/6-

♦ Insert - VAS6779/7-1A-
♦ Hydraulic Press - VAS6178- with Bearing Installer - Wheel
Hub/Bearing Kit Pressure Head - T10205/13-
♦ Press Plate - VW401-
♦ Press Piece - Multiple Use - VW412-
Caution


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– Remove the stabilizer bar bolts -1-.

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– Remove the pendulum support. Refer to ⇒ Engine Mechani‐

at
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cal, Fuel Injection and Ignition; Rep. Gr. 10 ; Subframe Mount;

p
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Pendulum Support, Removing and Installing or ⇒ Engine Me‐

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chanical, Fuel Injection and Glow Plug; Rep. Gr. 10 ; Sub‐

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frame Mount; Pendulum Support, Removing and Installing . C py
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Pressing Out the Bonded Rubber Bushing

– Install the Hydraulic Press - Bushing Tool Kit - VAS6779- as
shown in the illustration on the subframe.
– Position the Thrust Piece - VAS6779-1- -1- with the flat side
-arrow- on the bonded rubber bushing in the driving direction.
2. Subframe 33
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1 - Thrust Piece - VAS6779/1- Prote AG.
2 - Tube - VAS6779/4-
3 - Thrust Piece - VAS6779/5-
4 - Hydraulic Press - VAS6178- with Bearing Installer - Wheel
5 - Hexagon Nut - VAS6779/3-
6 - Threaded Rod - VAS6779/2-

– Press out both bonded rubber bushings until the upper bonded
rubber bushing -2- is visible through the opening for the pen‐
dulum support -arrow- in the subframe.
– Perform a visual inspection of the upper bonded rubber bush‐
ing -2- outer race.
• If the upper bonded rubber bushing -2- outer race is deformed,
it must be destroyed through the opening for the pendulum
support -arrow- in the subframe.
– Using a chisel or similar tool -1-, make a break in the upper
bonded rubber bushing -2- outer race.
Note
This work sequence is necessary to prevent tilting of the bonded

rubber bushing outer race in the area of the pendulum support
opening in the subframe.
– Completely press out both bonded rubber bushings at the

same time.
Prepare the Bonded Rubber Bushing Before Pressing In.

– Place the bonded rubber bushings -1 and 2- on top of each
other so the openings -arrows- lay exactly over each other.
– Tighten the bonded rubber bushings -1 and 2- using the orig‐
inal bolt -3- hand tight.
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– Place the bonded rubber busing -1- aut with the bolt head facing ra
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– Align the bonded rubber bushing -1- in the Funnel -

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2. Subframe 35
– Press the bonded rubber bushing -3- in the Funnel -

VAS6779/6- as shown in the illustration until stop.
1- Press Piece - Multiple Use - VW412-
2- Thrust Piece - VAS6779/5- , the side with the letter »A«
points up
3- Bonded rubber bushing
4- Funnel - VAS6779/6-
5- Tube - VAS6779/4-
6- Press Plate - VW401-
– Insert the Counter Hold - VAS6779/7- -1- into the subframe.

– Insert the Insert - VAS6779/7-1A- -2- in the pendulum support
opening in the subframe.
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tee
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Installing the Bonded Rubber Bushing

– Install the Threaded Rod - VAS6779/2- -7- in the Counter Hold
nform
ercia
- VAS6779/7- -1-.
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– Install the Hydraulic Press - Bushing Tool Kit - VAS6779- as

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shown in the illustration on the subframe.

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1 - Counter Hold - VAS6779/7-

2 - Funnel - VAS6779/6- , -arrow marking- on the Funnel -
VAS6779/6- must align in the center of both bolts -arrow-.
3 - Thrust Piece - VAS6779/9-
4 - Incremental Ring - VAS6779/8- , the marking -I- on the Incre‐
mental Ring - VAS6779/8- must align with the marking -X- on the
Thrust Piece - VAS6779/9-
6 - Hexagon Nut - VAS6779/3-
7 - Threaded Rod - VAS6779/2-
– Press in both bonded rubber bushing at the same time.
– Remove Hydraulic Press - Bushing Tool Kit - VAS6779- from
the subframe and check seating of the pressed in bonded rub‐
ber bushing.
– Fasten the stabilizer bar with the subframe and the coupling
rod.
– Install the pendulum support. Refer to ⇒ Engine Mechanical,
Fuel Injection and Ignition; Rep. Gr. 10 ; Subframe Mount;
Pendulum Support, Removing and Installing or ⇒ Engine Me‐
2. Subframe 37
chanical, Fuel Injection and Glow Plug; Rep. Gr. 10 ; Sub‐

frame Mount; Pendulum Support, Removing and Installing .
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– Install the front noise insulation.
Vol
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Rep. Gr. 66 ; Noise Insulation;
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2.7 Stabilizer Bar, Removing and Installing
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Removing
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– Remove the nut -1-.

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– Remove the bracket -2- for the Left Front Level Control System
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2. Subframe 39

– Remove the Left Front Level Control System Sensor - G78-
-2- or Right Front Level Control Sensor - G289-
– Remove the clips -1 and 2- for the wiring harness -3- from the
subframe and the steering gear.
– Remove the stabilizer bar bolts -1-.

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– Pry the steering gear out of the subframe alignment sleeves.
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– Secure the subframe (refer to
⇒ “2.2 Subframe, Securing”, page 17 ) and lower it approxi‐
mately 10 cm. wage
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– Lower the subframe with the -VAS6931- until the stabilizer bar
t to the co
can be removed toward the rear.
Installing
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2. Subframe 41
Note

♦ The level control system sensor lever must point toward vehi‐
cle exterior. agen
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The thread on the vehicle level sensor must be installed y V into
o
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the exterior hole in the control arm. The tab on theorvehicle
ise
level nte
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sensor bracket must lock into the inner hole inauorder
th to assure ra
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♦ Refer to
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⇒ “2.1 Overview - Front Level Control System Sensor”,
page 277
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record it in the vehicles axle alignment log.
AG.
2.8 Coupling Rod, Removing and Installing

Caution


♦ Nut - Coupling Rod to Suspension Strut
Removing

– Remove the nut -arrow- and coupling rod -1- from the sus‐
pension strut.
– Remove the hex nut -1- from the coupling rod -3-.
– Remove the coupling rod -3- from the stabilizer bar -2-.
Installing
• Tighten the coupling rod nuts on the suspension strut or sta‐
bilizer bar, counterholding on the multipoint socket head if
necessary.
2.9 Thread in Longitudinal Member, Servic‐

ing
It is possible to service the threads of the weld nuts in the longi‐
tudinal member depending on certain conditions. Refer to ⇒ Body
Repair; Rep. Gr. 50 .
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2. Subframe 43
3 Suspension Strut and Upper Control

Arm
⇒ “3.1 Overview - Suspension Strut and Upper Control Arm”, page
44
⇒ “3.2 Suspension Strut, Removing and Installing”, page 45
⇒ “3.3 Suspension Strut, Servicing”, page 51
3.1 Overview - Suspension Strut and Upper Control Arm
1 - Spring Seat
❑ Note the installation po‐
sition
2 - Shock Absorber
❑ Different versions. Re‐
fer to the Parts Catalog.
3 - Bolt
❑ 70 Nm + 180°
❑ The bolt tip must face in
direction of travel.
4 - Wheel Bearing Housing
5 - Nut
6 - Protective Sleeve
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7 - Coil Spring olksw not
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❑ Removing and instal‐ orise nte
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⇒ “3.3 Suspension ss c
Strut, Servicing”,
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page 51 .
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❑ Surface of spring coil

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8 - Axial Groove Ball Bearing

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9 - Stop Buffer
❑ Different versions. Refer to the Parts Catalog.
rrectne
10 - Suspension Strut Bearing

s
❑ Note installation position. Refer to ⇒ page 49 .

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11 - Nut
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❑ 60 Nm
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12 - Body Front
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13 - Bolt
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❑ 15 Nm + 90°
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Rep. Gr.40 - Front Suspension
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14 - Cover
3.2 Suspension Strut, Removing and Instal‐

ling
♦ Spreader Tool - 3424-
♦ Drive Shaft Remover - T10520-
Removing
– Loosen drive axle bolt on the wheel hub. Refer to
⇒ “6.4 Drive Axle Threaded Connection, Loosening and Tight‐
ening”, page 101 .
Caution
The wheel bearing must not be under load when the drive axle
threaded connection on the wheel side is loose.
If the wheel bearings are under the load of the vehicle weight,
the wheel bearing will be damaged. This reduces the service
life of the wheel bearings. AG. VolkswagenAG do n
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The drive axle bolt may be loosened Vol maximum 90° when the
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vehicle is standing on its wheels.
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Vehicles without a drive axle
aut must not be moved, otherwise the or
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♦ Install an outer joint in place of the drive axle.

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♦ Tighten the outer joint to 120 Nm.

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– Remove the wheel.
rrectness of i
– Remove the nut -arrow- and the coupling rod -1- from the sus‐
l purpos
pension strut.
– Disengage the wire for the ABS speed sensor from the sus‐
nf
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pension strut.
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3. Suspension Strut and Upper Control Arm 45


– Remove the nuts -arrows-.

– Remove the wheel bearing housing with the ball joint from the
control arm.
– Remove the drive axle outer joint from the wheel hub.
If the drive axle cannot be pulled out of the wheel bearing, then
the drive axle can be pushed out of the wheel bearing using the
Drive Shaft Remover - T10520- .
Before using the -T10520- , make sure that the thrust piece -1- is
installed.
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Using the -T10520- :

t to the co
– Secure the -T10520- -1- with three wheel bolts -2- on the wheel
hub, so that the drive axle -3- can be pressed out.
rrectness of i
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Rep. Gr.40 - Front Suspension cted agen
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– Follow the specified sequence exactly.

I - Tighten the knurled nut -1- hand-tight.
II - Only turn the bolt -2- using a wrench and press out the drive
axle using the -T10520- .
Note
At the end of the tasks or to set back, the spindles must be brought
back into the original position so that the hydraulic operation can
be used.
– Secure the drive axle to the body using wire.
Caution
The drive axle must not hang down, otherwise the inner joint
will be damaged by over bending.
Vehicles with Adaptive Chassis DCC

– Disconnect the connector -1- from the shock absorber -2-.
Note
If there is moisture in the connector area, blow compressed air on

the contacts on the shock absorber and the connectors.

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– Insert a screwdriver -1- in the brake rotor betweenaut the brake
h eo
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caliper and brake carrier. ss c
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– Secure the -VAS6931- using -T10149- -2- to wheel hub with
du
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♦ Do not lift or lower the vehicle when the -VAS6931- is un‐
es, in part or in w
der the vehicle. The vehicle could slip off the hoist.
t to the co
♦ Do not leave the -VAS6931- under the vehicle any longer

than necessary.
rrectness of i
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– Disconnect the threaded connection for the wheel bearing

housing/suspension strut -arrow-.
– Insert -3424- into wheel bearing housing slot.
Note
Pay attention that the -3424- is only inserted in the wheel bearing
housing. Only insert it far enough that the suspension strut metal
retainer is not damaged.
– Turn the ratchet 90° and remove it from the -3424- .

– Press the brake rotor toward the suspension strut by hand.
Otherwise the shock absorber tube could tilt in the wheel bearing
housing hole.
– Lower the wheel bearing housing -1- using the -VAS6931- in

the direction of the -arrow-. en AG. V
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– Lower the wheel bearing housing d-1-by so that the shock ab‐
Vo gu
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sorber tube hangs freely -arrow-.
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– Fasten the ball joint to the scontrol
sa arm again and secure the c
wheel bearing housing to the subframe.
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– Remove the -VAS6931- from underneath the -T10149- .

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WARNING
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♦ Do not leave the -VAS6931- under the vehicle any longer

spec
than necessary.
es, in part or in w
t to the co
– Remove the seal from the entire length of the plenum chamber
rrectness of i
cover.
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– Remove the clips.

nform
ercia
– Lift the plenum chamber cover -1- to maximum 60 mm.

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om
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– Remove the bolts -1- for upper strut mount and remove shock
absorber mount.
Installing
– Position the suspension strut so that the arrows -1- are always
inside.
– One of the two arrows -1- on the spring plate -2- must point in
the direction of travel.
AG. Volkswagen AG d
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– Insert the suspension
aut
h strut and fasten the bolts -1- to the body. ra
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– Place the -VAS6931- under the -T10149- and secure the

ss
wheel bearing housing.

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– Untie the wheel bearing housing from the subframe.

form
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– Remove the nuts -arrows-. d byV ua
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– Remove the wheel bearing housing with the
au ball joint from the
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– Lower the wheel bearing housing -1- using the -VAS6931- in
the direction of the -arrow-.
l purpos
– Push the wheel bearing housing with the -VAS6931- upward

and install it on the suspension strut at the same time.
nf
ercia
or
– Re-bolt the ball joint to the control arm and push the wheel
m
m
atio
bearing housing upward again until the end position on the
om
suspension strut is reached.
n in
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– Remove the -3424- .
– Insert the new bolt with tip facing the direction of travel.
– Fasten the wheel bearing housing with the new nut -arrow- to
the suspension strut.
Further installation is the reverse order of removal. Note the fol‐
lowing:

Note AG. Volkswagen AG d

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♦ Tighten the nuts -arrows- in curb weight position. d bRefer to
y V gu
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⇒ “3.8.1 Wheel Bearing in Curb Weight, Lifting riseVehicles with nte
ho eo
Coil Spring, Front Axle”, page 6 . s aut ra
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s
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nl
pt
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cle exterior.
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♦ The thread on the vehicle level sensor must be installed into
ility
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the exterior hole in the control arm. The tab on the vehicle level
wit
, is n
sensor bracket must lock into the inner hole in order to assure
h re
a correct installation position.
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
♦ Refer to
⇒ “3.1 Overview - Suspension Strut and Upper Control Arm”,
page 44
nf
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♦ Refer to
atio
m
⇒ “4.1 Overview - Lower Control Arm and Ball Joint”,

o
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c
page 54
or
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♦ Refer to
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page 277
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♦ Refer to ⇒ “6.2 Overview - Drive Axle”, page 80
c by lksw
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Prote AG.
♦ Refer to
⇒ “1.1 Wheel Bolt Tightening Specifications”, page 286
3.3 Suspension Strut, Servicing

♦ Spring Compressor Kit - Spring Tensioner - VAG1752/1-
♦ Spring Compressor Kit - Spring Retainer w/Inserts -
VAG1752/4-
♦ Spring Compressor Kit - Strut Clamping Block - VAG1752/20-
♦ Shock Absorber Set - T10001-
♦ Shock Absorber Set - Socket - T10001/5-
♦ Shock Absorber Set - Extension SW7 - T10001/8-
♦ Shock Absorber Set - Reversible Ratchet - T10001/11-
♦ Ratchet (commercially available)
♦ Torque Wrench 1332 Insert - Ring Wrench - 21mm -
VAG1332/7-

Caution
AG. Volkswagen AG d
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This procedure contains mandatory replaceable parts. ReferVolksw
oes
not
gu
to component overview prior to starting procedure. se
db
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♦ Nut - Shock Absorber
itte
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– Remove the suspension strut. Refer to ⇒ page 45 .
ility
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Removing Spring
h re
ole,
spec
– Clamp the Spring Compressor Kit - Strut Clamping Block -
VAG1752/20- -4- in a vise.
t to the co
– Tighten the suspension strut in the Spring Compressor Kit -
Strut Clamping Block - VAG1752/20- -4-.
rrectne
– Pretension the coil spring using the Spring Compressor Kit -
Spring Tensioner - VAG1752/1- until the upper axial groove
s
ball bearing is free.
s o
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f in
1- Torque Wrench 1332 40-200Nm - VAG1332-
form
mer
2- Shock Absorber Set - Extension SW7 - T10001/8-
atio
om
n
c
3- Spring Compressor Kit - Spring Tensioner - VAG1752/1-
i
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4- Spring Compressor Kit - Strut Clamping Block -

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VAG1752/20-
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5- Spring Compressor Kit - Spring Retainer w/Inserts -
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6- Shock Absorber Set - Socket - T10001/5-
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7- Shock Absorber Set - Reversible Ratchet - T10001/11-
WARNING
First pre-load spring far enough so that tension is relieved on

upper spring plate!
– Make sure the coil spring fits correctly inside the Spring Com‐
pressor Kit - Spring Retainer with Inserts - VAG1752/4-
-arrow-.

Installing Spring
– Place the spring support -1- in the shock absorber -2-.
– Place the coil spring -3- with the Spring Compressor Kit -
Spring Tensioner - VAG1752/1- on the lower spring support.
End of spring coil must rest against stop -arrow-.
– Assemble all additional parts and tighten the new nut on the
piston rod.
– Relieve the tension on the Spring Compressor Kit - Spring
Tensioner - VAG1752/1- and remove from the coil spring.
– Remove the suspension strut from the Spring Compressor Kit
- Strut Clamping Block - VAG1752/20-
Volkswa
.
AG. gen AG
agen do
– Install the suspension
olks
w
strut. Refer to es not g
yV
⇒ “3.2 Suspension
se
d b Strut, Removing and Installing”,
ua
ran page 45 .
ri tee
ho
Tightening
au
t Specifications or
ac
ss
♦ Refer to
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pt
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page 44
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4 Lower Control Arm and Ball Joint

⇒ “4.1 Overview - Lower Control Arm and Ball Joint”, page 54
⇒ “4.2 Lower Control Arm, Removing and Installing”, page 55
. Volkswage n AG d n AG
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⇒ “4.3 Ball Joint, Checking”,
yV
olkpage
s 61 not
gu
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⇒ “4.4 Ball Joint, Removing
horis and Installing”, page 62 nte
eo
aut ra
⇒ “4.5 Front Lower
ss Control Arm Bonded Rubber Bushing, Re‐ c
placing”, page 65
ce
e
nl
pt
du
an
itte
⇒ “4.6 Lower Control Arm Rear Bonded Rubber Bushing, Re‐
y li
erm
ab
placing”, page 67
ility
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4.1 Overview - Lower Control Arm and Ball Joint
, is n
h re
hole
spec
es, in part or in w
t to the co
fer to the Parts Catalog
rrectness of i
ling. Refer to
l purpos
⇒ “5.2 Wheel Bearing

Housing, Removing and
nf
ercia
Installing”, page 70
orm
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2 - Nut
atio
om
n in
❑ 60 Nm
or c
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e

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3 - Ball Joint
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ng

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ling. Refer to
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⇒ “4.4 Ball Joint, Re‐
ht
pyri by
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moving and Installing”,
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page 62 Prote AG.
4 - Nut
❑ 40 Nm +45°
❑ Tighten in the curb
weight position. Refer to
⇒ “3.8.1 Wheel Bearing
in Curb Weight, Lifting
Vehicles with Coil
Spring, Front Axle”,
page 6 .
5 - Lower Control Arm
ling. Refer to
⇒ “4.2 Lower Control
Arm, Removing and In‐
stalling”, page 55
6 - Front Bonded Rubber
Bushing
❑ Replacing. Refer to ⇒ “4.5 Front Lower Control Arm Bonded Rubber Bushing, Replacing”, page 65
7 - Bolt
❑ 70 Nm + 180°
❑ Tighten in the curb weight position. Refer to
⇒ “3.8.1 Wheel Bearing in Curb Weight, Lifting Vehicles with Coil Spring, Front Axle”, page 6 .

8 - Bolt
❑ 70 Nm + 180°
9 - Rear Bonded Rubber Bushing
❑ Replacing. Refer to ⇒ “4.6 Lower Control Arm Rear Bonded Rubber Bushing, Replacing”, page 67
10 - Nut
11 - Subframe
4.2 Lower Control Arm, Removing and In‐

stalling
⇒ “4.2.1 Lower Control Arm, Removing and Installing, Vehicles
with Manual Transmission, DSG Transmission 0CW”, page 55
with DSG Transmission 0D9”, page 57
4.2.1 Lower Control Arm, Removing and In‐

stalling, Vehicles with Manual Transmis‐
sion, DSG Transmission 0CW
n AG. gen AG Volkswa
Special tools and workshop wage
olks equipment required
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♦ Torque Wrenchris1332
ed 40-200Nm - VAG1332- nte
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Removing s au ra
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ility
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h re
– Remove the noise insulation. Refer to ⇒ Body Exterior; Rep.

ole,
Gr. 66 ; Noise Insulation; Overview - Noise Insulation .

spec
t to the co
– Loosen the wheel housing liner in the rear area and fold for‐
ward.
rrectne

ss
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cial p

inform

mer
atio
m

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4. Lower Control Arm and Ball Joint 55


– Remove the control arm from the ball joint and then turn the
wheel bearing housing toward the outside to take the load off
the control arm.
AG. Volkswagen AG d
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– Remove the bolts -arrows-.
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Note
ility
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The rear bolt is attached with a nut. Counterhold the nut when
h re
hole
loosening.
spec
es, in part or in w
t to the co
rrectness of i
l purpos
– Swivel the control arm -1- toward the rear and then remove it
nf
ercia
from the subframe in direction of -arrow-.
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Installing
atio
om
n in
c

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– Insert the rear control arm -1- into the subframe in direction of
-arrow- and swivel it forward.

– Tighten the screws -arrows-.
Note
The rear bolt must be attached with a new nut. Counterhold the
nut when tightening.

lowing:
AG. Volkswagen AG d
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es, in part or in w
cle exterior.
t to the co
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♦ Refer to
at
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riv

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or
page 54
f
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ng
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op
♦ Refer to C py
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⇒ “2.1 Overview - Front Level Control System Sensor”, rig ht
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page 277 co Vo
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Prote AG.
♦ Refer to
4.2.2 Lower Control Arm, Removing and In‐

stalling, Vehicles with DSG Transmis‐
sion 0D9
♦ Engine Support - T10533-
Removing

AG. Volkswagen AG d
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Golf 2015 ➤ , Golf Variant 2015 ➤ ed b ara
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Suspension, Wheels, Steering - Edition
ut
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o eo
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– Loosen the wheel housing liner in the rear area and fold for‐
ility
ot p
ward.
wit
is n
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ole,
spec
t to the co
rrectne
ss o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
e

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– Remove the control arm from the ball joint and then turn the
r
fo
en
ng
wheel bearing housing toward the outside to take the load off
t.
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the control arm. C py
ht. rig
rig ht
– Remove the pendulum support. Refer to ⇒ Rep. Gr. 10 ; Sta‐
py by
co Vo
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bilizer Bar; Pendulum Support, Removing and Installing . Prote
cted AG.
agen
– Loosen the exhaust system double clamp. Refer to ⇒ Rep.

Gr. 26 ; Exhaust Pipes/Mufflers; Overview - Muffler .

-arrows-.
– Completely assemble the -T10533- to reach the shortest
length.
– Install the -T10533- -2- with the highest angle -arrow- on the
transmission. To do so use the shortest bolt of the pendulum
support thread -1-.
– Push the engine/transmission assembly forward until the -
T10533/5- -3- can be inserted in the pendulum support bear‐
ing.

– Turn the -T10533- until the distance -a- between the bolt for
the control arm -1- and the transmission is reached.
a = 85 mm
AG. Volkswagen AG d
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ility
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t to the co
rrectness o
cial p
f inform
mer
– Swivel the control arm -1- toward the rear and then remove it
atio
from the subframe in direction of -arrow-.
om
n
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or
Installing n thi
te
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Cop py
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Prote AG.
– Insert the rear control arm -1- into the subframe in direction of
-arrow- and swivel it forward.

Golf 2015 ➤ , Golf Variant 2015 ➤ AG. Volkswagen AG d
Suspension, Wheels, Steering - Edition 03.2016 agen oes
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– Tighten the screws -arrows-. hor eo
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Note
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Tighten the bolts -arrows- and nuts in curb weight position. Refer
ility
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to
wit
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hole
spec
es, in part or in w
t to the co
rrectness of i
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nf
ercia
Note
orm
m
atio
m
Tighten the nuts -arrows- in curb weight position. Refer to

o
n in
c

or
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te
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– Remove the -T10533- .
f
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t.
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op
– Remove the exhaust system double clamp. Refer to ⇒ Rep. C py
ht. rig
Gr. 26 ; Exhaust Pipes/Mufflers; Exhaust Pipes/Mufflers, Sep‐ rig ht
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arating . co Vo
by lksw
cted agen
Prote AG.
– Install the pendulum support. Refer to ⇒ Rep. Gr. 10 ; Sub‐
frame Mount; Pendulum Support, Removing and Installing .

– Install the exhaust system bracket from the subframe

-arrows-.
lowing:
Note
cle exterior.

♦ Refer to
page 54
♦ Refer to
page 277
♦ Refer to
A n AG d G. Volkswage
agen
♦ Double clamp for exhaust pipes. Refer
V olkswto ⇒ Rep. Gr. 26 ;
oes
not
Exhaust Pipes/Mufflers; Overview
ed by - Muffler . gu
ara
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♦ Exhaust system to subframe.
au Refer to ⇒ Rep. Gr. 26 ; Exhaust
th ra
Pipes/Mufflers; Overview
s - Muffler .
s c
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un
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4.3 Ball Joint, Checking

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Axial Play, Checking

wit
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– Forcefully pull control arm down in direction of -arrow- and

ole,
press up again.
spec
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
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pr
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t.
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Cop py
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cted agen
Prote AG.

Radial Clearance, Checking

– Forcefully push lower part of wheel inward and outward in di‐
rection of -arrow-.
Note
♦ There should not be any noticeable or visible “play” in either

of the two checks.
♦ Observe lower ball joint while performing checks.
♦ Make allowance for any wheel bearing play or “play” in strut
mounting at top.
♦ Check rubber boot for damage, replace lower ball joint, if nec‐
essary.
4.4 Ball Joint, Removing and Installing

♦ Puller - Ball Joint - 3287A-
♦ Digital Torque Wrench - VAG1756A-
VAG1332/10-
♦ Torx Key Socket Set - VAG1603A-
Removing
– Loosen drive axle bolt on the wheel hub. Refer to
Caution AG. Volkswagen AG d

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The wheel bearing must not be under ised load
b when the drive axle ara
nte
threaded connection on the wheel ut
hor
side is loose. eo
a ra
s c
If the wheel bearings are under
s the load of the vehicle weight,
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e

nl
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life of the wheel bearings.

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The drive axle bolt may be loosened maximum 90° when the
ility
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Vehicles without a drive axle must not be moved, otherwise the

hole
spec

es, in part or in w

t to the co

rrectness of i
l purpos

nf
ercia

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atio

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n in
or c
thi
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Cop py
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Prote AG.
AG. Volkswagen AG d
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➤ , Golf Variant 2015 ➤
h
aut
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c - Edition 03.2016
ss
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nl
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ility
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Sensor - G78- or Right Front Level Control Sensor - G289- , is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
ercia
– Pull the drive axle slightly off the wheel hub.

m
at
om
ion
c
in t
or
his
ate
-T10520- .
do
priv
cum
for
en
ng
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Cop py
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installed.



Note
be used.

– Move the control arm downward as much as needed.
– Loosen the nut on the ball joint -2- but do not remove it.
Caution
To protect the thread, screw the nut

agen
AG.on
Volkthe
swapin aGfew
gen A
do turns.
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– Remove the ballthojoint from the wheel bearing housing. Thenee or
au
remove the nut
ss and the ball joint -2-.
ac
ce
le
1- -3287A-
un
pt
an
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Installing
erm
ab
ility
ot p

wit
is n
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– Insert ball joint into wheel bearing housing.

ole,
spec
– Install drive axle in wheel hub.

t to the co
– Install the new self-locking nut while counterholding using -

T40- from the TORX® ( -VAG1603A- ).
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
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pr
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t.
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Cop py
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Prote AG.

AG. Volkswagen AG d
– Tighten nuts -arrows-. ksw
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Note auth
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♦ Make sure the ball joint boot is not damaged or twisted.
wit
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♦ The level control system sensor lever must point toward vehi‐ hole
spec
cle exterior.
es, in part or in w
t to the co
rrectness of i
l purpos
– Install the wheel and tighten.

– Tighten drive axle bolt onto the wheel hub. Refer to
nform
ercia

m
at
om
ion
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or
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ate
Note
do
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Vehicle must not be standing on its wheels when doing this, oth‐
n
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erwise wheel bearing will be damaged. Cop py
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basic setting for the wheel damping electronics using the Prote AG.

♦ Refer to
page 54
♦ Refer to
page 277
♦ Refer to
4.5 Front Lower Control Arm Bonded Rub‐

ber Bushing, Replacing
♦ Wishbone Rubber Mount Assembly Tool - T10219-
♦ Press Piece - Rod - VW411-
♦ Installation Lubricant - G 294 421 A1-

Caution


♦ Nuts - Lower Control Arm to Ball Joint
♦ Bolts - Subframe to Lower Control Arm
– Remove the lower control arm. Refer to
⇒ “4.2 Lower Control Arm, Removing and Installing”,
page 55 .
– Press out bonded rubber bushings as depicted in the illustra‐
tion.
1- Press Piece - Rod - VW411-
2- Wishbone Rubber Mount Assembly Tool - Tube - T10219/1-
(the opening must face the control arm)
lkswage es n
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ir se tee
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Installing the Bonded Rubber Bushing
erm
ab
ility
ot p
– Align the bonded rubber bushing -1- with the control arm -2-.
wit
, is n
h re
The grooves -3- must point to the control arm -2- as shown.
hole
spec
– Apply Installation Lubricant - G 294 421 A1- onto the outside
es, in part or in w
t to the co
of the bonded rubber bushing.
rrectness of i
l purpos
nform
ercia
– Install the bonded rubber bushing as illustrated.

m
at
om
ion
1- Wishbone Rubber Mount Assembly Tool-Drift - T10219/2-

c
in t
or
his
e

at
do
priv
cum
or
3- Wishbone Rubber Mount Assembly Tool - Tube - T10219/1-

f
en
g
(the opening must face the control arm)

n
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
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cted agen
Prote AG.
Note
The bonded rubber bushing will be crooked for a short time at the
beginning of the installation. Later it will straighten out. It will not
be necessary to guide it.

– Install the bonded rubber bushing until the core -1- and the
transverse link hole -2- are at the same height.
AG. Volkswagen AG d
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au ra
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un
pt
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d
itte
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rm
ab
pe
ility
ot
wit
, is n
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hole
spec
– Press back bearing slightly in control arm.
es, in part or in w
t to the co
2- Wishbone Rubber Mount Assembly Tool -Tube - T10219/1-
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
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rp
c
Dimensions -a and b- must be identical.
um
fo
en
ng
t.
– Install the lower control arm. Refer to
yi Co
op py
⇒ “4.2 Lower Control Arm, Removing and Installing”, t. C rig
gh ht
page 55 . yri
p by
co Vo
by lksw
cted agen
Prote AG.
4.6 Lower Control Arm Rear Bonded Rub‐

ber Bushing, Replacing
♦ Bearing Installer - Wheel Bearing - 3345-
♦ Bearing Installer - Multiple Use - 3348-
♦ Bearing Installer - Ball Joint/Bushing/Bearing - VW459-
– Remove the control arm. Refer to
page 55 .
♦ Vehicles with manual transmission, DSG transmission 0CW.
Refer to
with Manual Transmission, DSG Transmission 0CW”,
page 55

♦ Vehicles with DSG Transmission 0D9. Refer to

with DSG Transmission 0D9”, page 57 .
Bonded Rubber Bushing, Pressing Out
– Press out the bonded rubber bushings as shown.
1- -VW411- lkswage es n
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byV ua
d
2- -3348- o
ir se
ran
tee
th or
u
3- Control Arm ss
a ac
ce
e
nl
4- -3345-
pt
du
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itte
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5- -VW401-
erm
ab
ility
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wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
Bonded Rubber Bushing Installed Position
nf
ercia
o
• The stamped arrow points between the markings -arrows A-
rm
in the control arm.
m
atio
om
n in
c
• The cam -arrow B- must always point to the outside of the

or
thi
vehicle. The open kidney-shape points to the vehicle center.
te
sd
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t.
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Cop py
t. rig
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pyri by
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by
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Prote AG.
Bonded Rubber Bushing, Pressing In

– Install the bonded rubber bushing as shown.
1- -VW412-
2- -VW459/2- , the inner offset in the sleeve -arrow- points
downward
3- Control Arm
4- -3345-
5- -VW401-
Note
Install the bonded rubber bushing far enough until the -3345-
contacts the control arm.

Greasing Bonded Rubber Bushing: AG. Volkswagen AG d

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The kidney-shaped area -1- of the bonded rubber bushing must d byV
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ara
be lubricated. orise nte
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– To do so, apply grease in the kidney-shaped areass-1- starting
a c
from the top working outward.
ce
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pt
an
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– Use the Grease - N.052.150.00.- .
itte
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pe
ility
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spec
es, in part or in w
t to the co
– The required quantity of grease together for both sides should
be approximately 1 cm -dimension a- as shown.
rrectness of i
• Half of the grease quantity (approximately 0.5 cm) must be
l purpos
applied per kidney-shaped area.

– The grease quantity must be applied on the top using a com‐
nform
ercia
mercially available brush.

m
– The contact surfaces to the control arm must not come in con‐
a
com
tio
tact with grease.
n in
r
te o
thi
– Install the control arm
s
iva
do
r
rp
cum
page 55 .
fo
en
ng
t.
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♦ Vehicles with manual transmission, DSG transmission 0CW. Cop py
Refer to ⇒ page 56
ht. rig
rig ht
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co Vo
♦ Vehicles with DSG Transmission 0D9. Refer to ⇒ page 59 .
by lksw
cted agen
Prote AG.

5 Wheel Bearing
⇒ “5.1 Overview - Wheel Bearing”, page 70
⇒ “5.2 Wheel Bearing Housing, Removing and Installing”,
page 70
⇒ “5.3 Wheel Bearing Unit, Removing and Installing”, page 75
5.1 Overview - Wheel Bearing
1 - Cover Plate
2 - Bolt
❑ 12 Nm
3 - Wheel Bearing Unit
ling. Refer to
Unit, Removing and In‐
❑ Cannot be serviced n AG. Volkswagen AG do
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4 - Bolt d byV
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❑ 200 Nm + 180° ir se tee
tho
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❑ Replace after removal ss
a ac
ce
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❑ Loosening and tighten‐

nl
pt
du
an
ing. Refer to
itte
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⇒ “6.4 Drive Axle Threa‐
erm
ab
ded Connection, Loos‐
ility
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ening and Tightening”,
wit
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page 101
h re
hole
spec
es, in part or in w
t to the co
❑ There are different ver‐
sions. For allocation.
Refer to the Parts Cata‐
rrectness of i
log.
l purpos
ling. Refer to
nf
ercia

or
m
m
atio
m
6 - Bolt
o
n in
or c
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❑ 70 Nm + 90°
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7 - Drive Axle
t.
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❑ Do not let the drive axle hang down. The inner joint could be damaged if it is bent too far.
C py
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❑ Lightly coat the splines on the outer joint with assembly paste before installing the outer joint into the
p by
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by lksw
wheel hub. Refer to the Parts Catalog. Prote
cted AG.
agen
5.2 Wheel Bearing Housing, Removing and

Installing
♦ Ball Joint Splitter - 3287A-


Removing
– Remove the drive axle bolt. Refer to
Caution
Vehicles without a drive axle must not be moved, otherwise
agen
AG.the
Volkswagen AG
does
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wheel bearing will be damaged. If a vehiclebymust
Vol be moved, not
gu
be sure to note the following: ris
ed ara
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♦ Install an outer joint in place of the
s a drive axle.
u ra
c
s
ce
le

un
pt
an
d
itte
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erm
ab
ility
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wit
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ole,
spec
t to the co
– Remove the brake caliper and tie it to the vehicle body with
wire. Refer to ⇒ Brake System; Rep. Gr. 46 ; Front Brakes;
Overview - Front Brakes . rrectne
– Remove the ABS speed sensor. Refer to ⇒ Brake System;
Rep. Gr. 45 ; Sensors; Front ABS Wheel Speed Sensor -
ss
G45- / -G47- , Removing and Installing .

o
cial p
f in
– Remove the brake rotor. Refer to ⇒ Brake System; Rep. Gr.

form
mer
46 ; Overview - Front Brakes .

atio
om
– Remove and free up the brake line bracket and electrical wires
n
c
i
or
from the wheel bearing housing.

thi
te
sd
iva
– Remove the cover plate -1- from the wheel bearing housing
pr
cum
r
fo
-arrow-.
en
ng
t.
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Cop py
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Prote AG.
5. Wheel Bearing 71
Caution AG. Volkswagen AG d

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To protect the thread, screw the nut on the pinisea few turns.
d b ara
nte
or eo
h
aut ra
ss c
– Remove the tie rod from the wheel bearing housing and re‐
ce
le
un
pt
move the nut.
an
d
itte
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1- -T10187- erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
rrectne
s
s o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
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o
r
– Loosen the nuts -arrows-.

p
cum
r
fo
en
ng
t.
– Remove the control arm from the ball joint. Cop
yi Co
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t. rig
– Remove the drive axle outer joint from the wheel hub. gh ht
pyri by
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If the drive axle cannot be pulled out of the wheel bearing, then Prote
cted AG.
agen
-T10520- .
installed.


– Follow the specified sequence exactly. n AG. Volkswagen AG do

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I - Tighten the knurled nut -1- hand-tight. d byV ua
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II - Only turn the bolt -2- using a wrench and press
utho out the drive or
axle using the -T10520- . ss
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ce
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Note
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pe
ility
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spec
es, in part or in w
t to the co
– Place the -VAS6931- under the wheel bearing housing.
rrectness of i
– Remove the threaded connection on the wheel bearing hous‐
l purpos
ing/suspension strut -arrow-.
nform
mercia
a
com
tion in
r
te o
thi
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iva
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ng
t.
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Cop py
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Prote AG.
5. Wheel Bearing 73
– Insert -3424- into wheel bearing housing slot.
Note
Pay attention that the -3424- is only inserted in the wheel bearing
housing. Only insert it far enough that the suspension strut metal
retainer is not damaged.
– Turn the ratchet 90° and remove it from the -3424- .

– Remove the wheel bearing housing from the suspension strut.
Note
If the wheel bearing housing is being replaced, then the ball joint
must also be replaced. New nuts must be used.
AG. Volkswagen AG d
Installing lksw
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Install in reverse order
rised of removal while noting the following: ara
nte
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– Tighten nuts -arrows-. ss c ce
e
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pt
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itte
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Note
erm
ab
ility
ot p
wit

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h re

hole
spec
Coil Spring, Front Axle”, page 6 .The level control system sen‐
es, in part or in w
sor lever must point toward vehicle exterior.

t to the co

rrectness of i
l purpos

nf
ercia
or

m
m
atio
m
o
n in
or c
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e
♦ Refer to ⇒ “5.1 Overview - Wheel Bearing”, page 70

t
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♦ Refer to
o
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ng
t.
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page 54 . Cop py
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rig
♦ Refer to py by
co Vo
by lksw
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Prote
page 44
AG.

♦ Refer to
page 277
♦ Refer to
♦ Speed sensor bolt. Refer to ⇒ Brake System; Rep. Gr. 45 ;
Sensors; Overview - Front Axle Speed Sensor .
♦ Bolts for cover plate, brake caliper and brake rotor. Refer to ⇒
Brake System; Rep. Gr. 46 ; Front Brakes; Overview - Front
Brakes .

5.3 Wheel Bearing Unit, Removing and In‐

stalling
Removing
Caution
AG. Volkswagen A
♦ Install an outer joint
olks
wain
geplace
n
of the drive axle.
G do
es n
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by
♦ Tighten the
ris outer joint to 120 Nm.
ed
ara
nte
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s
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e
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pt
du
an
itte

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erm
ab
ility

ot p
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– Remove the brake caliper and tie it to the vehicle body with
h re
hole
wire. Refer to ⇒ Brake System; Rep. Gr. 46 ; Front Brakes;

spec
Overview - Front Brakes .

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– Remove the brake rotor. Refer to ⇒ Brake System; Rep. Gr.

46 ; Overview - Front Brakes .
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5. Wheel Bearing 75
– Remove the hex nut -1- from the coupling rod -3-.

– Remove the drive axle outer joint from the wheel hub.
– Attach the ball joint to the control arm again -arrows-.

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– Remove wheel bearing unit from wheel
Vol bearing housing.
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• The wheel bearing -1- must face up in order to remove the
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5. Wheel Bearing 77
Note

cle exterior.

♦ Refer to
page 54
♦ Refer to
⇒ “2.1 Overview - Front Level Control System Sensor”, agen
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Overview - Front Brakes . aut ra
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6 Drive Axle
⇒ “6.1 Overview - Drive Axle”, page 79
⇒ “6.2 Overview - Drive Axle”, page 80
⇒ “6.3 Drive Axle, Removing and Installing”, page 85
⇒ “6.4 Drive Axle Threaded Connection, Loosening and Tighten‐
ing”, page 101
⇒ “6.5 Drive Axle Heat Shield, Removing and Installing”,
page 102
⇒ “6.6 Drive Axle, Disassembling and Assembling”, page 103
⇒ “6.7 Outer CV Joint, Checking”, page 113
⇒ “6.8 Inner CV Joint, Checking”, page 114
6.1 Overview - Drive Axle
I-
⇒ “6.2.1 Overview - Drive Axle,
CV Joint VL 100”, page 80
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Difference of Drive Axles in Installed Condition

VL100 VL107 AAR3300i At‐ AAR3300i Bol‐
tached ted
Diameter of inner joint in mm 100 107 - -
6. Drive Axle 79
VL100 VL107 AAR3300i At‐ AAR3300i Bol‐

tached ted
Cover between inner joint and - X - -
flange shaft
Inner joint inserted into transmis‐ - - X -
sion
(automatic transmission only)

⇒ “6.2.1 Overview - Drive Axle, CV Joint VL 100”, page 80
⇒ “6.2.2 Overview - Drive Axle, CV Joint VL 107”, page 82
⇒ “6.2.3 Overview - Drive Axle, Triple Roller Joint AAR3300i”,
page 84
6.2.1 Overview - Drive Axle, CV Joint VL 100
1 - Outer CV Joint
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2 - Bolt
❑ 200 Nm +180°
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❑ Check for tears and
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❑ Material: polyelastomer
6 - Clamp
❑ Tensioning. Refer to ⇒ Fig. ““Tightening Clamping Sleeve on Outer Joint”“ , page 106

7 - Plate Spring
❑ Installed position. Refer to
⇒ Fig. ““Installed Location of Spring Washer and Thrust Washer on Outer Joint”“ , page 104
❑ Allocation. Refer to the Parts Catalog.
8 - Thrust Ring
❑ Installed position. Refer to
⇒ Fig. ““Installed Location of Spring Washer and Thrust Washer on Outer Joint”“ , page 104
9 - Locking Ring
❑ Insert in shaft groove
10 - CV Boot
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14 - Internal Multipoint Bolt
❑ 40 Nm
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❑ First tighten diagonally to 10 Nm, then tighten diagonally again to the tightening specification
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15 - Locking Ring
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❑ Checking. Refer to ⇒ “6.8 Inner CV Joint, Checking”, page 114
18 - Plate Spring
❑ Installed position. Refer to ⇒ page 105
6. Drive Axle 81
6.2.2 Overview - Drive Axle, CV Joint VL 107
1 - Bolt
❑ 200 Nm +180°
ing. Refer to
page 101 .
❑ Before installing, clean
the threads in the CV
joint with a tap.
2 - Outer CV Joint
❑ Replace only as com‐
plete unit.
❑ Removing. Refer to
⇒ page 107 .
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page 109
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9 - CV Boot
❑ Without vent hole
❑ Drive off CV joint using drift

10 - Clamp
❑ Tensioning. Refer to ⇒ Fig. ““Tightening Clamping Sleeve On Outer Joint”“ , page 109
11 - Locking Plate
12 - Cover
❑ Carefully drive off using a drift
❑ Adhesive surface must be free of oil and grease
13 - Inner CV Joint
❑ Replace only as complete unit.
❑ Removing. Refer to ⇒ Fig. ““Removing the Inner CV Joint”“ , page 108
❑ Installing. Refer to ⇒ Fig. ““Pressing On Inner CV Joint”“ , page 108
❑ Checking. Refer to ⇒ “6.8 Inner CV Joint, Checking”, page 114 .
14 - Locking Ring
❑ Remove and install using Circlip Pliers - VW161A- .
15 - Cover
❑ Always replace if removed
❑ Removing. Refer to ⇒ Fig. ““Drive Off Cover for Inner Joint”“ , page 107
❑ 70 Nm
❑ M10 x 52
AG. Volkswagen AG d
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6.2.3 Overview - Drive Axle, Triple Roller Joint AAR3300i
1 - Bolt
❑ 200 Nm +180°
ing. Refer to
page 101 .
joint with a tap.
2 - Outer CV Joint
plete unit.
⇒ page 110 .
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The chamfer -arrow- faces the drive axle splines.
❑ Removing. Refer to ⇒ page 110 .
9 - Locking Ring
10 - Clamp

⇒ Fig. ““Tightening the Tensioning Clamp on the Smaller Diameter on the Inner/Outer Joint”“ ,
page 113
11 - CV Boot for Triple Roller Joint
12 - Clamp
⇒ Fig. ““Tightening the Tensioning Clamps on the Larger Diameter on the Inner Joint.”“ , page 112
13 - Adapter
14 - Joint
❑ 70 Nm
❑ M10 x 23
16 - Joint
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6.3 Drive Axle, Removing and Installing ho eo
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Joint VL 100 and VL 107”, page 85
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⇒ “6.3.2 Drive Axle, Removing and Installing, Right Drive Axle,
ility
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⇒ “6.3.3 Drive Axle, Removing and Installing, Triple Roller Joint
hole
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spec
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⇒ “6.3.4 Drive Axle, Removing and Installing, Triple Roller Joint
AAR3300i Bolted”, page 97
6.3.1 Drive Axle, Removing and Installing,

rrectness of i
Left Drive Axle, CV Joint VL 100 and VL

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107
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Removing
6. Drive Axle 85
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– Remove the nuts -arrows- from the ball joint.

– Disengage the control arm from the ball joint.
– Remove the drive axle from the flange shaft/transmission

-arrows-.
– Push the wheel bearing housing to the left.
– Pull the drive axle out of the wheel hub.
-T10520- .
installed.
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6. Drive Axle 87

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– Remove the drive axle.

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♦ Refer to
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• For vehicles with a level control system sensor, perform a
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Gr. 94 ; Headlamp; Headlamp, Adjusting .
6.3.2 Drive Axle, Removing and Installing,

Right Drive Axle, CV Joint VL 100 and
VL 107
Caution

in the joint by over bending.
6. Drive Axle 89
Removing
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rrectness of i
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6. Drive Axle 91

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Caution

6. Drive Axle 93
Removing
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control arm.
– Pull the drive axle out of the wheel hub and tie it securely to
the body.
-T10520- .
installed.
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Note Prote AG.
be used.
6. Drive Axle 95
– Place the -T10161- -1- between the transmission housing and

the triple roller joint.
– Using a rubber hammer, hit the inner joint on the -T10161- and
remove it from the transmission.
Installing
– Install new circlip into the groove on the joint pin.
– Engage the outer and inner splines of joint and transmission.
– Grab the drive axle by hand and push it into the joint up to the
stop.
– Now slide the joint into the transmission Awith a »jerk«.
G. Volkswagen n AG do
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– Make sure the drive axle fits securely inside the transmission.
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The joint pulls against the resistance of the circlip.
spec
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Caution
When checking, only pull on the joint piece and not on the drive rrectne
axle.
ss o
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– Install the outer joint as far as possible into the wheel hub
inform
splines.
mer
atio
– Install the lower noise insulation. Refer to ⇒ Body Exterior;

om

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– Attach the ball joint to the control arm -arrows-.
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Tightening Specifications C py
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♦ Refer to
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ening”, page 101
♦ Refer to
page 277
♦ Refer to
page 54
♦ Refer to
6.3.4 Drive Axle, Removing and Installing, Tri‐

ple Roller Joint AAR3300i Bolted
Caution

6. Drive Axle 97
Removing
Caution

wage es n
– Remove the lower noise insulation. Refer y V to ⇒ Body Exterior;
o lks ot g
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Rep. Gr. 66 ; Noise Insulation; Overview
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- Noise Insulation . ran
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– Remove the hex nut -1- from the
s au right and left coupling rod ac
-3-. s
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control arm.
– Remove the drive axle from the wheel hub.
-T10520- .
installed.
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6. Drive Axle 99

Note
be used.
Installing
Remove any paint residue and/or corrosion on the outer joint
threads/splines.
– Insert the drive axle.
– Install the outer joint as far as possible
n AG. Vinto
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Prote AG.

Note

– Position the drive axle inner joint and tighten the bolts in a
diagonal sequence to 10 Nm.
– Tighten the internal multi-point bolts diagonally to the tighten‐
ing specification.
Note
cle exterior.
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– For vehicles with a level control system sensor, perform the Vol
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basic setting for the wheel damping electronics using the ed ran
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⇒ Vehicle diagnostic tester. ut
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– Install the lower noise insulation. Refer to ⇒ Body
s Exterior;
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– Tighten drive axle bolt onto the wheel hub. Refer to
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♦ Refer to
ening”, page 101
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♦ Refer to
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page 277
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♦ Refer to
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Noise Insulation; Overview - Noise Insulation . p by
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Prote AG.
6.4 Drive Axle Threaded Connection, Loos‐

ening and Tightening
♦ Socket AF 24 mm - T10361A-
6. Drive Axle 101

Caution
The wheel bearing must not be under a load while the drive
axle threaded connection on the wheel side is loose.
Loosening the 12-Point Bolt

– With vehicle still resting on wheels, loosen the twelve-point
bolt with Socket AF 24 - T10361A- maximum 90°, otherwise,
wheel bearing will be damaged.
– Lift the vehicle just enough so that the wheels are hanging free.
– Press the brake pedal. A second technician will be needed.
– Remove the twelve-point bolt -arrow-.
Twelve-Point Bolt, Fastening
– Replace the twelve-point bolt.
AG. Volkswagen AG d
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Wheels must not yet touch the ground to tighten the drive axle, s
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– Tighten the twelve-point bolt to 200 Nm.

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– Lower the vehicle onto its wheels.

spec
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– Turn the twelve-point bolt an additional 180°.

t to the co
6.5 Drive Axle Heat Shield, Removing and

rrectness of i
Installing
l purpos
Front Wheel Drive (FWD)

nform
ercia
Component Tightening Specification

m
Bolts -1- 25 Nm
com
tion in
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Prote AG.

All Wheel Drive (AWD)

Nuts -1- 20 Nm
6.6 Drive Axle, Disassembling and Assem‐

bling
⇒ “6.6.1 Drive Axle, Disassembling and Assembling, CV Joint
VL100”, page 103
⇒ “6.6.2 Drive Axle, Disassembling and Assembling, CV eJoint
VL107”, page 106 olks
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⇒ “6.6.3 Drive Axle, Disassembling and Assembling, Triple Roller nte
oris
Joint AAR3300i”, page 109 auth eo
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6.6.1 Drive Axle, Disassembling and Assem‐
ce
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un
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bling, CV Joint VL100
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♦ Press Piece - Rod - VW408A-
rrectne
♦ Press Piece - 37mm - VW416B-
♦ Press Piece - Multiple Use - VW447H-
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♦ Circlip Pliers - VW161A- f inform

mer

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♦ Clamping Pliers - VAG1682A-

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♦ Tripod Joint Tool - T10065-

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♦ Slide Hammer Set - VW771- t. Cop py
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♦ Puller - Driveshaft - T10382/1- Prote AG.
♦ Spindles - T10382/2-
Caution


♦ Bolt - Outer CV Joint to Drive Axle
♦ Clamps - CV Boot
6. Drive Axle 103

Removing the Outer CV Joint

– Secure the drive axle with protective covers in a vise clamp.
– Fold back boot.
– Align the Puller - Driveshaft - T10382- so that the flat side of
the Puller - Driveshaft - T10382/1- faces the Spindles -
T10382/2- .
– Attach the Puller - Driveshaft - T10382- to the Slide Hammer
Set - VW771- .
– Remove the CV joint from the drive axle using the Puller -
Driveshaft - T10382- and Slide Hammer Set - VW771- .
1- Puller - Driveshaft - Removing Plate - T10382/1-
2- Puller - Driveshaft - Spindles - T10382/2-
Installing the Outer CV Joint
Installed Location of Spring Washer and Thrust Washer oneOuter

Joint olks
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1- Plate Spring rise nte
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2- Thrust Ring au ra
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– Install the new circlips.

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– Slide new CV boot onto drive axle if necessary.

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– Use a plastic hammer to install it on the shaft until the locking

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Removing the Inner CV Joint

Assembling
AG. Volkswagen AG d
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Installed Location of the Plate Springuthon Inner Joint
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Pressing on Inner CV Joint
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Note
m
a
com
Chamfer on inner diameter of ball hub (splines) must face the

ion in
contact shoulder on the drive axle.

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6. Drive Axle 105

Tightening Clamping Sleeve on Outer Joint

– Position Clamping Pliers - VAG1682A- as shown in illustration.
When doing this, make sure that edges of clamping pliers are
seated in corners -arrows B- of clamp.
– Tension clamp by turning spindle with a torque wrench (do not
tilt clamp tool).
Note
♦ The hard material of the joint boot (compared to rubber) makes

it necessary to use a stainless steel hose clamp. It is only pos‐
sible to tighten the hose clamp with Clamping Pliers -
VAG1682A- .
♦ Tightening specification: 25 Nm. n AG. Volkswagen AG do
lkswage es n
♦ Use torque wrench -C- with adjustment by V range 5 to 50 Nm (for
o ot g
ua
example Torque Wrench 5-50Nm ir se- VAG1331- ).
d ran
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♦ Be sure thread of spindle -A-
ss of clamp tool moves freely.
a ac
Grease with MOS 2 grease if necessary.
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♦ If the thread is tight, for example, dirty, the required tensioning

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force for the hose clamp will not be achieved in spite of correct
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torque specification settings.
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Tensioning Clamp on Small Diameter
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
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thi
s
iva
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rp

um
fo
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bling, CV Joint VL107

t.
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Prote AG.

♦ CV Joint Press Sleeve - VW522-
♦ Press Block - 40-204A-
♦ Puller - Driveshaft - T10382/1-
♦ Puller - Driveshaft - T10382-
♦ Slide Hammer Set - VW771-

Caution
AG. Volkswagen AG d
agen oes
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This procedure contains mandatory replaceable dparts. by V Refer gu
ara
horise nte
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Removing the Outer CV Joint hole
spec
es, in part or in w
t to the co
– Fold back boot.
rrectness of i
T10382/2- .
l purpos

Set - VW771- .
nform
ercia
m
at
om
ion
c
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Installing the Outer CV Joint

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– Install the new circlips.
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– Slide new CV boot onto drive axle if necessary.
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ring locks secure.
Drive Off Cover for Inner Joint

– Remove the circlip.
– Remove both clamps, and push the CV boot toward outer joint.
– Drive off the CV boot with a drift.
6. Drive Axle 107


Assembling
Pressing On Inner CV Joint

– Press on joint until stop.
– Install the circlip.
– Coat the cover sealing surface with -D 454 300 A2- .

. Volkswagen AG
gen AG does
– Apply a continuous sealant bead with a 2 toVo3lkmm swa diameter in not
the area of the inner holes -arrow- on theed
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– Align new cover with bolts -arrows- to bolt holes.

It must be aligned exactly because it cannot be aligned after driv‐
rrectne
ing on.
– Drive cover on with a plastic hammer.
ss o
– Wipe away any sealant leaking out.

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Prote AG.

Tightening Clamping Sleeve On Outer Joint

tilt clamp tool).
Note

VAG1682A- .
♦ Tightening specification: 25 Nm.
♦ Use torque wrench -C- with adjustment range 5 to 50 Nm (for
example Torque Wrench 5-50Nm - VAG1331- ).
♦ Be sure thread of spindle -A- of clamp tool moves freely.
Tensioning Clamp On Small Diameter

Outer CV joint, checking. Refer to
Inner CV joint, checking. Refer to
⇒ “6.8 Inner CV Joint, Checking”, pageag114
en AG. V
olkswagen AG
do w es n
olks ot g
CV joint, checking function. Refer
ed
by to ⇒ page 115
V ua
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hole
spec
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rrectness of i

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nform
ercia

m
at
om

on
c
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or
♦ Hose Clip Pliers - VAG1275A-

his
ate
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♦ Clamping Pliers - VAG1682A- opyri
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♦ Puller - Driveshaft - T10382/1-
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Prote AG.
6. Drive Axle 109


♦ Slide Hammer Set - VW771-
Caution


♦ Lock Ring - Triple Roller Joint
♦ Lock Ring - Triple Roller Star with Rollers
Removing the Outer CV Joint
– Fold back boot.
T10382/2- .
Set - VW771- .
AG. Volkswagen AG d
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Installing Outer CV Joint Volksw not
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– Install the new circlips. horise nte
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– Slide new CV boot onto drivess axle if necessary. c
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ring locks secure.

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Triple Roller Joint, Disassembling

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h re
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spec
– Open both clamps at inner joint and slide back CV boot.

t to the co
– Remove joint from drive axle.

rrectne

s
1 - Pliers (commercially available)

s o
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- or Circlip Pliers - VW161A-

nform
mer
– Insert the drive axle into the press.

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Prote AG.

– Press the triple roller star off the axle shaft.

– Pull off CV boot from shaft.
– Clean shaft, joint and groove for oil seal.
Triple Roller Joint, Assembling
– Slide small clamp for joint protective boot onto shaft.
– Slide CV boot onto shaft.
Triple Roller Star, Installing
The chamfer on triple roller star -arrow- faces the shaft. This is
used as an assembly aid.
– Install the triple roller star all the way onto the shaft.
– Make sure the pressure
gen AG
does
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– If necessary,
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Lubricating
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– Insert
ss
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ce
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nl
– Press half of the total amount of grease from the repair kit into
pt
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the triple roller joint.

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– Position the boot adapter on the joint.

ility
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– Slide joint piece over rollers and secure.

h re
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spec
– Press the remaining amount of grease from the repair kit into
es, in part or in w
the rear side of the triple roller joint.

t to the co
rrectness of i
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– Slide the CV boot onto the boot adapter and make sure the
nf
ercia
CV boot engages correctly in the groove on the adapter

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Prote AG.
6. Drive Axle 111

– Install the clamping sleeve.
Note
The clamping ear of the clamp in direction of -arrow A- must be

between the fixing flanges of the joint -B arrows-. This is to make
sure that the internal multipoint bolts are installed correctly when
installing the drive axle.
Tightening the Tensioning Clamps on the Larger Diameter on the

Inner Joint.
tilt clamp tool).
Note

VAG1682A- .
Grease with MOS 2 grease if necessary. G. Volkswagen
nA AG do
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♦ If the thread is tight, for example,
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tilt clamp tool).

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112
Prote AG.
Tightening the Tensioning Clamp on the Smaller Diameter on the

Inner/Outer Joint
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6.7 Outer CV Joint, Checking
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It is necessary to disassemble the joint whenever replacing the
ility
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Removing
ole,
spec
– Mark position of ball hub to ball cage and to housing before
t to the co
disassembling, using electro-writer or grindstone.
– Swivel the ball hub and ball cage.
rrectne
– Remove the balls one after the other.
ss o
cial p
f inform
mer
atio
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– Turn cage until the two rectangular windows -arrow- are

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aligned with the joint housing.
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6. Drive Axle 113

– Swing segment of hub into rectangular window of cage.

– Fold hub out from cage.
The 6 balls of each joint belong to one tolerance group. Check
stub axle, hub, cage and balls for small depressions (pitting build-
up) and chafing. Excessive circumferential backlash in joint
makes itself noticed via tip-in shock, in such cases joint should be
replaced. Flattening and running marks of balls are no reason to
replace joint.
Installing
– Press in half of the total grease amount (40 grams) into joint
body.
– Insert cage with hub into joint body.
– Press in opposing balls in sequence, during this, previous po‐
sition of ball hub to ball cage and to joint body must be
established again.
– Install new circlip into the hub.
– Distribute remaining grease in the joint boot.
6.8 Inner CV Joint, Checking

Removing
The joint must be disassembled for the following work:
♦ Replace the grease if it is very dirty
♦ For checking the contact surfaces for wear
♦ For checking the bearings for wear
– Swivel the ball hub and ball cage. agen
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– Flip out ball hub from ball cage via running path of ball
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– Check joint piece, ball hub, ball cage and balls for small broken
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– Insert ball hub into ball cage via two chamfers. The installation
position is at random. Press balls into cage.
Ball hub has 2 different distances between ball tracks, a larger
and a smaller.
– Insert hub with cage and balls upright into joint piece.
When inserting, make sure that in each case the wide gap -a- at
joint piece contacts narrow gap -b- at hub after swinging in.
Chamfer on inner diameter of ball hub (splines) must face large
diameter of joint piece.
– Also note chamfer on inner diameter of ball hub, it must be
visible after swiveling in.
AG. Volkswagen AG d
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6. Drive Axle 115

7 Special Tools

equipment required
♦ Digital Torque Wrench -
VAG1756A-
♦ Torque Wrench 1332 Insert
- Ring Wrench - 18mm -
VAG1332/10-
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♦ Torque Wrench 1332

40-200Nm - VAG1332-
VAS6931-
♦ Engine/Gearbox Jack
Adapter - Wheel Hub Sup‐
port - T10149-
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7. Special Tools 117

♦ Wishbone Rubber Mount

Assembly Tool - T10219-
♦ Press Piece - Rod -
VW411-
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40-200Nm - VAG1332-
VAS6931-
♦ Digital Torque Wrench -
VAG1756A-
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♦ Bearing Installer - Wheel

Hub/Bearing Kit - T10205-
40-200Nm - VAG1332-
♦ Hydraulic Press -
VAS6178-
♦ Pneumatic/Hydraulic Foot
Pump - VAS6179-
♦ Hydraulic Press - Bushing
Tool Kit - VAS6779-
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♦ Press Piece - Multiple Use
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♦ Bearing Installer - Ball
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Joint/Bushing/Bearing -
VW459-
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♦ Four Locating Pins -

T10486/1-
VAS6931- with Universal
Support Plate -
VAG1359/2-
40-200Nm - VAG1332-
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♦ Puller - Driveshaft -
T10382-
♦ Slide Hammer Set -
VW771- AG. Volkswagen AG d
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♦ Drive Axle Wedge Tool -

T10161-
♦ Drive Shaft Remover -
T10520-
40-200Nm - VAG1332-
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VW408A-
VW411-
♦ Press Piece - 37mm -
VW416B-
- VW447H-
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♦ Hose Clip Pliers -

VAG1275A-
5-50Nm - VAG1331-
40-200Nm - VAG1332-
♦ Clamping Pliers -
VAG1682A-
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♦ Circlip Pliers - VW161A-

5-50Nm - VAG1331-
40-200Nm - VAG1332-
VAG1682A-
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127
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Prote AG.
7. Special Tools

40-200Nm - VAG1332-
♦ Spring Compressor Kit -
Spring Tensioner -
VAG1752/1-
Spring Retainer w/Inserts -
VAG1752/4-
♦ Shock Absorber Set -
T10001-
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VW408A-
♦ CV Joint Press Sleeve -
VW522-
♦ Press Block - 40-204A-
VAG1682A-
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VAG1332/7-
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AG. Volkswagen AG d
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42 – Rear Suspension
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⇒ “1.2 Rear Axle, Lowering”, page 136
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⇒ “1.1.2 Overview - Rear Axle, Multi-Link Suspension”,
page 133
⇒ “1.1.3 Overview - Rear Axle, Multi-Link Suspension, AWD”,
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1.1.1 Overview - Rear Axle, Torsion Beam Axle
nform
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ion
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132 Rep. Gr.42 - Rear Suspension

1.1.2 Overview - Rear Axle, Multi-Link Suspension
I - Refer to
⇒ “3 Subframe”, page 157
II - Refer to
⇒ “4 Stabilizer Bar”,
page 177
III - Refer to
⇒ “5 Control Arm, Tie Rod”,
page 181
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1. Rear Axle 133

IV - Refer to
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⇒ “7 Wheel Bearing and Trail‐ lkswagen oes
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1.1.3 Overview - Rear Axle, Multi-Link Suspension, AWD
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⇒ “4 Stabilizer Bar”, rise
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1. Rear Axle 135

AG. Volkswagen AG d
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Golf 2015 ➤ , Golf Variant
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VI - Refer to
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1.2 Rear Axle, Lowering

⇒ “1.2.1 Rear Axle, Lowering, Multi-Link Suspension”,
page 136
⇒ “1.2.2 Rear Axle, Lowering, Multi-Link Suspension, AWD”,
page 139
1.2.1 Rear Axle, Lowering, Multi-Link Suspen‐

sion
♦ Subframe Bushing Tool Kit - 3301-
♦ Bearing Installer - Control Arm - 3346-
Caution



Volkswagen AG
Lower the Subframe with Attachments.
swa
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hole
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t to the co
Overview - Muffler or ⇒ Engine Mechanical, Fuel Injection and
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– Disconnect the connector -1-.
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– Unclip the right and left speed sensor wires from the bracket
-1- -arrows-.
– Push the lever on the brake caliper -2- in direction of -arrow-.

– Disengage the parking brake cable -1- from the lever on the
brake caliper -2-.
– Squeeze the tabs -3- and remove the parking brake cable
-1- from the bracket -4- on the brake caliper.
1. Rear Axle 137

– Pull the brake cable -1- out of the retainer -arrow A- on the
bracket -2-.
– Remove the brake cable -1- from the guide -arrow B- on the
bracket -2-.
– Remove the clamps -1- on both sides of the vehicle.

– Free up the brake lines from the bracket.
Note
Do not disconnect the brake line.
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– Secure both
ss sides of the vehicle on the hoist arms using Ten‐ c
sioning Straps - T10038- .
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The vehicle could slide off the hoist if it is not secured.

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– Secure the subframe on the two front bolts. Refer to

⇒ “3.2 Subframe, Securing”, page 158 .
rrectness of i
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– Remove the bolt from the back of the subframe on the right
side -arrow-.
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– Install the Bearing Installer - Component - 3346/2- with the

Subframe Bushing Tool Kit - 3301- and Nut - Component -
3346/3- into the threaded hole in the longitudinal member.
1- Bearing Installer - Component - 3346/2-
2- Subframe
3- Subframe Bushing Tool Kit - 3301-
4- Nut - Component - 3346/3-
– Remove the left rear bolt from the subframe.
– Turn the Nut - Component - 3346/3- on the Bearing Installer -
Component - 3346/2- until the subframe is lowered by dimen‐
sion -a- = 40 mm.
Subframe with Attachments, Installing
Volkswagen AG
Installation is the reverse of removal, with special attention to the swagen AG. does
following: by
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Tightening Specifications oris eo
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♦ Refer to ⇒ “3 Subframe”, page 157 ss
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♦ Refer to
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⇒ Engine Mechanical, Fuel Injection and Glow Plugs; Rep.
hole
spec
es, in part or in w
t to the co
• For vehicles with a vehicle level sensor, perform the basic set‐
nostic Tester .
rrectness of i
• On vehicles with level control system sensor, perform head‐
l purpos
lamp basic setting. Refer to ⇒ Electrical Equipment; Rep. Gr.

94 ; Headlamp; Headlamp, Adjusting .
nform
ercia
– Evaluating need for axle alignment. Refer to

⇒ “3.6 Evaluating Need for Axle Alignment”, page 304 .
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1.2.2 Rear Axle, Lowering, Multi-Link Suspen‐
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Caution


Lower the Subframe with Attachments.
1. Rear Axle 139

– Remove the brake calipers on both sides of the vehicle and

hang on the body.
– Remove the rear muffler. Refer to ⇒ Engine Mechanical, Fuel
Injection and Ignition; Rep. Gr. 26 ; Exhaust Pipes/Mufflers;
Overview - Muffler or .⇒ Engine Mechanical, Fuel Injection
and Glow Plugs; Rep. Gr. 26 ; Exhaust Pipes/Mufflers; Over‐
view - Muffler
Vehicles with A Vehicle Level Sensor
– Disconnect the connector -1- from the vehicle level sensor
-2-.
– Disconnect the right and left connectors from the ABS speed
sensor.
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– Unclip the right and
oris left speed sensor wires from the bracket
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-1- -arrows-. auth ra
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Prote AG.

– Secure both sides of the vehicle on the hoist arms using Ten‐
WARNING
– Secure the subframe. Refer to

⇒ “3.2 Subframe, Securing”, page 158 . agen
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– Carefully lower the subframe with its attachments approxi‐ e d by gu
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– Disconnect the connector from the Haldex clutch above
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final drive.
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– Unclip the brake line -1- from the clip -arrow- on the left side.
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Note
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This will destroy the clip, so it will have to be replaced.
t to the co
– Carefully lower the subframe with its components approxi‐
rrectness of i
mately 140 mm.
l purpos
Subframe with Attachments, Installing

Installation is the reverse of removal, with special attention to the
nform
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following:
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♦ Refer to
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⇒ “3.1.2 Overview - Subframe, Multi-Link Suspension, AWD”,
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page 158
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♦ Refer to ⇒ Engine Mechanical, Fuel Injection and Ignition; p by
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Prote
⇒ Engine Mechanical, Fuel Injection and Glow Plugs; Rep.
AG.

nostic Tester .
– Evaluating need for axle alignment. Refer to
1. Rear Axle 141

1.3 Rear Axle, Removing and Installing

⇒ “1.3.1 Rear Axle, Removing and Installing, Torsion Beam Axle”,
page 142
⇒ “1.3.2 Rear Axle, Removing and Installing, Multi-Link Suspen‐
sion, FWD”, page 144
⇒ “1.3.3 Rear Axle, Removing and Installing, Multi-Link Suspen‐
sion, AWD”, page 147
olkswagen AG
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1.3.1 Rear Axle, Removing yV
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Special tools and workshop equipment
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Removing
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– Release and disconnect the connector from the Right and Left
rrectness of i
Rear ABS Wheel Speed Sensors .
l purpos
– Remove the rear brake cable. Refer to ⇒ Brake System; Rep.

Gr. 46 ; Parking Brake; Rear Brake Cable, Removing and In‐
stalling .
nform
ercia
– Remove the right and left brake calipers and tie them to the
m
at
om
body with wire. Refer to ⇒ Brake System; Rep. Gr. 46 ; Rear

ion
c
Brakes; Overview - Rear Brakes . in t

or
his
ate
do
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– Unclip the wire -1- from the bracket -2- on both sides of the
p
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or
axle beam -arrows-.

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Prote AG.

– Release and disconnect the connector -1- from the Left Rear
Level Control System Sensor - G76- .
– Unclip the wire -2- from the clip -arrow-.

– Unclip the brake line -1- on the right mounting bracket from the
clip -arrow-. agen
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⇒ “6.4 Spring, Removing and Installing”, page 202 . ot p
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– Secure both sides of the vehicle on the hoist arms using -
T10038- .
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1- -T10038-
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WARNING
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– Place the -VAS6931- underneath.
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– Mark the position of the bolts -arrows- on the mounting bracket
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-1- on the right and left vehicle side and remove them. Prote AG.
1. Rear Axle 143

– Remove the rear axle from the shock absorbers -arrows-.

– Lower the rear axle using -VAS6931- -1-.
1- -VAS6931-
2- -VAG1359/2-
Installing
olkswagen AG
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• Tighten the shock absorber threaded connection
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Tightening Specifications autho eo
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♦ Refer to ⇒ “2.1 Overview - Axle Beam”, page 150
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♦ Refer to
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⇒ “6.1.1 Overview - Suspension Strut, Shock Absorber and
erm
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Spring, Torsion Beam Axle”, page 191
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♦ Refer to
h re
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spec
♦ Bolts for brake caliper and brake rotor. Refer to ⇒ Brake Sys‐
t to the co
tem; Rep. Gr. 46 ; Overview - Rear Brakes .
• For vehicles with a level control system sensor, perform the
rrectne
ss
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inform
mer
atio
om
1.3.2 Rear Axle, Removing and Installing,
n
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Multi-Link Suspension, FWD

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♦ Tensioning Strap - T10038- Cop py
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♦ Torque Wrench 1332 40-200Nm - VAG1332- p by
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Removing the Subframe and its Attachments Prote AG.


– Disconnect and free up the right and left connector -1- from
the ABS speed sensor.
– Disconnect the right and left electromechanical parking brake
connector -2- from the brake caliper.
– Remove and free up the wiring harness from the retainers
-arrows-.

– Remove the Left Rear Level Control System Sensor - G76-
-3- from the transverse link. agen
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Continuation for all Vehicles byV ua
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– Remove the springs. Refer toutho or
ac
⇒ “6.4 Spring, Removing and
ss Installing”, page
a
202 .
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Note

rrectness of i
– Remove the left and right brake caliper and with the brake lines
l purpos
attached secure to the body. Refer to ⇒ Brake System; Rep.

Gr. 46 ; Overview - Rear Brakes .
nf
ercia
– Remove the rear muffler. Refer to ⇒ Rep. Gr. 26 ; Exhaust

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AG.

1. Rear Axle 145

– Unclip and free up the wire -2- on the mounting bracket -1-.
– Mark the mounting bracket -1- installation position on the
body.
– Remove the bolts -arrows-. AG. Volkswagen AG d
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– Carefully lower the subframe with its components 30 mm max‐d by V gu
ara
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– Remove the brake line from the clips -arrows-.
h re
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spec
t to the co
Note
♦ The clips will get damaged while doing this and will have to be
rrectne
replaced.
♦ For better illustration, the subframe is shown from above and
ss
is removed.
o
cial p
f inform
mer
– Lower subframe with attachments.
atio
om
n
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Note
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When lowering, ensure the brake lines and wires have sufficient
r
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clearance.
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Subframe, Installing with Attachments yri
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♦ Refer to ⇒ “3 Subframe”, page 157
♦ Refer to ⇒ “7.2 Overview - Trailing Arm”, page 213
♦ Refer to
Spring, Multi-Link Suspension”, page 192
♦ Refer to
⇒ “2.2 Overview - Rear Level Control System Sensor”,
page 278
♦ Refer to
– Evaluate if an axle alignment is needed. Refer to

1.3.3 Rear Axle, Removing and Installing,

Multi-Link Suspension, AWD
Removing the Subframe and its Attachments
– Disconnect and free up the right and left connector -1- from
the ABS speed sensor.
– Disconnect the right and left electromechanical parking brake
connector -2- from the brake caliper.
– Remove and free up the wiring harness from the retainers
-arrows-.
AG. Volkswagen AG d
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-3- from the transverse link.

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– Remove the left and right brake caliper and with the brake lines copy Vo
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attached secure to the body. Refer to ⇒ Brake System; Rep. cted agen
Prote AG.
Gr. 46 ; Overview - Rear Brakes .
1. Rear Axle 147


T10038- .
1- -T10038-
WARNING

– Unclip and free up the wire -2- on the mounting bracket -1-.
– Mark the mounting bracket -1- installation position on the
body.
– Carefully lower the subframe with its attachments approxi‐
mately 20 mm.
wage es n
– Disconnect the connector from the Haldex clutch yV
oabove the
lks ot g
final drive. ir se
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– Carefully lower the subframe with its attachments
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When lowering, make sure there is enough clearance between
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the brake lines, electrical lines and centering pins to the drive axle.
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– Remove the brake line on both sides from the clips -arrows-.
Note
♦ The clips will get damaged while doing this and will have to be
replaced.
♦ For better illustration, the subframe is shown from above and
is removed.
– Carefully lower subframe with components.
AG. Volkswagen AG d
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Make sure there is enough clearance for brake
horis
lines, electrical nte
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lines and drive axle centering pin whens lowering.
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Subframe, Installing with Attachments
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♦ Refer to
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page 158
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♦ Refer to
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♦ Refer to
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page 278
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♦ Refer to
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♦ Double clamp for exhaust pipes. Refer to ⇒ Rep. Gr. 26 ; C py
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• For vehicles with a level control system sensor, perform the Prote
cted AG.
agen
– Evaluate if an axle alignment is needed. Refer to
1. Rear Axle 149

2 Axle Beam
⇒ “2.1 Overview - Axle Beam”, page 150
⇒ “2.2 Axle Beam Bonded Rubber Bushing, Replacing”,
page 150
2.1 Overview - Axle Beam
1 - Cover
2 - Bolt
❑ 50 Nm + 45°
3 - Bolt
❑ 70 Nm + 360°
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5 - Axle Beam
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⇒ “1.3.1 Rear Axle, Re‐
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Torsion Beam Axle”,
page 142 t to the co

6 - Bonded Rubber Bushing
❑ Note the installation po‐
rrectne
sition
❑ Replacing. Refer to
ss
⇒ “2.2 Axle Beam Bon‐

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cial p
ded Rubber Bushing,

inform
Replacing”, page 150

mer
atio
7 - Mounting Bracket
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2.2 Axle Beam Bonded Rubber Bushing,
Replacing
♦ Vibration Damper Assembly Tool - T10254-
♦ Engine and Gearbox Jack - VAS6931- -2- with Universal Sup‐
port Plate - VAG1359/2-


Hub/Bearing Kit - Pressure Head - T10205/13-
-T10495/2- , Modifying
Caution
To use the -T10495/2- properly, it must be modified before us‐

ing.
The -T10495/2A- must not be modified.
– Clamp the -T10495/2- in a vise with jaw protectors.

– The red areas -a- must be cut out.
a = 18 mm
– Use a file to deburr the edges after cutting out the areas.
– An -A- must be added to the number identification on the tool.
The new tool number is now -T10495/2A- .
– Apply corrosion protection.
Removing
– Loosen the wheel bolts. AG. Volkswagen AG d
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– Remove the wheels. hor eo
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Vehicles with Level Control System Sensor h re

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spec
– Release and disconnect the connector -1- from the Left Rear
es, in part or in w
t to the co
Level Control System Sensor - G76- .

– Unclip the wire -2- from the clip -arrow-.
rrectness of i
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mercia
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– Remove the lever of the Left Rear Level Control System Sen‐
f
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2. Axle Beam 151

– Unclip the brake line -1- on the right mounting bracket from the
clip -arrow-.
Note
– Unclip the wire -1- from the bracket -2- on both sides of the
axle beam -arrows-.
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T10038- .
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WARNING
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– Loosen the right and left bolt -1-.

nform
ercia
– Place the -VAS6931- and -VAG1359/2- with suitable padding

underneath.
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– Unclip the wire -2- from the mounting bracket -1-.
– Carefully lower the rear axle using the -VAS6931- until it is

possible to remove the bolt -1-.
– Remove the bolts -1- for the right and left axle beam.
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– Mount the special tools as illustrated.
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2. Axle Beam 153

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1 - -T10254/5-
2 - -T10254/4-
3 - -VAS6178- with -T10205/13-
4 - -T10495/3-
5 - -T10495/2-
6 - -T10495/1-
7 - -T10254/4-
– Activate the pump and remove the bonded rubber bushing.

Installing
– Pay attention to the installed location of the bonded rubber
bushing -1- on the axle beam -2-.
The tab -arrow A- of the bonded rubber bushing -1- must point to
the notch -arrow B- in the axle bearing -2-.
– Mount the special toolsn Aas

G. illustrated.
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1 - -T10254/5- by Vol gu
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2 - -T10254/4-
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3 - -VAS6178-
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4 - -T10495/1-
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6 - -T10495/3- wit
is n
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7 - -T10254/4- spec
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
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rig ht
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2. Axle Beam 155

AG. Volkswagen AG d
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ility
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– Before installing bonded rubber bushing, make sure that the C py
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mark on the bonded rubber bushing aligns with the mark on gh ht
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the axle beam.
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– Press in the bonded rubber mount to the stop.
– Check the installed position of the bonded rubber bushing.
Further installation is the reverse order of removal.
♦ Refer to ⇒ “2.1 Overview - Axle Beam”, page 150
♦ Refer to
page 278
♦ Refer to

3 Subframe
⇒ “3.1 Overview - Subframe”, page 157
⇒ “3.2 Subframe, Securing”, page 158
⇒ “3.3 Subframe, Servicing”, page 165
3.1 Overview - Subframe

⇒ “3.1.1 Overview - Subframe, Multi-Link Suspension”,
page 157
page 158
3.1.1 Overview - Subframe, Multi-Link Suspension
1 - Subframe
❑ Subframe with attach‐agen AG. Volkswagen AG do
ments, removingVoand lksw in‐ es n
ot g
y
stalling. Refer ed to
b ua
ran
⇒ “1.3.2 tRear ris Axle, Re‐ tee
ho or
moving ss
au
and Installing, ac
Multi-Link Suspension,
ce
le
un
FWD”, page 144 . pt

an
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itte
2 - Bolt y li
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❑ 70 Nm + 180°
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3 - Bolt
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t to the co
❑ 50 Nm + 45°
rrectness of i
4 - Bolt
❑ 70 Nm + 180°
l purpos

nform
mercia
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tion in
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te o
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Prote AG.
3. Subframe 157
3.1.2 Overview - Subframe, Multi-Link Suspension, AWD
1 - Subframe
❑ Subframe with attach‐
ments, removing and in‐
stalling. Refer to
⇒ “1.3.3 Rear Axle, Re‐
moving and Installing,
Multi-Link Suspension,
AWD”, page 147 .
2 - Rear Bonded Rubber Bush‐
ing
⇒ “3.3.2 Rear Bonded
Rubber Bushing, Re‐
placing”, page 171 .
3 - Front Bonded Rubber
Bushing
⇒ “3.3.1 Front Bonded
Rubber Bushing, Re‐ agen
AG. Volkswagen AG d
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placing”, page 165 . olksw not
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4 - Bolt horis
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❑ 70 Nm +180° ss a c
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mer
3.2 Subframe, Securing

atio
om
n
c
⇒ “3.2.1 Subframe, Securing, Multi-Link Suspension, FWD”, page

i
or
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e
158
t
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pr
⇒ “3.2.2 Subframe, Securing, Multi-Link Suspension, AWD”, page

um
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162
ng
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3.2.1 Subframe, Securing, Multi-Link Suspen‐
. C rig
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♦ Locating Pins - T10096-
♦ Rear Axle Support - T10552-

-T10552- , Preparing
– Loosen the bolts -arrows- and adjust the dimension -a-.
a - 250 mm
Tighten the bolts -arrows-.
– Loosen the bolt -arrow- for the -T10552/2- -2-.
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– Turn sthe
s -T10552/2- -2- so that the profile is perpendicular to
the direction of travel.
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– Adjust the dimension -b-.

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b - 330 mm
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Tighten the bolt -arrow- to 30 Nm.

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es, in part or in w
t to the co
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– Loosen the -T10552/1- -3- on both sides at the bottom.

nf
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– Adjust the dimension -c-.

orm
m
c - 47 mm
atio
om
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Prote AG.
3. Subframe 159
– Turn the -T10552/1- -3- on both sides until the dimension -d-
is set.
d - 230 mm
– Place the -T10552- -1- on the -VAG1383A- or -VAS6931- .
AG. Volkswagen AG d
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V gu
– Tighten the bolt -arrow- to 30 Nm.sed by ara
nte
ri
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es, in part or in w
t to the co
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– Position the -T10552- -1- with the -VAG1383A- or -VAS6931-

-5- under the rear axle and move it upward.
l purpos
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tion in
r
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gh ht
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AG. Volkswagen AG d
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es, in part or in w
t to the co
rrectness of i
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nform
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ion
c
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ate
do
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cum
for
en
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t.
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Cop py
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rig ht
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Prote AG.
– Insert the -T10552/1- -2- into the holes on the rear axle
-A arrows-.
– Secure the -T10552/2- -3- to the rear axle using a Tensioning
Strap -4-.
-T10096- , Installing
– Remove the left and right bolt -1-.
• To secure the subframe, the -T10096- must be installed at the
positions -2 and 3- one after the other on both sides of the
vehicle.
3. Subframe 161
– Unscrew one of the front bolts of the subframe -arrow-.
– Install the - T10096- -1-.

AG. Volkswagen AG d
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Note d by V gu
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The -T10096- mayss aonly be tightened to a maximum of 20 Nm,
u ra
c
otherwise the threads of the locating pins will be damaged.
ce
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un
pt
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itte
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– The same procedure must be performed for the second front
rm
ab
bolt and the rear bolts of the subframe.
pe
ility
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wit
The subframe position is now secured.
, is n
h re
hole
spec
es, in part or in w
3.2.2 Subframe, Securing, Multi-Link Suspen‐ t to the co

sion, AWD
rrectness of i

l purpos

nform
ercia
♦ Rear Axle Support - T10552-

m
a
com
tio
-T10552- , Preparing
n in
r
te o
thi
– Loosen the bolts -arrows- and adjust the dimension -a-.

s
iva
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a - 250 mm
fo
en
ng
t.
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Tighten the bolts -arrows-.
Co
Cop py
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cted agen
Prote AG.
– Loosen the bolt -arrow- for the -T10552/2- -2-.

– Turn the -T10552/2- -2- so that the profile is in the direction of

travel.
– Adjust the dimension -b-.
b - 410 mm
Tighten the bolt -arrow- to 30 Nm.
– Loosen the -T10552/1- -3- on both sides at the bottom.

– Adjust the dimension -c-.
c - 47 mm
– Turn the -T10552/1- -3- on both sides until the dimension -d-
is set. gen AG
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d a oes
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d - 215 mmd by Vo gu
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ility
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es, in part or in w
t to the co
– Place the Rear Axle Support - T10552- -1- on the -VAG1383A-

or -VAS6931- .
rrectness of i
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ion
c
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ate
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3. Subframe 163
Suspension, Wheels, Steering - Edition 03.2016 en AG. Volkswagen AG
wag doe
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Vol t gu
– Tighten the bolt -arrow- to 30 Nm. d by ara
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ris
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itte
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ility
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hole
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es, in part or in w
t to the co
rrectness of i
– Position the -T10552- -1- with the -VAG1383A- or -VAS6931-
-1- under the rear axle and move it upward.
l purpos
nform
mercia
at
om
ion
c
in t
or
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ate
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cum
for
en
ng
t.
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Cop py
t. rig
gh ht
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cted agen
Prote AG.
– Insert the -T10552/1- -2- into the holes on the rear axle
-A arrows-.
– Secure the -T10552/2- -3- to the rear axle using a Tensioning
Strap -4-.

-T10096- , Installing
To secure the subframe, the -T10096- must be installed at the
positions -1- one after the other on both sides of the vehicle.
– Remove a hex bolt -1- from both sides.
Note
Only the left side of the vehicle is shown in the illustration.
AG. Volkswagen AG d
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by
– Install the - T10096- -1-. rised ara
nte
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Note
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The -T10096- may only be tightened to a maximum of 20 Nm,
erm
ab
otherwise the threads of the locating pins will be damaged.
ility
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is n
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– Replace the bolts on the subframe one after the other with the
ole,
spec
-T10096- -1- on both sides and tighten to 20 Nm.
t to the co
The subframe position is now secured.
rrectne
3.3 Subframe, Servicing
ss
⇒ “3.3.1 Front Bonded Rubber Bushing, Replacing”, page 165
o
cial p
f in
⇒ “3.3.2 Rear Bonded Rubber Bushing, Replacing”, page 171
form
mer
atio
3.3.1 Front Bonded Rubber Bushing, Replac‐
om
n
c
ing
i
or
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sd
va

i
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pr
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t.
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♦ Hydraulic Press - Rear Subframe Bushing Tool Kit - T10263-
t. C rig
gh ht
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Vo
o
♦ Subframe Bushing Assembly Tool Kit - T10356- by c lksw
cted agen
Prote AG.
Hub/Bearing Kit - Pressure Head - T10205/13-
♦ Bearing Installer - Wheel Hub/Bearing Kit - T10205A-
3. Subframe 165
Note
♦ If a bonded rubber bushing is faulty, then the bonded rubber

bushing on the opposite side must also be replaced. For the
correct allocation. Refer to the Parts Catalog.
♦ Check the other bearing before switching out a defected bon‐
ded rubber bushing.
♦ If there are any tears or other visible damages, replace the
bonded rubber bushing.
♦ To replace the rubber bonded bushing, the subframe must be
lowered at the front or the rear. It is not necessary to remove
the subframe.
♦ Identify mounting location to subframe before removing the
Pressing Out Bonded Rubber Bushing, Front

– Remove the spring. Refer to
AG. Volkswagen AG d
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ed
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ut
Do not disconnect the brake line. ss a ra
c
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pt
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an
itte
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erm
ab
ility
ot p
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, is n
h re
hole
spec
es, in part or in w
– Secure both sides of the vehicle on the hoist arms using Ten‐ t to the co
rrectness of i
l purpos
WARNING
nf
ercia

orm
m
atio
om
n in
c

or
thi
e

t
sd
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en
ng
t.
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Cop py
ht. rig
rig ht
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co Vo
by lksw
cted agen
Prote AG.

– Mark the installation location of the bonded rubber bushing on

the subframe with a felt-tip pen -1-.
Note
Apply the mark -1- on the subframe in the middle of the recess on
the bonded rubber mounting -2-.
lkswage es n
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d ran
ir se tee
o
– Use a screwdriver -2- pry off the anti-twist mechanism
auth -1- near or
ac
the bonded rubber bushing mounting retaining ss lugs.
ce
le
un
pt
– Lower the subframe approximately 100 mm (3.93 in.) using
an
d
itte
the Engine and Gearbox Jack - VAS6931- .
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pe
ility
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spec
es, in part or in w
t to the co
rrectness of i
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nform
ercia
Note
m
a
com
tio
n in
r
te o
thi
s
iva
do
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cum
fo
en
ng
t.
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Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
– Use the special tools as shown.
3. Subframe 167
lkswage es n
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tho
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a ac
ss
ce
le
un
pt
an
d
itte
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erm
ab
ility
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is n
h re
ole,
spec
1 - Nut - T10263/5-
t to the co
2 - Press Piece - T10356/1-

3 - Subframe
rrectne
4 - Subframe Bushing Assembly Tool Kit-Pipe - T10356/2- , side

with shoulder points to subframe
ss o
5 - Bearing Installer - Wheel Hub/Bearing Kit - 1 - T10205/1-

cial p
f inform

mer
atio

om
n
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7 - Nut - T10263/5-
or
n thi
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sd
a
8 - Threaded Rod - T10263/4-

iv
o
pr
cum
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– Pretension special tools.

en
ng
t.
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op
– Press out the bonded rubber mount.
C py
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Note
. Volkswagen AG
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swa
♦ When removing the bonded rubber mounting, the bearing y Volk outer race is shorn off. There
not is a loud crack when
gu
this happens. risedb ara
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♦ ut
After removing the bonded rubber bushing, its amust be removed from the Tube - T10356/2- by tapping ra lightly
c
with a hammer. s
ce
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un
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an
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itte
Press In on the Front Bonded Rubber Bushing
y li
erm
ab
ility
– Apply a line -1- on the vertical rib of the bonded rubber bushing
ot p
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to help mount.
is n
h re
ole,
spec
t to the co
rrectness o
cial p
f inform
mer
atio
om
– Apply mounting paste to the outer edge of the bonded rubber
n
c
i
or
n
bushing.
thi
te
sd
iva
o
– Insert special tools with bonded rubber bushing into subframe
pr
cum
r
fo
as illustrated.
en
ng
t.
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Cop py
t. rig
gh ht
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Vo
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by c lksw
cted agen
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3. Subframe 169
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pt
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itte
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hole
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es, in part or in w
t to the co
rrectness of i
l purpos
nform
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tion in
r
te o
thi
s
iva
do
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cum
fo
en
ng
t.
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Cop py
t. rig
gh ht
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co lksw
by
cted agen
Prote AG.
1 - Nut - T10263/5-
2 - Thrust Piece - T10356/7- - the mark -A- points to the subframe
3 - Subframe
4 - Adjust the bonded rubber bushing to the marks (the marks
need to align)
5 - Bushing - T10356/8- - the flattened sides need to fit into the
cover of the bonded rubber bushing -arrows-.
6 - Gripping Device - T10205/1-
8 - Nut - T10263/5-
– Check the position of the bonded rubber bushing and, if nec‐
essary, align and pre-tighten special tools with bonded rubber
bushing.

Note
♦ Make sure that the hose from the Hydraulic Press - VAS6178-
to the Pneumatic/Hydraulic Foot Pump - VAS6179- runs be‐
tween the trailing arm and the fuel tank when installed.
♦ When installing, make sure the bonded rubber bushing does
not tilt, otherwise the outer ring could be damaged.
– Operate the pump to press in the bonded rubber bushing until

the shoulder is positioned on the subframe “without gap”.
Install in reverse order of removal, note the following:
Tightening Specifications AG. Volkswagen AG d
agen oes
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♦ Refer to by Vol not
gu
ara
⇒ “3.1.2 Overview
rise
d - Subframe, Multi-Link Suspension, nteAWD”,
page 158ut ho eo
ra
s a c
s
♦ Refer to
ce
e
nl
pt
du
an
itte
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♦ Refer to ⇒ Rep. Gr. 26 ; Exhaust Pipes/Mufflers; Overview -
erm
ab
Muffler .
ility
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, is n
3.3.2 Rear Bonded Rubber Bushing, Replac‐

h re
hole
spec
ing
es, in part or in w
Special tools and workshop equipment required t to the co

rrectness of i
♦ Hydraulic Press - Rear Subframe Bushing Tool Kit - T10263-

l purpos
♦ Subframe Bushing Assembly Tool Kit - T10356-

nform
ercia
♦ Hydraulic Press - VAS6178- with Pressure Head - T10205/13-

m
at
om
ion
c

in t
or
his
te

a
do
priv
cum
for
en
ng
t.
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Note
Co
Cop py
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gh ht
yri by
♦ If a bonded rubber bushing is faulty, then the bonded rubber
cop Vo
by lksw
bushing on the opposite side must also be replaced. For the cted agen
Prote AG.
correct allocation. Refer to the Parts Catalog.
♦ Check the other bearing before switching out a defected bon‐
ded rubber bushing.
♦ If there are any tears or other visible damages, replace the
♦ To replace the rubber bonded bushing, the subframe must be
lowered at the front or the rear. It is not necessary to remove
the subframe.
♦ Identify mounting location to subframe before removing the
Pressing Out Rear Bonded Rubber Bushing

3. Subframe 171

Note
AG. Volkswagen AG d
agen oes
lksw not
Do not disconnect the brake line. d by
Vo gu
ara
ise nte
or eo
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aut ra
ss c
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un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
– Secure both sides of the vehicle on the hoist arms using Ten‐
hole
spec
es, in part or in w
t to the co
WARNING
rrectness of i
l purpos
nform
ercia

m
a
com
tion in
r
te o
thi
s
iva
– Mark the installation location of the bonded rubber bushing on
do
r
rp
c
the subframe with a felt-tip pen -1-.
um
fo
en
ng
t.
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Cop py
t.
Note
rig
gh ht
pyri by
Vo
o
by c lksw
cted
Apply the mark -1- on the subframe in the middle of the recess on
agen
Prote AG.
the bonded rubber mounting -2-.
– Use a screwdriver -2- to pry off the anti-twist mechanism -1-

near the bonded rubber bushing mounting retaining lugs.
– Lower the subframe approximately 100 mm (3.93 in.) using
the Engine and Gearbox Jack - VAS6931- .

Note
– Use the special tools as shown.
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss
ce
le
un
pt
an
d
itte
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ab
pe
ility
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wit
, is n
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hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
1 - Nut - T10263/5-
r
rp
cum
fo
en
g
2 - Thrust Piece - T10356/5-

n
t.
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Cop py
3 - Subframe
t. rig
gh ht
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4 - Tube - T10356/6- , side with offset points to subframe
c by lksw
cted agen
Prote AG.
3. Subframe 173
6 - Hydraulic Press - VAS6178- with Pressure Head - T10205/13-

7 - Nut - T10263/5-
– Pretension special tools.
Note
♦ When removing the bonded rubber mounting, the bearing outer race is shorn off. There is a loud crack when
this happens. wage
es n
lks ot
Vo
♦ After removing the bonded erubber
d by bushing, it must be removed gfromua
ran the Tube - T10356/6- by tapping lightly
with a hammer. thoris tee
u or
a ac
ss
Press In the Rear Bonded Rubber Bushing
ce
e
nl
pt
du
an
– Apply a line -1- on the vertical rib of the bonded rubber bushing
itte
y li
to help mount.
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
ercia
– Apply mounting paste to the outer edge of the bonded rubber

m
at
bushing.
om
ion
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2 - Assembly Tool - Bushing - T10356/7- - the marking -B- points Prote AG.
to the subframe
3 - Subframe
4 - Adjust the bonded rubber bushing to the marks (the marks
need to align)
5 - Assembly Tool - Bushing - T10356/8- - the flattened sides need
to fit into the cover of the bonded rubber bushing -arrows-.
7 - Hydraulic Press - VAS6178- with Pressure Head - T10205/13-
8 - Nut - T10263/5-
– Check the position of the bonded rubber bushing and, if nec‐
essary, align and pre-tighten special tools with bonded rubber
bushing.
3. Subframe 175
Note
When installing, make sure the bonded rubber bushing does not
tilt, otherwise the outer ring could be damaged.
– Operate the pump to press in the bonded rubber bushing until

the shoulder is positioned on the subframe “without gap”.
♦ Refer to
page 158
♦ Refer to
♦ Refer to ⇒ Rep. Gr. 26 ; Exhaust Pipes/Mufflers; Overview -
Muffler .
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4 Stabilizer Bar
⇒ “4.1 Overview - Stabilizer Bar”, page 177
⇒ “4.2 Stabilizer Bar, Removing and Installing”, page 178
⇒ “4.3 Coupling Rod, Removing and Installing”,
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6 - Nut
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❑ Counterhold at connect‐
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7 - Stabilizer Bar
❑ With rubber bushings
ling. Refer to
ling”, page 178 .
8 - Subframe
4. Stabilizer Bar 177

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8 - Subframe
4.2 Stabilizer Bar, Removing and Installing

Caution


♦ Bolt - Stabilizer Bar to Subframe
Removing

Note
The following work steps are described for the left side of the ve‐
hicle. These work steps also apply simultaneously for right side
of vehicle.
– Remove the bolts -arrows- for the stabilizer bar -1-
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4.3 Coupling Rod, Removing and Installing

Removing
4. Stabilizer Bar 179

Vehicles with Stone Chip Protection

– Remove the expanding rivets -1-.
– Remove the bolts -2- for the stone chip protection -3-.
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♦ Refer to

5 Control Arm, Tie Rod

⇒ “5.1 Overview - Transverse Link”, page 181 n AG. Volkswagen AG do
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4 - Bolt
❑ 130 Nm + 180°
❑ Always tighten the
threaded connections in
curb weight position.
Refer to
in Curb Weight, Rear
Axle, Lifting Vehicles
with Coil Spring”,
page 8 .
6 - Bolt
❑ 70 Nm + 180°
Refer to
page 8 .
7 - Nut
5. Control Arm, Tie Rod 181

8 - Expanding Rivet
9 - Stone Chip Protection
10 - Bolt
❑ 8 Nm
❑ Removing and installing. Refer to ⇒ “5.4 Lower Transverse Link, Removing and Installing”, page 187
12 - Eccentric Bolt
❑ Perform a vehicle alignment after loosening
❑ Do not turn more than 90° right or left (that is smallest to largest possible adjustment).
13 - Eccentric Washer
❑ Inner bore with tab
14 - Nut agen
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⇒ “3.8.2 Wheel Bearing in Curb Weight, Rear Axle, Lifting Vehicles with Coil Spring”, page 8 .
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5.1.2 Overview - Transverse Link, Multi-Link Suspension, AWD
1 - Washer
2 - Nut
3 - Upper Transverse Link
ling. Refer to
⇒ “5.3 Upper Trans‐
verse Link, Removing
and Installing”,
page 185 . agen
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12 - Bolt
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13 - Subframe
14 - Eccentric Bolt
❑ Do not turn more than 90° right or left (that is smallest to largest possible adjustment)
15 - Nut
❑ 95 Nm
❑ Always tighten threaded connections in curb weight position.
17 - Eccentric Bolt

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5.2 Overview - Tie Rod
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⇒ “5.2.1 Overview - Tie Rod, Multi-Link Suspension, FWD”, page
184
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⇒ “5.2.2 Overview - Tie Rod, Multi-Link Suspension, AWD”, page

185
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5.2.1 Overview - Tie Rod, Multi-Link Suspension, FWD
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189
5 - Bolt
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page 8 .
6 - Nut

5.2.2 Overview - Tie Rod, Multi-Link Suspension, AWD
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5.3 Upper Transverse Link, Removing and

Installing
⇒ “5.3.1 Upper Transverse Link, Removing and Installing”,
page 185
⇒ “5.3.2 Upper Transverse Link, Removing and Installing, All
Wheel Drive”, page 186
5.3.1 Upper Transverse Link, Removing and

Installing
Caution



♦ Bolt - Wheel Bearing Housing to Upper Transverse Link
♦ Nut - Wheel Bearing Housing to Upper Transverse Link
Removing
– Disengage the line -1- from the bracket -2- -arrows-.
– Remove the nut -3- and the washer -4-.
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– Remove the upper control arm -1-.
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5.3.2 Upper Transverse Link, Removing and
Prote AG.
Installing, All Wheel Drive

Caution


♦ Bolt - Wheel Bearing Housing to Upper Transverse Link
♦ Nut - Wheel Bearing Housing to Upper Transverse Link

Removing
– Disengage the line -1- from the bracket -2-.
– Remove the nut -6- and the washer -5-.
– Remove the bolt -3- and washer -4-.
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Removing
AG.



– Remove the Left Rear Level Control System Sensor -2- brack‐
et.

– Remove the bolts -2- for the stone chip protection a-3-.
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⇒ “6.4 Spring, Removing and Installing”,
ss page 202 .
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– Mark the position of the eccentric screw -2- in relation to the

subframe, for example using a felt-tip pen.
– Unscrew the nut -1- and remove the bolt -2-.
– Remove lower transverse link.
Installing
♦ Refer to
⇒ “2.4 Left/Right Rear Level Control System Sensor G76 /
G77 , Removing and Installing”, page 282
♦ Refer to
♦ Rear exhaust system. Refer to ⇒ Rep. Gr. 26 ; Exhaust Pipes/
Mufflers; Overview - Muffler .
• Observe the mark made for the eccentric screw -2- in relation
to the subframe.
• Only fasten the transverse link in the curb weight position.
• For vehicles with a level control system sensor, perform
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Removing

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– Remove the tie rod -2-.
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Installing
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♦ Refer to ⇒ “5.2 Overview - Tie Rod”, page 184 atio

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– Perform an axle alignment.
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6 Suspension Strut/Shock Absorber,

Spring
⇒ “6.1 Overview - Suspension Strut, Shock Absorber and Spring”,
page 191
⇒ “6.2 Shock Absorber, Removing and Installing”, page 193
⇒ “6.3 Shock Absorber, Servicing”, page 200
⇒ “6.4 Spring, Removing and Installing”, page 202
6.1 Overview - Suspension Strut, Shock Ab‐

sorber and Spring
6.1.1 Overview - Suspension Strut, Shock Absorber and Spring, Torsion Beam
Axle
1 - Bolt
❑ 50 Nm + 45°
2 - Shock Absorber
ling. Refer to
⇒ “6.2 Shock Absorber,
ling”, page 193
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page 202
5 - Clamping Ring
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Cop py
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pyri by
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Prote AG.
6. Suspension Strut/Shock Absorber, Spring 191

7 - Axle Beam
AG. Volkswagen AG d
9 - Expanding Rivet agen oes
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10 - Bolt orise nte
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❑ 70 Nm + 180° aut ra
ss c
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❑ Always tighten threaded connection in curb weight position
itte
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ility
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6.1.2 Overview - Suspension Strut, Shock Absorber and Spring, Multi-Link Sus‐
h re
hole
pension
spec
es, in part or in w
t to the co
1 - Bolt
❑ 50 Nm + 45°
rrectness of i
l purpos
2 - Shock Absorber
nf
ercia
or
ling. Refer to
m
m
atio
om
n in
or c
ling”, page 193
thi
te
sd
iva
❑ Observe the installation
o
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position of the cable tie
o
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closure
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❑ Always vent and drain
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rig
faulty shock absorbers py by
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before disposal.
by c lksw
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3 - Upper Spring Support
❑ Place on body “tab”.
4 - Spring
ling. Refer to
⇒ “6.4 Spring, Remov‐
202
5 - Clip
❑ Serves as an assembly
aid
6 - Low Spring Support
❑ Spring end rotated up to
stop
❑ When assembling, in‐
sert the pin into the
spring mount opening
on the lower transverse
link -arrow-.
8 - Nut
❑ 70 Nm + 180°
❑ Always tighten threaded connection in curb weight position

swage es n
9 - Bolt byV
olk ot g
ua
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❑ Replace after removal ir se tee
tho
u or
a ac
ss
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le
un
pt
6.2 Shock Absorber, Removing and Instal‐
an
d
itte
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ling
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pe
ility
ot
wit
⇒ “6.2.1 Shock Absorber, Removing and Installing, Torsion Beam
, is n
h re
Axle”, page 193
hole
spec
⇒ “6.2.2 Shock Absorber, Removing and Installing, Multi-Link
es, in part or in w
t to the co
Suspension, Left Shock Absorber”, page 195
⇒ “6.2.3 Shock Absorber, Removing and Installing, Multi-Link
Suspension, Right Shock Absorber”, page 197
rrectness of i
6.2.1 Shock Absorber, Removing and Instal‐
l purpos
ling, Torsion Beam Axle
nform
ercia

m
a
com
t
ion in
r
te o
♦ Torque Wrench 1410 - VAG1410-
thi
s
iva
do
r

rp
cum
fo
en
g
♦ Spring Compressor Kit - Spring Retainer with Inserts -

n
t.
yi Co
op
VAG1752/3A- C py
t. rig
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pyri by
Vo
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by
Caution cted agen
Prote AG.


♦ Bolts - Shock Absorber to Body
♦ Bolts - Shock Absorber to Axle Beam
Removing
– Remove the rear wheel housing liner. Refer to ⇒ Body Exte‐
rior; Rep. Gr. 66 ; Wheel Housing Liner; Rear Wheel Housing
Liner, Removing and Installing .
– Remove the lever of the Left Rear Level Control System Sen‐
sor - G76- -2- from the axle beam -3-


– Remove the wire -3- from the shock absorber -2- -arrow-.
Note

the contacts on the shock absorber and the connector.
– Insert the Spring Tensioner -1-.

2- Spring Compressor Kit - Spring
n ARetainer with
G. Volkswag Inserts -
en AG
VAG1752/3A- wage does
olks not
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WARNING tho eo
s au ra
c
s
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e
Make sure the coil spring is seated correctly in the Spring

nl
pt
du
Compressor Kit - Spring Retainer with Inserts - VAG1752/3A-

an
itte
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-2- (danger of accident).
erm
ab
ility
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– Tension the coil spring until the shock absorber is not under h re
hole
spec
tension.
es, in part or in w
t to the co
– Remove the bolts -1- from the shock absorber -2-.

rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
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Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.


– Remove the shock absorber.
Installing
Installation is the reverse of removal, with Vspecial attention to the
. olkswagen AG
following: swagen AG does
k not
Vol g
– For vehicles with a vehicle by level sensor, perform the basic set‐
ua
ed ran
oris
ting for the wheel damping electronics. Refer to Vehicle Diag‐ tee
th or
nostic Tester . ss au ac
ce
le
un
pt
an
d
itte
y li
♦ Refer to
rm
ab
pe
ility
ot
wit
, is n
h re
♦ Refer to
hole
spec
es, in part or in w
t to the co
♦ Refer to ⇒ Body Exterior; Rep. Gr. 66 ; Wheel Housing Liner;
Rear Wheel Housing Liner, Removing and Installing .
rrectness of i
l purpos
ling, Multi-Link Suspension, Left Shock

Absorber
nform
ercia

m
a
com
tio
n in
r
te o
♦ Torque Wrench 1410 - VAG1410- thi

s
iva
do
r
rp
cum

fo
en
ng
t.
yi Co
♦ Spring Compressor Kit - Spring Retainer with Inserts - Cop py
VAG1752/3A- ht. rig
rig ht
py by
o Vo
♦ Spring Compressor Kit - Adapter Blocks - VAG1752/9-
by c lksw
cted agen
Prote AG.
Caution


♦ Bolts - Shock Absorber to Body
♦ Bolt - Shock Absorber to Lower Transverse Link
♦ Nut - Shock Absorber to Lower Transverse Link
Removing


-2- bracket.

Note
AG. Volkswagen AG d
agen oes
ksw
If there is moisture in the connector area, blow compressed
by
Vol air on not
gu
rised ara
nte
ho eo
aut ra
c
Continuation for All Vehicles ss
ce
e
nl
pt
du
an
itte
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– Insert the Spring Compressor -3-.
erm
ab
ility
ot p
1- Spring Compressor Kit - Spring Retainer with Inserts -
wit
, is n
VAG1752/3A-
h re
hole
2- Spring Compressor Kit - Adapter Blocks - VAG1752/9-
spec
es, in part or in w
t to the co
WARNING
rrectness of i
l purpos

-2- (danger of accident).
nform
mercia
at
om
io
– Tension the coil spring until the shock absorber is not under
n
c
in t
tension.
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
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pyri by
Vo
o
by c lksw
cted agen
Prote AG.


– Remove the bolts -2- for the stone chip protection
Volkswa
-3-.
AG. gen AG
agen do
– Remove the stone chip protection
olks -3- from the lower trans‐
w es n
ot g
yV
verse link -4-. sed b ua
ran
ri tee
ho
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t or
ac
ss
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un
pt
an
d
itte
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rm
ab
pe
ility
ot
wit
, is n
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hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
– Remove the nut -1- and the bolt -2-.

nform
ercia
Installing
m
a
com
ti
on in
following:
r
te o
thi
s
iva
do
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c
um
fo
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nostic Tester .
n
t.
yi Co
Cop py
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gh ht
pyri by
Vo
o
♦ Refer to by c lksw
cted agen
⇒ “6.1.2 Overview - Suspension Strut, Shock Absorber and Prote AG.
♦ Refer to
• Only fasten the shock absorber with the transverse link in the

ling, Multi-Link Suspension, Right Shock
Absorber
♦ Spring Compressor Kit - Spring Retainer with Inserts -
VAG1752/3A-
♦ Spring Compressor Kit - Adapter Blocks - VAG1752/9-

Caution

Mandatory Replacement Parts n AG. Volkswagen AG do

lkswage es n
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yV
♦ Bolts - Shock Absorber to Body ir se
d b ua
ran
o tee
h
♦ Bolt - Shock Absorber to Lower Transverse
aut
Link or
ac
ss
♦ Nut - Shock Absorber to Lower Transverse Link
ce
le
un
pt
an
d
itte
Removing
y li
erm
ab
ility
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ole,
spec
t to the co
rrectne
s
s o
cial p
f in
form
mer
-2- bracket.
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
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r
fo
en
ng
t.
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Cop py
t. rig
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pyri by
Vo
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Vehicles with Adaptive Chassis DCC Prote AG.

Note

– Position the Spring Retainer with Inserts - VAG1752/3A- -1-

with the Spring Compressor Kit - Adapter Blocks - VAG1752/9-
-2- on the uppermost spring coil -3-.

– Position the Spring Compressor -3- on the Spring Compressor

Kit - Adapter Blocks - VAG1752/9- -2-.
– Insert the lower Spring Retainer with Inserts - VAG1752/3A-
into the spring -4- at the same time.
– Fasten the Spring Compressor -3- to the Spring Compressor
Kit - Adapter Blocks - VAG1752/9- -2-.
1- Spring Compressor Kit - Spring Retainer with Inserts -
VAG1752/3A-
2- Spring Compressor Kit - Adapter Blocks - VAG1752/9-
4- Spring
WARNING

-arrow- (danger of accident).
– Tension the coil spring until the shock absorber is not under
tension.
AG. Volkswagen AG d
agen oes
olksw not
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d by ara
ise nte
or eo
h
aut ra
Vehicles with Stone Chip Protection ss c
ce
le
un
pt

an
d
itte
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rm
ab
pe
ility
ot
– Remove the stone chip protection -3- from the lower trans‐
wit
, is n
verse link -4-.

h re
hole
spec

es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote
199
AG.
6. Suspension Strut/Shock Absorber, Spring
– Remove the nut -1- and the bolt -2-.

Installing
following:
– For vehicles with a vehicle level sensor, perform the basic nset‐
AG. Volkswagen AG d
ting for the wheel damping electronics. Refer to Vehicle
olksw Diag‐
age oes
not
nostic Tester . d byV gu
ar
e an
ris tee
Tightening Specifications tho or
au ac
ss
♦ Refer to
ce
e
nl
pt
du
an
itte
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erm
ab
ility
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wit
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♦ Refer to
h re
hole
spec
es, in part or in w
t to the co
• Only fasten the shock absorber with the transverse link in the
rrectness of i
l purpos
6.3 Shock Absorber, Servicing
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
♦ Shock Absorber Set - Socket - T10001/1-
o
r
rp
cu
o
m
f
♦ Shock Absorber Set - Extension with Counter Holder 1 -

en
ng
t.
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T10001/9- . Cop py
rig
ht ht
rig
♦ Commercially available ring spanner insert, such as »Hazet py by
o Vo
6630c-21«
by c lksw
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Prote AG.
Caution


♦ Nut - Shock Absorber Mount to Shock Absorber

1 - Shock Absorber
ling. Refer to
ling”, page 193 .
❑ Always vent and drain
faulty shock absorbers
before disposal.
❑ Removed shock ab‐
sorber, checking
2 - Protective Tube
3 - Stop Buffer
4 - Shock Absorber Mount
5 - Nut
❑ 25 Nm
ing. Refer to
⇒ Fig. ““Loosening and
Tightening Bolted Con‐ AG. Volkswagen AG d
nection for Shock Ab‐ agen oes
olksw not
sorber Mount”“ , byV gu
ara
ed
page 201 horis nte
eo
aut ra
6 - Cover ss c
ce
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un
pt
an
d
itte
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erm
ab
ility
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is n
h re
ole,
spec
t to the co
rrectne
Loosening and Tightening Bolted Connection for Shock Absorber
Mount
ss o
1- Commercially available ring spanner insert, such as “Hazet
cial p
f in
6630c-21”
form
mer
2- Shock Absorber Set - Extension with Counter Holder 1 - atio

m
T10001/9-
o
n
c
i
or
n thi
3- Ratchet (commercially available)

te
sd
iva
o
pr

um
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fo
en
ng
t.
5- Shock Absorber Set - Socket - T10001/1-
yi Co
Cop py
ht. rig
6- Shock absorber mount rig ht
py by
co Vo
by lksw
Installation is the reverse of removal, with special attention to the cted agen
Prote AG.
following:

– Slide the protective pipe -1- onto the shock absorber mount
-2-.
– Install and tighten the cable tie -3-.
Note
The closure -arrow- of the cable tie -3- must be in area -a-.
♦ Refer to ⇒ “6.3 Shock Absorber, Servicing”, page 200
6.4 Spring, Removing and Installing

⇒ “6.4.1 Spring, Removing and Installing, Torsion Beam Axle”,
page 202
⇒ “6.4.2 Spring, Removing and Installing, Multi-Link Suspension”,
page 204
6.4.1 Spring, Removing and Installing, Tor‐

sion Beam Axle
Special tools and workshop equipment required en AG. Volkswagen AG
wag does
♦ -VAG1752/1- olks not
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ed nte
ris
♦ -VAG1752/3A- tho eo
au ra
c
♦ -VAG1752/9- , not ss
illustrated
ce
e
nl
pt
du
Removing
an
itte
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erm
ab

ility
ot p
wit

, is n
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hole

spec
es, in part or in w
– Remove the clip -1- in the direction of -arrow- until stop.

t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

– Insert the Spring Tensioner -1-.

1- -VAG1752/1-
2- -VAG1752/3A-
WARNING
Make sure the coil spring is seated correctly in the -

VAG1752/3A- -2- (danger of accident).
– Tension the coil spring and remove it.
Note
Use a wrench or a reversible ratchet to tighten the spring com‐

pressor.
Installing
olkswagen AG
Install in reverse order of removal. Note the following:swagen AG. V does
k not
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– Make sure the washer is not damaged. sed by ara
nte
ri
ho eo
– Replace the washer if necessary. aut ra
c
ss
ce
le
un
– Install the washer on the coil spring.
pt
an
d
itte
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The spring start -arrow- must touch the stop of lower spring sup‐
erm
ab
port.
ility
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wit
is n
– Install the spring and the spring support.
h re
ole,
spec
– Spring seat has a pin on bottom.
t to the co
– Insert this pin into the torsion beam axle opening.
rrectness o
cial p
f in
– Insert the top of the spring support into the upper spring end.
form
mer
– The bead on the spring support -arrow- must fit into the coil
atio
m
spring correctly.
o
n
c
i
or
n thi
– Release the tension on the spring, guiding upper spring sup‐

te
sd
va
port onto tab of body.

i
o
pr
cum
r
fo
– Remove the Spring Compressor .

en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

– Press in the clip -1- in the reverse direction of -arrow- until stop.
AG. Volkswagen AG d
Tightening Specifications agen oes
olksw not
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♦ Refer to rised
nte
⇒ “1.1 Wheel Bolt Tightening Specifications”,
aut page 286
ho eo
ra
ss c
ce
le
un
pt
an
d
itte
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rm
ab
pe
ility
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, is n
h re
hole
spec
es, in part or in w
t to the co
6.4.2 Spring, Removing and Installing, Multi-
Link Suspension
rrectness of i
l purpos
nform
ercia

m
a
com
tion in
♦ Spring Compressor Kit - VAG1752-
r
te o
thi
s
iva
♦ Engine and Gearbox Jack - VAS6931- or Engine and Gearbox
do
r
rp
c
Jack - VAG1383A-
um
fo
en
ng
t.
Removing
yi Co
Cop py
ht. rig
– Loosen the wheel bolts. rig ht
py by
co Vo
by lksw
– Raise the vehicle. cted agen
Prote AG.

T10038- .
1- -T10038-
WARNING

et.
Continuation for All Vehicles.

– Press the tabs -arrows- on the assembly aid -1- inward.

– Remove the assembly aid -1- upward.
– Position the - VAS6931- or -VAG1383A- under the transverse
link and push lightly upward.
– Insert the Spring Compressor -3-.

1- -VAG1752/3A-
2- -VAG1752/9-
3- -VAG1752/1-
4- Spring
WARNING
Make sure the coil spring is seated correctly in the ge-n AG

. Volkswagen AG
does
swa
VAG1752/3A- -arrow- (danger of accident). yV
olk not
gu b ara
ed nte
oris e
th or
au ac
ss
ce
le
Note
un
pt
an
d
itte
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rm
Use a wrench or a reversible ratchet to tighten the spring com‐
ab
pe
ility
pressor.
ot
wit
, is n
h re
– Tension the coil spring.
hole
spec
es, in part or in w
t to the co
– Remove the nut -1- and then the bolt -2- for the coupling rod
-3-.
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

– Remove the nut -1- and then the bolt -2- for the shock absorber
threaded connection.
– Remove the nut -3- and then the bolt -4- for the wheel bearing
housing threaded connection.
WARNING
Hold the -VAG1752/1- with the spring tensioned (risk of acci‐

dent).
– Slowly lower the -VAS6931- or -VAG1383A- under the lower

transverse link, until the -VAG1752/1- with the tensioned
spring can be removed.
Installing
– Make sure the washer is not damaged.

– Replace the washer if necessary.
– Install the washer on the coil spring.
The spring start -arrow- must touch the stop of lower spring sup‐
port. olksw AG. V agen AG
agen does
– Install the spring and the spring
Vosupport.
lksw not
gu
y
db ara
– Spring seat has a pin onhorbottom.
ise nte
eo
t
au ra
c
ss
ce
e
nl
pt
du
an
itte
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erm
ab
– Insert this pin into hole of lower transverse link -arrow-.

ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
– Insert the top of the spring support into the upper spring end.
om
ion
c
in t
r
– The bead on the spring support -arrow- must fit into the coil
o
his
te
spring correctly.
a
do
priv
cum
for
en
g
WARNING
n
t.
yi Co
Cop py
t. rig
gh ht
Hold the -VAG1752/1- with the spring tensioned (risk of acci‐ yri
p by
o Vo
dent).
c by lksw
cted agen
Prote AG.
– Push the - VAS6931- or -VAG1383A- under the transverse link

upward.

– Insert the bolt -4- for connecting the wheel bearing housing
and tighten the nut -3-.
– Insert the bolt -2- for connecting the shock absorber and tight‐
en the nut -1-.
– Insert the bolt -2- for the coupling rod -3- and tighten the nut
-1-.
– Release the tension on the spring -4- while positioning the up‐
. Volkswagen AG
per spring support onto tab of body. swa
gen AG does
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– Remove the Spring Tensioner -3-. ed by ara
nte
ris
1- -VAG1752/3A- utho eo
ra
a c
ss
2- -VAG1752/9-
ce
e
nl
pt
du
an
3- -VAG1752/1-
itte
y li
erm
ab
4- Spring
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

– Insert the assembly aid -1- and push downward.

– The tabs -arrows- must engage.
♦ Refer to
⇒ “6.1 Overview - Suspension Strut, Shock Absorber and
Spring”, page 191
♦ Refer to
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
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tho eo
au ra
ss c
ce
le
un
pt
an
d
itte
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rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
208
Prote AG.
Rep. Gr.42 - Rear Suspension
7 Wheel Bearing and Trailing Arm

⇒ “7.1 Overview - Wheel Bearing”, page 209
⇒ “7.2 Overview - Trailing Arm”, page 213
⇒ “7.3 Wheel Bearing Housing, Removing and Installing”,
page 213
⇒ “7.4 Wheel Bearing Unit, Removing and Installing”, page 222
⇒ “7.5 Wheel Bearing Housing Bonded Rubber Bushing, Replac‐
ing”, page 229
⇒ “7.6 Trailing Arm with Mounting Bracket, Removing and Instal‐
ling”, page 234
⇒ “7.7 Trailing Arm, Servicing”, page 237
7.1 Overview - Wheel Bearing

⇒ “7.1.1 Overview - Wheel Bearing, Torsion Beam Axle”,
page 209
⇒ “7.1.2 Overview - Wheel Bearing, Multi-Link Suspension”, page
211 agen
AG. Volkswagen AG d
o w es n
olks ot g
⇒ “7.1.3 Overview - WheeledBearing,
by
V
Multi-Link Suspension, ua
ran
AWD”, page 212 horis tee
t or
au ac
7.1.1 Overview - Wheel Bearing, Torsion Beam Axle
ss
ce
le
un
pt
an
d
itte
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erm
ab
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6 - Bolt
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❑ Clean the threads in the stub axle with a thread tap first.
❑ Removing and installing. Refer to ⇒ “7.4 Wheel Bearing Unit, Removing and Installing”, page 222
❑ The wheel bearing and wheel hub are installed together in a housing.
❑ The wheel bearing unit is maintenance free and has zero play. Adjusting or servicing is not possible!
8 - Bolt
❑ Tightening specification. Refer to ⇒ Brake System; Rep. Gr. 46 ; Rear Brakes; Overview - Rear Brakes
9 - Heat Shield
❑ Removing and installing. Refer to ⇒ Brake System; Rep. Gr. 46 ; Rear Brakes; Overview - Rear Brakes

7.1.3 Overview - Wheel Bearing, Multi-Link Suspension, AWD
1 - Drive Axle
2 - Bolt
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❑ Removing and installing. Refer to
⇒ “7.4.3 Wheel Bearing Unit, Removing and Installing, Multi-Link Suspension, AWD”, page 227 .
❑ The wheel bearing and wheel hub are installed together in a housing.
❑ The wheel bearing unit is maintenance free and has zero play. Adjusting or servicing is not possible!
9 - Bolt
❑ Tightening specification. Refer to ⇒ Brake System; Rep. Gr. 46 ; Rear Brakes; Overview - Rear Brakes .
10 - Heat Shield
❑ Removing and installing. Refer to ⇒ Brake System; Rep. Gr. 46 ; Rear Brakes; Overview - Rear Brakes .

7.2 Overview - Trailing Arm
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⇒ “7.6 Trailing Arm with
Mounting Bracket, Re‐
moving and Installing”, page 234
❑ Note the installation position
❑ Replacing. Refer to ⇒ “7.7 Trailing Arm, Servicing”, page 237
7.3 Wheel Bearing Housing, Removing and

Installing
⇒ “7.3.1 Wheel Bearing Housing, Removing and Installing, Multi-
Link Suspension, FWD”, page 213
⇒ “7.3.2 Wheel Bearing Housing, Removing and Installing, Multi-
Link Suspension, AWD”, page 217
7.3.1 Wheel Bearing Housing, Removing and

Installing, Multi-Link Suspension, FWD

Suspension, Wheels,enSteering
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– Disconnect the connector from the ABS speed sensor.

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– Remove the wheel bearing housing -2-.

Installing
Complete the following steps in the exact order specified.
– Insert the wheel bearing housing -2-.

– Insert the bolt -1- and tighten hand-tight.

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Threaded connection of trailing link/wheel bearing housing must

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absorber always) of the respective wheel suspension have been
already assembled. To tighten, suspension must be unloaded.
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page 211
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7.3.2 Wheel Bearing Housing, Removing and

Installing, Multi-Link Suspension, AWD
Removing
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– Remove the heat shield. Refer to ⇒ Brake System; Rep. Gr.
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– Disconnect the connector from the ABS speed sensor.


T10038- .
1- -T10038-
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ward.
– Remove the bolts -2- and -3- one after the other.

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– Remove the -VAS6931- with the -T10149- from the wheel hub.
Threaded connection of trailing link/wheel bearing housing must

only be tightened when all other components (spring and shock
absorber always) of the respective wheel suspension have been
already assembled. To tighten, suspension must be unloaded.
into the position required -arrows-.
– Install the coil spring. Refer to
– Tighten the bolts
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page 278
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7.4 Wheel Bearing Unit, Removing and In‐

stalling
⇒ “7.4.1 Wheel Bearing Unit, Removing and Installing, Torsion
Beam Axle”, page 222
⇒ “7.4.2 Wheel Bearing Unit, Removing and Installing, Multi-Link
Suspension”, page 225
⇒ “7.4.3 Wheel Bearing Unit, Removing and Installing, Multi-Link
Suspension, AWD”, page 227
7.4.1 Wheel Bearing Unit, Removing and In‐

stalling, Torsion Beam Axle
♦ Seal Installer - Camshaft Installer Kit - Sleeve - 3241/4-
♦ Puller - Grease Cap - VW637/2-
♦ Socket - XZN 18mm - T10162A-
Caution


♦ Bolt - Wheel Bearing Unit to Wheel Bearing Housing
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Rear Brakes; Overview - Rear Brakes .

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– Remove the wheel bearing unit from the axle stub.
Caution
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and damaging the seal.

The wheel bearing -1- must always face up.

– Always set the wheel bearing unit down on the wheel hub
-2-.
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– Carefully slide the wheel hubs/wheel bearing unit onto the axle
stub.
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♦ Always replace dust caps.

♦ Damaged dust caps allow moisture to enter. Therefore, al‐
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♦ Refer to
⇒ “7.1.1 Overview - Wheel Bearing, Torsion Beam Axle”, page
209
♦ Refer to
♦ Refer to ⇒ Brake System; Rep. Gr. 46 ; Rear Brakes; Over‐
view - Rear Brakes .


stalling, Multi-Link Suspension
♦ Seal Installer - Camshaft Installer Kit - Sleeve - 3241/4-
♦ Puller - Grease Cap - VW637/2-
♦ Socket - XZN 18mm - T10162A-
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Rear Brakes; Overview - Rear Brakes .
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Suspend brake caliper from body.

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Caution
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– Remove the wheel bearing unit from the axle stub.
Caution
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l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

Note
♦ First tighten the bolt to the specification using the torque

wrench.
♦ Using a rigid wrench when tightening additionally.
Caution
Never use an impact wrench when tightening the bolt -1- using
– Install a new dust cap.

1- Sleeve - 3241/4-
Note
♦ Always replace dust caps.

♦ Damaged dust caps allow moisture to enter. Therefore,agal‐
en AG. V
olkswagen AG
do
ways use the tool shown. yV
olks
w es n
ot g
b ua
ed ran
ris tee
Tightening Specifications tho or
au ac
ss
♦ Refer to
ce
le
un
pt
⇒ “7.1.2 Overview - Wheel Bearing, Multi-Link Suspension”,
an
d
itte
page 211
y li
erm
ab
ility
♦ Refer to
ot p

wit
is n
h re
ole,
♦ Refer to ⇒ Brake System; Rep. Gr. 46 ; Rear Brakes; Over‐

spec
view - Rear Brakes . t to the co

stalling, Multi-Link Suspension, AWD
rrectne

ss o

cial p
f inform

mer
atio
om
n
c
Caution
or
n thi
te
sd
iva
o
r

p
cum
r
fo

en
ng
t.
yi Co
Cop py
t. rig
gh ht
yri
p by
co Vo
by lksw
cted agen
♦ Bolt - Wheel Bearing Housing to Brake Caliper
Prote AG.

Removing agen
AG. Volkswagen AG d
oes
olksw not
– Loosen the outer drive axle threaded connection. Referedtob y V gu
ara
⇒ “8.2 Drive Axle Threaded Connection, Loosening and horis Tight‐ nte
eo
ening”, page 241 . aut ra
c
ss
– Remove coil spring. Refer to
ce
e
nl
pt
du
an
itte
y li
erm
ab
– Remove the drive axle. Refer to
ility
ot p
⇒ “8.3 Drive Axle, Removing and Installing”, page 242 .
wit
, is n
h re
hole
spec
Rear Brakes; Overview - Rear Brakes . es, in part or in w
t to the co
Note
rrectness of i
Do not let the brake caliper hang on the brake hose - risk of dam‐
l purpos
age.
nf
ercia
orm
m
atio
m

o
n in
or c
– Remove the wheel bearing unit from the wheel bearing hous‐
thi
te
sd
ing.
iva
o
r
rp
cu
o
m
f
en
ng
Caution
t.
yi Co
Cop py
t. rig
gh ht
• Avoid contaminating with dirt and damaging the seal when pyri by
Vo
co
setting down/storing.
by lksw
cted agen
Prote AG.
• The wheel bearing -1- must always face up.

• Always set the wheel bearing unit down on the wheel hub
-2-.

• Never reach into the inside when lifting the wheel bearing.
• Hold the wheel bearing only on the outside.
The same procedure also applies to the wheel bearing without a
wheel hub.
Installing
• Only fasten the bolted connections on the wheel bearing hous‐
ing in the curb weight position.
♦ Refer to
⇒ “7.1.3 Overview - Wheel Bearing, Multi-Link Suspension,
AWD”, page 212
♦ Refer to
Volkswa
♦ Refer to agen
AG. gen AG
does
ksw
⇒ “8.2 Drive Axle Threaded Connection,by VLoosening and Tight‐
ol not
gu
ara
ening”, page 241 ris
ed
nte
tho eo
♦ Refer to ⇒ Brake System; Rep.
ss
au Gr. 46 ; Rear Brakes; Over‐ ra
c
view - Rear Brakes .
ce
le
un
pt
an
– Evaluating Need for Axle Alignment. Refer to the table.
d
itte
y li
erm
ab
ility
ot p
7.5 Wheel Bearing Housing Bonded Rubber
wit
is n
Bushing, Replacing
h re
ole,
spec
⇒ “7.5.1 Wheel Bearing Housing Bonded Rubber Bushing, Re‐
t to the co
placing, FWD”, page 229
⇒ “7.5.2 Wheel Bearing Housing Bonded Rubber Bushing, Re‐
placing, AWD”, page 231
rrectne
7.5.1 Wheel Bearing Housing Bonded Rubber
Bushing, Replacing, FWD ss o
cial p
f inform

mer
atio
m

o
n
c
i
or
n thi

te
sd
iva
o
r
♦ Bearing Installer - Carrier Bearing - 3350-

p
cum
r
fo
en
ng

t.
yi Co
Cop py
t. rig
♦ Torque Adapter - 3390- opyri
gh by
Vo
ht
c lksw
by
cted agen
Prote AG.
Removing


et.
AG. Volkswagen AG d
agen
Vehicles with Stone Chip Protection Volksw
oes
not
by gu
d ara
– Remove the expanding rivets -1-. orise nte
eo
h
ut ra
– Remove the bolts -2- for the stone
ss achip protection -3-. c
ce
le

un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
rrectness o
cial p
f inform
mer
atio
m
Pressing Out Bonded Rubber Bushing

o
n
c
i
or
n thi
1- -3346/3-
te
sd
iva
o
r
2- Thrust piece from the -3301-

p
cum
r
fo
en
ng
3- -3390-
t.
yi Co
Cop py
t. rig
4- Sleeve from -3350- opyri
gh by
Vo
ht
by c
5- Nut
lksw
cted agen
Prote AG.
6- -3346/2-
– Remove the bonded rubber bushing by turning the -3346/3-
-1-. While doing so counterhold on the -3346/2- -6-.

Bonded Rubber Bushing, Installing

1- -3346/3-
2- Thrust piece from the -3301-
3- -T10356/5-
4- Bonded Rubber Bushing
5- Wheel Bearing Housing
6- Sleeve from -3350- AG. Volkswagen AG d
agen oes
lksw not
7- Nut d by Vo gu
ara
rise nte
8- -3346/2- utho eo
ra
s a c
– Install the bonded rubber bushing until it stops by turning the s
ce
e
nl
-3346/3- -1-. While doing so counterhold on the -3346/2- -8-.
pt
du
an
itte
y li
erm
ab
ility
Note
ot p
wit
, is n
h re
♦ Do not use lubricant!
hole
spec
es, in part or in w
♦ Insert the bearing carefully so that it is not tilted.
t to the co
Installing
rrectness of i
l purpos
nf
ercia
or
♦ Refer to
m
m
atio
om
n in
or c
thi
te
♦ Refer to
sd
iva
o
r
⇒ “4.1.1 Overview - Stabilizer Bar, Multi-Link Suspension,

rp
cu
o
FWD”, page 177

f
en
ng
t.
yi Co
op
• Only fasten the threaded connections to the lower transverse C py
t. rig
link in the curb weight position.
gh ht
pyri by
Vo
co lksw
by
• For vehicles with a level control system sensor, perform the cted agen
Prote AG.
7.5.2 Wheel Bearing Housing Bonded Rubber

Bushing, Replacing, AWD
♦ Bearing Installer - Carrier Bearing - 3350-
♦ Press Tool For Viscous Fan - 3367-
♦ Torque Adapter - 3390-
Removing


et.
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
Pressing out Bonded Rubber Bushing

t.
yi Co
Cop py
t. rig
1- Bearing Installer - Control Arm - Nut - 3346/3- opyri
gh by
Vo
ht
c
2- Thrust piece from the Subframe Bushing Tool Kit - 3301-
by lksw
cted agen
Prote AG.
3- Torque Adapter - 3390-
4- Sleeve from Bearing Installer - Carrier Bearing - 3350-
5- Nut
6- Bearing Installer - Control Arm - Spindle - 3346/2-
– Remove the bonded rubber bushing by turning the Bearing
Installer - Control Arm - Nut - 3346/3- -1-. While doing so
counterhold on the Bearing Installer - Control Arm - Spindle -
3346/2- -6-.
Bonded Rubber Bushing, Installing

Note
♦ When installing pay attention that the tip of the Subframe

Bushing Tool Kit - Bolt - 3301/1- does not come into contact
with the wheel bearing housing.
1- Nut from Subframe Bushing Tool Kit - 3301-

3- Thrust piece from the Bearing Installer - Control Arm -
3346- , with the open side to the wheel bearing housing
5- Bonded Rubber Bushing
AG. Volkswagen AG d
6- Press Tool For Viscous Fan - Thrust Piece -lk3367/2-
swa
gen oes
not
o
yV gu
7- Replacement Bolt for 3301 kit - 3301/1- edb ara
ris nte
ho eo
– By turning the Subframe Bushing Toolaut Kit - 3301- -1- pull the ra
ss c
bonded rubber bushing until it is just in front of the wheel bear‐
ce
e
nl
ing housing. While doing so counterhold on the Subframe
pt
du
an
Bushing Tool Kit - Bolt - 3301/1- -8-.
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.

– Remove the tools as shown and install again.

1- Nut from Subframe Bushing Tool Kit - 3301-
3- Thrust piece from the Bearing Installer - Control Arm -
3346- , with the open side to the wheel bearing housing
5- Press Tool For Viscous Fan - Thrust Piece - 3367/2-
6- Subframe Bushing Tool Kit - Thrust. VPiece
olkswag-e3301/2-
n AG d n AG
oes wage
7- Replacement Bolt for y3301
Vol kit - 3301/1-
ks not
gu
d b ara
e
– Install the bondedhorubber bushing until it stops by turning thentee
ris
Bearing Installer au- Control Arm - Nut - 3346/3- -1-. While doing
t or
ac
ss
so counterhold on the Bearing Installer - Control Arm - Spindle
ce
le
- 3346/2- -8-.
un
pt
an
d
itte
y li
rm
ab
pe
ility
Note
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
Installing
rrectness of i
l purpos
nform
ercia
♦ Refer to
m

com
tio

n in
r
te o
thi

s
iva
do
r
rp
cum
♦
fo
en
ng
t.
yi Co
• Only fasten the threaded connections to the lower transverse Cop py
link in the curb weight position. ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
hicle Diagnostic Tester ⇒ Vehicle diagnostic tester.

7.6 Trailing Arm with Mounting Bracket, Re‐

moving and Installing
Caution



♦ Bolts - Trailing Arm to Wheel Bearing Housing
♦ Bolt - Trailing Arm to Mounting Bracket
Removing
– Remove the rivet inner pin -arrow- toward the inside and re‐
move the bracket -1-.
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
– Secure both sides of the vehicle
ut
h on the hoist arms using Ten‐
o eo
ra
a
sioning Straps - T10038- .ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
WARNING
ility
ot p
wit
, is n
The vehicle could slide off the hoist if it is not secured. h re

hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
tie rod and push lightly upward.

nf
– Remove the bolts -2 and 3- one after the other.

ercia
orm
m
– Remove the Engine and Gearbox Jack - VAS6931- -1- from

atio
m
under the tie rod.

o
n in
or c
thi
– Mark the mounting bracket installation location on the body.

te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.


– Remove the trailing arm with mounting bracket.
Installing
olkswagen AG
– Tighten the bolts -arrows- onto the old impression or the mark‐ swagen AG. V does
ing applied previously. by
Vol
k not
gu
ara
ed nte
ris
tho eo
au ra
c
ss
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
tie rod and push lightly upward.
rrectness of i
– Install the bolts -2 and 3- by hand.
l purpos
– Remove the Engine and Gearbox Jack - VAS6931- -1- from

under the tie rod.
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
The threaded connection of trailing arm/wheel bearing housing ht. rig
rig ht
may only be tightened when all other components (spring and py by
co Vo
by lksw
shock absorber always) of the respective suspension have been Prote
cted AG.
agen
already installed. To tighten, the suspension must be unloaded.
into the position required in direction of -arrows-.
– Install the spring. Refer to

AG. Volkswagen AG d
– Tighten the bolts -2 and 3-. agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
ss c
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
– Position the bracket -1- on the trailing arm.
rrectne
– Insert a new rivet and push in a new inner pin -arrow-.
ss o
cial p
f
inform
mer
After Installation, the Axle Alignment Must Be Checked on an
atio
m
Alignment Rack.
o
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
ht. rig
7.7 Trailing Arm, Servicing
rig ht
py by
co Vo
by lksw
cted agen
Special tools and workshop equipment required Prote AG.
♦ Bearing Installer - Wheel Bearing - 3345-

♦ Press Piece - Trailing Arm Bushing - T10496-
Caution


♦ Bolts - Trailing Arm to Wheel Bearing Housing
♦ Bolt - Trailing Arm to Mounting Bracket
– Remove trailing arm with mounting bracket. Refer to
⇒ “7.6 Trailing Arm with Mounting Bracket, Removing and In‐
stalling”, page 234 .

– Clamp the trailing arm -1- in the vise with protective covers.
– Remove the bolt -2- and remove the mounting bracket -3- from
the trailing arm.

– Mount the tools as illustrated.
2- Bearing Installer - 3346/1- from the Bearing Installer - Con‐
trol Arm - 3346- (the deep recess points to the bonded
rubber bushing)
3- Trailing arm
5- Bearing Installer - Wheel Bearing - 3345-
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
ise nte
Installing the Bonded Rubberuthor
Bushing eo
ra
s a c
– Mark the position of sthe bonded rubber bushing on the trailing
ce
e
arm with a right angle.

nl
pt
du
an
itte
y li
– Place the outer edge of the right angle on the upper -1- and
erm
ab
lower radius -2- of the hole.

ility
ot p
wit
, is n
– Make a mark over and under the bushing on the trailing arm
h re
-arrows-.
hole
spec
es, in part or in w
a - 90°
t to the co
rrectness of i
Position the bonded rubber bushing on the trailing arm so that the
l purpos
marked line -arrows- runs along the ribs -1-.

nform
ercia
Note
m
at
om
ion
c
Make absolutely sure that the bonded rubber bushing is in the

in t
or
his
correct installation position in relation to the trailing arm socket.

ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

– Mount the tools as illustrated.

2- Press Piece - Trailing Arm Bushing - T10496-
4- Trailing arm
5- Bearing Installer - Wheel Bearing - 3345-
– Install the bonded rubber bushing.
. Volkswagen AG
gen AGto
Determining Installation Position of Mounting Bracket kRelative does
l swa not
Trailing Arm by
Vo gu
ara
ed nte
oris eo
th
au ra
c
ss
ce
e
nl
pt
du
an
itte
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erm
ab
ility
ot p
– Clamp the trailing arm -2- in the vise with jaw protectors.
wit
, is n
h re
– Position the mounting bracket -1- on the trailing arm -2-.
hole
spec
– Install the bolt -3-.
es, in part or in w
t to the co
– Adjust the dimension -a- to 37 mm and tighten the bolt -3-.
– Install the trailing arm with mounting bracket. Refer to
rrectness of i
⇒ “7.6 Trailing Arm with Mounting Bracket, Removing and In‐
stalling”, page 234 .
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

8 Drive Axle
AG. Volkswagen AG d
agen
⇒ “8.1 Overview - Drive Axle”, page 240 Volksw
oes
not
gu
d by ara
⇒ “8.2 Drive Axle Threaded Connection, Loosening oand
ris Tighten‐
e nte
eo
ing”, page 241 aut
h
ra
ss c
⇒ “8.3 Drive Axle, Removing and Installing”, page 242
ce
e
nl
pt
du
an
⇒ “8.4 Drive Axle, Disassembling and Assembling”, page 247
itte
y li
erm
ab
ility
ot p
wit
⇒ “8.6 Inner CV Joint, Checking”, page 252 , is n
h re
hole
spec
es, in part or in w
t to the co
1 - Outer CV Joint
rrectness of i
plete unit.
l purpos
⇒ Fig. ““Outer CV Joint,
nf
ercia
Pressing Off”“ ,
or
page 248 .
m
m
atio
m

o
n in
c
tic hammer, drive onto

or
thi
e
the shaft as far as the

t
sd
iva
stop
o
r
rp
cu
o
m
f
❑ Divide the grease even‐
en
ng
t.
yi
ly in the joint
Co
Cop py
t. rig
❑ Checking. Refer to
gh ht
yri by
⇒ “8.5 Outer CV Joint,
op Vo
by c lksw
cted
Checking”, page 251
agen
Prote AG.
2 - Bolt
❑ 200 Nm +180°. Refer to
page 241 .
joint with a tap.
3 - Drive Axle
❑ Allocation. Refer to the
Parts Catalog.
4 - Clamp
⇒ Fig. ““Tensioning
Clamp on Small Diame‐
ter”“ , page 251
5 - CV Boot
6 - Clamp

7 - Plate Spring n AG. Volkswagen AG do

wage es n
❑ With inner spline yV
olks ot g
ua
d b
❑ Installed position. Refer to ⇒ Fig. ““Installed
o
ir se Position, Plate Spring on the Outer
ran
teJoint”“ , page 248
th eo
8 - Locking Ring au ra
c
ss
ce
le
un
pt
an
d
itte
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erm
ab
9 - CV Boot
ility
ot p
wit
is n
h re
ole,
❑ Without vent hole
spec
t to the co
❑ Drive off CV joint using drift
rrectne
10 - Clamp
ss o
❑ Tensioning. Refer to ⇒ Fig. ““Tensioning Clamp on Small Diameter”“ , page 251
cial p
f inform
11 - Locking Plate
mer
atio
m

o
n
c
i
or
n
❑ 40 Nm
thi
te
sd
va

i
o
pr
cum
r
fo
en
ng
t.
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op
13 - Cover C py
t. rig
gh ht
❑ Always replace if removed yri
p by
co Vo
by lksw
❑ Removing. Refer to ⇒ Fig. ““Drive Off Cover for Inner Joint”“ , page 249 cted agen
Prote AG.
14 - Locking Ring
❑ Remove and install using Circlip Pliers - VW161A- .
15 - Seal
❑ Bonding surface on CV joint must be free of grease and oil!
16 - Inner CV Joint
❑ Replace only as complete unit.
❑ Divide the grease evenly in the joint
❑ Removing. Refer to ⇒ Fig. ““Removing the Inner CV Joint”“ , page 249
❑ Installing. Refer to ⇒ Fig. ““Pressing On Inner CV Joint”“ , page 250
❑ Checking. Refer to ⇒ “8.6 Inner CV Joint, Checking”, page 252 .
17 - Plate Spring
❑ With inner spline
❑ Installed position. Refer to ⇒ Fig. ““Installed Location of the Plate Spring on Inner Joint”“ , page 249
8.2 Drive Axle Threaded Connection, Loos‐

ening and Tightening
8. Drive Axle 241

Caution
. Volkswagen AG
gen AG does
swa
This procedure containsby
Volmandatory replaceable parts.
k not Refer
gu
to component overview
ris
ed prior to starting procedure. ara
nte
tho eo
s au ra
c
s
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
Caution
wit
is n
h re
ole,
spec
t to the co
rrectne
s
s o
cial p
f in
form
mer
atio
om
n
c
i
or
n
♦ Install an outer joint in place of the drive axle. thi
te
sd
va

i
o
pr
cum
r
fo
en
ng
t.
yi Co
op py
Loosening the 12-Point Bolt t. C rig
gh ht
pyri by
– With vehicle still resting on wheels, loosen the twelve-point
co Vo
by lksw
cted
bolt with Socket AF 24 - T10361A- maximum 90°, otherwise,
agen
Prote AG.
wheel bearing will be damaged.
– Lift the vehicle just enough so that the wheels are hanging free.
– Remove the twelve-point bolt -arrow-.
Twelve-Point Bolt, Fastening
– Replace the twelve-point bolt.
Note
Wheels must not yet touch the ground to tighten the drive axle,
the wheel bearing may otherwise be damaged.

– Tighten the twelve-point bolt to 200 Nm.
– Lower the vehicle onto its wheels.
– Turn the twelve-point bolt an additional 180°.
8.3 Drive Axle, Removing and Installing


Caution


♦ Lock Ring - Drive Axle
♦ Bolt - Shock Absorber to Lower Transverse Link
♦ Nut - Wheel Bearing Housing to Lower Transverse Link
♦ Bolt - Wheel Bearing Housing to Lower Transverse Link
♦ Bolt - Tie Rod to Subframe
Caution agen
AG. Volkswagen AG d
oes
olksw not
y V gu
b ara
When disassembling and performing rise
d
repairs on vehicle, the nte
drive axles must not be allowed aut to hang down and contact the
ho eo
ra
stops in the joint by overflexing.
ss c
ce
e
nl
pt
du
an
itte
y li
Removing
erm
ab
ility
ot p
– Loosen the outer drive axle threaded connection. Refer to
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
Caution
rrectness of i

l purpos
nf
ercia
orm
m
atio
m

o
n in
or c
thi

te
sd
a

iv
o
r
rp
cu

o
m
f
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– Remove coil spring. Refer to
8. Drive Axle 243


-2- bracket.

Note
G. Volkswagen AG d
If there is moisture in the connector area, blow compressedlkair
swaon
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the contacts on the shock absorber and the connector. db
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– Remove the nut -1- from the coupling rod -2-. Cop py
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– Remove the stabilizer bar -1- from the subframe -2- and pivot
downward.
– Remove the nut -1- and then the bolt -2- for the shock absorber
threaded connection.
– Remove the nut -3- and then the bolt -4- for the wheel bearing
housing threaded connection.
– Remove the bolt -1- for the tie rod -2-.olkswagen AG

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axle from the stransmission
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Before using the Drive Shaft Remover - T10520- , make sure that
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rrectness of i
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8. Drive Axle 245

Using the Drive Shaft Remover - T10520- :

– Secure the Drive Shaft Remover - T10520- -1- with three
wheel bolts -2- on the wheel hub, so that the drive axle -3- can
be pressed out.
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axle using the Drive Shaft Remover - T10520- .
Note
be used.
– Pivot the drive axle downward and remove it from the wheel
bearing.
Installing
• Only fasten the bolted connections on the wheel bearing hous‐
ing in the curb weight position.
nostic Tester . gen AG
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• Lightly coat thed bsplines
yV
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on the outer joint with assembly
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ua paste
before installing
rise the outer joint into the wheel hub. Refer
ran
teto the
tho
Parts Catalog. eo
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♦ Refer to
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AWD”, page 183

h re
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spec
♦ Refer to
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⇒ “5.2.2 Overview - Tie Rod, Multi-Link Suspension, AWD”,

t to the co
page 185
♦ Refer to
rrectness of i

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♦ Refer to
nform
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page 278
m
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♦ Refer to
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um
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8.4 Drive Axle, Disassembling and Assem‐

bling
8. Drive Axle 247


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♦ Circlip Pliers - VW161A- agen oes
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♦ Torque Wrench 1332 40-200Nm
ss a - VAG1332- ra
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Caution
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Disassembling
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Outer CV Joint, Pressing Off
mer
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o
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c
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– Remove the clamp.
thi
te
sd
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– Fold back boot.

p
cum
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– Drive CV joint from drive axle using a drift -A-.

t.
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The drift must be precisely positioned on the CV joint ball hub.
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Driving Joint On
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Installed Position, Plate Spring on the Outer Joint

1- Plate Spring
– Insert a new circlip.
– Drive the joint onto the shaft using a plastic hammer until the
circlip locks into place.

Drive Off Cover for Inner Joint

– Press off CV from joint using drift.
– Remove both clamps, and push the CV boot toward outer joint.
Assembling
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Installed Location of the Plate Spring on Inner Joint

spec
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1- Plate Spring
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8. Drive Axle 249

Pressing On Inner CV Joint AG. Volkswagen AG d

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Chamfer on inner diameter of ball hub (splines) must face the s
ce
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contact shoulder on the drive axle.
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– Press on joint until stop.
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– Align new cover with bolts -arrows- to bolt holes.
atio
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Note
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It must be aligned exactly because it cannot be aligned after driv‐
r
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tilt clamp tool).
Note

VAG1682A- .

Tensioning Clamp on Small Diameter
8.5 Outer CV Joint, Checking

The joint is to be disassembled if badly contaminated to replace
the grease, or when the ball contact surfaces show wear or dam‐
age.
Removing
– Before disassembling mark ball hub position in relation to the
ball cage and housing with an electro-writer or oil stone
-arrow-.
– Tilt ball hub and ball cage and remove balls one after another.
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– Turn cage until the two rectangular windows -arrow- are
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aligned with the joint housing.
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– Lift out cage with hub.

spec
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8. Drive Axle 251

– Swing a hub segment in a cage window.

– Fold hub out from cage.
Note
♦ The six balls of each joint belong to one tolerance group.

Check stub axle, hub, cage and balls for small depressions
(pitting build-up) and chafing.
♦ Excessive circumferential backlash in joint makes itself no‐
ticed via tip-in shock, in such cases joint should be replaced.
♦ Flattening and running marks of balls are no reason to replace
joint.
Installing
– Press half of the grease amount from the repair kit into the joint
housing.
– Insert cage with hub into joint body.
Note
AG. Volkswagen AG d
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Cage must be installed d by laterally correct.
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– Press in opposing balls in sequence, during this, previous po‐
ra
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sition of ball hub to ball cage and to joint body must be
ce
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established again.
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– Install new circlip in shaft.

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– Distribute remaining grease in the joint boot.

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8.6 Inner CV Joint, Checking

spec
es, in part or in w
t to the co
The joint is to be disassembled if badly contaminated to replace

the grease, or when the ball contact surfaces show wear or dam‐
age.
rrectness of i
l purpos
Note
nform
ercia
Ball hub and joint piece are paired. Before removing, mark in re‐
lation to each other using a waterproof felt-tip pen.
m
at
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ion
c
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Removing
or
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do
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– Swivel the ball hub and ball cage.

p
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for
– Remove the joint in the direction of the -arrow-.

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– Remove the balls from the cage. t. C rig
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Volkswagen AG
n AG.Suspension,
swage Wheels,
does Steering
- Edition 03.2016
olk not
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– Flip out ball hub from ball cageorvia
ise running path of ball nte
-arrows-. auth eo
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– Check joint piece, ball hub, ball cage and balls for small broken
ce
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pt
off depressions (pitting build-up) and chafing.
du
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Note
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Excessive backlash in joint will be noticed as a knock during load
spec
changes. Joint must be replaced in such cases. Flattening and
es, in part or in w
t to the co
running marks of balls are no reason to replace joint.
rrectness of i
Installing
l purpos

– Insert ball hub into ball cage via two chamfers. The installation
nform
ercia
position is at random. Press balls into cage.

m
at
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i
– Insert hub with cage and balls upright into joint piece.
on
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When inserting, make sure that in each case the wide gap -a- at
agen
Prote AG.
joint piece contacts narrow gap -b- at hub after swinging in.
Chamfer on inner diameter of ball hub (splines) must face large
diameter of joint piece.
– Also note chamfer on inner diameter of ball hub, it must be
visible after swiveling in.
– Swing in ball hub, to do this swing out hub far enough from
cage -arrows- so that the balls have the distance of the running
paths.
8. Drive Axle 253

– Swing in hub with balls by pressing forcefully onto cage

-arrow-.
CV joint, checking for function:
CV joint is properly assembled, if ball hub can be slid back and
forth by hand over whole compensation length.
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9 Special Tools

equipment required
♦ Subframe Bushing Tool Kit
- 3301-
♦ Press Tool For Viscous Fan
- 3367-
40-200Nm - VAG1332-
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VW408A- AG. Volkswagen AG d
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♦ Press Piece - Rod - d b ara
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♦ Press Piece - 37mm - ss
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VW416B-
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- VW447H-
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AG. Volkswagen AG d
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2015 ➤
ris
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e o 03.2016
au ra
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un
♦ Circlip Pliers - VW161A-
pt
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5-50Nm - VAG1331-
ility
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40-200Nm - VAG1332-
spec
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VAG1682A-
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tion in
r
te o
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Prote AG.


40-200Nm - VAG1332-
VAS6931-
AG. Volkswagen AG d
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- 3301-
♦ Bearing Installer - Control
Arm - 3346-
40-200Nm - VAG1332-
VAS6931-
AG. Volkswagen AG d
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nf
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AG. Volkswagen AG d
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Golf 2015 ➤ , Golf Variant rise2015 ➤
d b ara
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Suspension, Wheels, aSteering
ut
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- Edition 03.2016 eo
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♦ Hydraulic Press - Ball Joint
ab
ility
Assembly Tools - T10254-
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♦ Pneumatic/Hydraulic Foot
h re
hole
Pump - Press Kit - T10495-
spec
es, in part or in w
t to the co
40-200Nm - VAG1332-
rrectness of i
VAS6931- -2- with Univer‐
sal Support Plate -
l purpos
VAG1359/2-
nf
ercia
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VAS6178- with Bearing In‐
rm
m
staller - Wheel Hub/Bearing
atio
m
Kit - Pressure Head -

o
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or c
T10205/13-
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- 3301-
Arm - 3346-
♦ Bearing Installer - Carrier
Bearing - 3350-
♦ Subframe Bushing Assem‐
bly Tool Kit - T10356-
40-200Nm - VAG1332-
AG. Volkswagen AG d
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Bearing - 3345-
Arm - 3346-
- VW412-
♦ Press Piece - Trailing Arm agen
AG. Volkswagen AG d
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Bushing - T10496- olksw not
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40-200Nm - VAG1332-
♦ Torque Wrench 1410 -
VAG1410-
Spring Tensioner -
VAG1752/1-
Spring Retainer with Inserts
- VAG1752/3A-
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♦ Hydraulic Press - Rear
Subframe Bushing Tool Kit
- T10263-
♦ Subframe Bushing Assem‐
bly Tool Kit - T10356-
VAS6931-
VAS6178- with Bearing In‐
staller - Wheel Hub/Bearing wagen AG. Volkswagen AG doe
Kit - Pressure Head - yV
olks s no
t gu
T10205/13- isedb ara
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ho
♦ Pneumatic/Hydraulic
sa
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ac
Pump - VAS6179-
s
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nl
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ility
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c
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do
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t.
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♦ Seal Installer - Camshaft

Installer Kit - Sleeve -
3241/4-
♦ Puller - Grease Cap -
VW637/2-
40-200Nm - VAG1332-
♦ Socket - XZN 18mm -
T10162A-
♦ Torque Wrench 1410 -
VAG1410-
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r
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AG. Volkswagen AG d
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43 – Level Control System

1 Electronic Damping
⇒ “1.1 Overview - Electronic Damping”, page 267
⇒ “1.2.1 Electronic Damping Control Module J250 , Removing
and Installing, Golf”, page 272
⇒ “1.3 Left/Right Front Body Acceleration Sensor G341 / G342 ,
Removing and Installing”, page 274
⇒ “1.4 Left Rear Body Acceleration Sensor G699 , Removing and
1.1 Overview - Electronic Damping

⇒ “1.1.1 Overview - Electronic Damping, Torsion Beam Axle,
Golf”, page 267
⇒ “1.1.2 Overview - Electronic Damping, Multi-Link Suspension,
Golf”, page 269
⇒ “1.1.3 Overview - Electronic Damping, Multi-Link Suspension,
Golf Wagon”, page 271
1.1.1 Overview - Electronic Damping, Torsion Beam Axle, Golf
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1. Electronic Damping 267

1 - Right Front Level Control

Sensor - G289-
ling. Refer to
⇒ “2.3 Left/Right Front
Level Control System
Sensor G78 / G289 , Re‐
page 280
2 - Right Front Body Accelera‐
tion Sensor - G342-
ling. Refer to
Body Acceleration Sen‐ AG. Volkswagen AG d
sor G341 / G342 , Re‐ agen oes
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page 274 horis nte
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3 - Left Rear Body Acceleration ss c
Sensor - G699-
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❑ Component location: in
itte
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the luggage compart‐
erm
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ility
ment on the left shock
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absorber tower behind
is n
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the left side trim panel
ole,
spec
ling. Refer to
t to the co
⇒ “1.4 Left Rear Body
Acceleration Sensor
G699 , Removing and
rrectne
4 - Electronic Damping Control
ss o
Module - J250-
cial p
f in
form
mer
ling. Refer to
atio
m
⇒ “1.2.1 Electronic
o
n
c
Damping Control Mod‐
i
or
n thi
ule J250 , Removing and Installing, Golf”, page 272
te
sd
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❑ Component location: the Electronic Damping Control Module - J250- is installed in the luggage com‐
pr
cum
r
fo
partment behind the left side trim panel.

en
ng
t.
yi Co
❑ If the Electronic Damping Control Module - J250- is being replaced, the Replace Control Module t. Cop py
function must be performed using the Vehicle Diagnostic Tester .
rig
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Vo
❑ If the control position was reprogrammed and if the vehicle has lane assist, then the front camera for the
o
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driver assistance systems must be calibrated. Prote AG.
5 - Left Rear Level Control System Sensor - G76-

⇒ “2.4.1 Left Rear Level Control System Sensor G76 , Removing and Installing, Torsion Beam Axle”,
page 282
6 - Left Front Body Acceleration Sensor - G341-
⇒ “1.3 Left/Right Front Body Acceleration Sensor G341 / G342 , Removing and Installing”, page 274
7 - Left Front Level Control System Sensor - G78-
⇒ “2.3 Left/Right Front Level Control System Sensor G78 / G289 , Removing and Installing”,
page 280
8 - Shock Absorber with Right Front Damping Adjustment Valve - N337-
❑ Removing and installing the suspension strut. Refer to
⇒ “3.2 Suspension Strut, Removing and Installing”, page 45 .
❑ Servicing the suspension strut. Refer to ⇒ “3.3 Suspension Strut, Servicing”, page 51 .
268 Rep. Gr.43 - Level Control System

9 - Shock Absorber with Right Rear Damping Adjustment Valve - N339-

❑ Shock absorber, removing and installing. Refer to
⇒ “6.2 Shock Absorber, Removing and Installing”, page 193 .
❑ Shock absorber, servicing. Refer to ⇒ “6.3 Shock Absorber, Servicing”, page 200 .
10 - Shock Absorber with Left Rear Damping Adjustment Valve - N338-
11 - Shock Absorber with Left Front Damping Adjustment Valve - N336-
❑ Servicing the suspension strut. Refer to ⇒ “3.3. Suspension
gen AG
Volkswagen AGStrut, Servicing”, page 51 .
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1.1.2 Overview - Electronic Damping, Multi-Link Suspension, Golf t eo
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Sensor - G289-
erm
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ility
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ling. Refer to
h re
hole
spec
es, in part or in w
t to the co
page 280
rrectness of i
tion Sensor - G342-
l purpos

ling. Refer to
nform
ercia

Body Acceleration Sen‐
m
sor G341 / G342 , Re‐ at

om
ion
c
in t
or
page 274
his
ate
do
riv
3 - Left Rear Body Acceleration

p
cum
or
Sensor - G699-
f
en
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t.
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❑ Component location: in Cop py
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ht ht
rig by
py
ment on the left shock co Vo
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ling. Refer to
Acceleration Sensor
G699 , Removing and
Module - J250-
ling. Refer to
ule J250 , Removing and Installing, Golf”, page 272
❑ If the Electronic Damping Control Module - J250- is being replaced, the Replace control module
function must be performed using the ⇒ “3.3 Suspension Strut, Servicing”, page 51 .

❑ If the control position was reprogrammed and if the vehicle has lane assist, then the front camera for the
driver assistance systems must be calibrated.
⇒ “2.4.2 Left Rear Level Control System Sensors G76 , Removing and Installing, Multi-Link Suspension”,
page 283 .
⇒ “1.3 Left/Right Front Body Acceleration Sensor G341wa/ gG342 , oRemoving
en AG. V
lkswagen AGand Installing”, page 274 .
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Vol t
7 - Left Front Level Control System Sensor - G78- ed by gu
ara
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❑ Removing and installing. Refer to ut
ho eo
ra
⇒ “2.3 Left/Right Front Level Control System
ss a Sensor G78 / G289 , Removing and Installing”, c
page 280 .
ce
le
un
pt
an
d
8 - Shock Absorber with Right Front Damping Adjustment Valve - N337-

itte
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rm
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pe
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1.1.3 Overview - Electronic Damping, Multi-Link Suspension, Golf Wagon

Sensor - G289- agen
AG. Volkswagen AG d
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❑ Removing and instal‐ by Vo gu
ara
ling. Refer to rise
d
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⇒ “2.3 Left/Right Front autho eo
ra
Level Control System ss c
ce
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nl
pt
du
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itte
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page 280 .
erm
ab
ility
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tion Sensor - G342- , is n
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hole
spec
ling. Refer to
es, in part or in w
t to the co
Body Acceleration Sen‐
sor G341 / G342 , Re‐
rrectness of i
page 274 .
l purpos
3 - Left Rear Body Acceleration

Sensor - G699-
nf
ercia
❑ Component location: In
orm
m
atio
m
ment on the left shock

o
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c

or
thi
e

t
sd
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rp
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ling. Refer to
f
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t.
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Co
op py
Acceleration Sensor
t. C rig
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G699 , Removing and p by
co Vo
Installing”, page 275 .
by lksw
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Prote AG.
Module - J250-
ling. Refer to
ule J250 , Removing and Installing, Golf Wagon”, page 273 .
❑ If the Electronic Damping Control Module - J250- is being replaced, the Replace control module
function must be performed using the Vehicle Diagnostic Tester .
❑ If the control position was reprogrammed and if the vehicle has lane assist, then it will then be necessary
to calibrate the driver assistance systems front camera. Refer to
⇒ “6.1 Driver Assistance Systems Front Camera, Calibrating”, page 327 .
❑ Removing and installing, FWD. Refer to
⇒ “2.4.2 Left Rear Level Control System Sensors G76 , Removing and Installing, Multi-Link Suspension”,
page 283 .
❑ Removing and installing, AWD. Refer to
⇒ “2.4.3 Left Rear Level Control System Sensors G76 , Removing and Installing, Multi-Link Suspension,
AWD”, page 284 .
⇒ “1.3 Left/Right Front Body Acceleration Sensor G341 / G342 , Removing and Installing”, page 274 .

7 - Left Front Level Control System Sensor - G78-

❑ Removing and installing. Refer to AG. Volkswagen AG d
agen
⇒ “2.3 Left/Right Front Level Control SystemVolkswSensor G78 / G289 , Removing
oes
not
gu
and Installing”,
page 280 . ed by ara
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or
8 - Shock Absorber with Right Front Damping
au
th Adjustment Valve - N337- or
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❑ Servicing the suspension strut. Refer to ⇒ “3.3 Suspension Strut, Servicing”, page 51 . erm
ab
ility
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es, in part or in w
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1.2 Electronic Damping Control Module -

f
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J250- , Removing and Installing
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and Installing, Golf”, page 272 Prote
cted AG.
agen

and Installing, Golf Wagon”, page 273
1.2.1 Electronic Damping Control Module -

J250- , Removing and Installing, Golf
Removing
Component location: the Electronic Damping Control Module -
J250- is installed in the luggage compartment behind the left side
trim panel.
– Disconnect the battery. Refer to ⇒ Electrical Equipment; Rep.
Gr. 27 ; Battery; Battery, Disconnecting and Connecting .
– Remove the ignition key.
System
wheel lock engages.
– Remove the left luggage compartment side trim panel. Refer
to ⇒ Body Interior; Rep. Gr. 70 ; Luggage Compartment Trim
Panels; Luggage Compartment Side Trim Panel, Removing
and Installing .

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– Release the release lever -1- in direction of -arrow-.
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– Remove the connector -2-.
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– Push the tabs -3 and 4- to the rear.
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– Slide the Electronic Damping Control Module - J250- -5- down‐
hole
spec
ward from the bracket -6-.
es, in part or in w
t to the co
Installing
rrectness of i
– If the Electronic Damping Control Module - J250- was re‐
placed, the Replace control module function must be per‐
l purpos
formed using the Vehicle Diagnostic Tester .
nf
ercia
– If the control position was reprogrammed and if the vehicle has
or
lane assist, then it will then be necessary to calibrate the driver
m
m
atio
assistance systems front camera. Refer to
om
⇒ “6.1 Driver Assistance Systems Front Camera, Calibrating”,
n in
or c
page 327 .
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1.2.2 Electronic Damping Control Module -
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J250- , Removing and Installing, Golf
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Wagon
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Removing
Component location: the Electronic Damping Control Module -
J250- is installed in the luggage compartment behind the left side
trim panel.
– Disconnect the battery. Refer to ⇒ Electrical Equipment; Rep.
– Remove the ignition key.
System
wheel lock engages.
Panels; Luggage Compartment Side Trim Panel, Removing
and Installing .
– Remove the tool bag.
– Release the tabs -arrows-.
– Remove the bracket -1-.

– Remove the control module -1- from the bracket -2-.
– Remove the release -1- in direction of -arrow-.

– Remove the connector -2-.
Installing
Install in reverse order of removal and note the following:
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– Push the control module -1- as far as possible in the bracket
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-2- until the tab -arrow- engages in the bracket.

un
pt
an
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itte
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– If the Electronic Damping Control Module - J250- was re‐

erm
ab
placed, the Replace control module function must be per‐

ility
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formed using the Vehicle Diagnostic Tester .

wit
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ole,
– If the control position was reprogrammed and if the vehicle has

spec
lane assist, then it will then be necessary to calibrate the driver

assistance systems front camera. Refer to
t to the co

page 327 .
rrectness o
cial p
f inform
mer
atio
om
n
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1.3 Left/Right Front Body Acceleration Sen‐

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t.
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sor -G341- / -G342- , Removing and Cop py
t. rig
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Installing
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Prote AG.
♦ Torque Wrench - VAG1410-

Removing
– Remove the seal from the entire length of the plenum chamber
cover.
– Remove the clips.
– Lift the plenum chamber cover -1- to maximum 60 mm.
a - 60 mm
AG. Volkswagen AG d
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spec
es, in part or in w
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– Remove the Front Body Acceleration Sensor .
rrectness of i
Installing
l purpos

following:
nform
mercia
at
om
ion
c
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or
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ate
do
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– Insert the Front Body Acceleration Sensor -1- so that the con‐
p
cum
or
nector connection -arrow- faces opposite the direction of trav‐

f
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ng
t.
el.
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Cop py
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– Secure the Front Body Acceleration Sensor -1- with the bolt
gh ht
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-2-.
co Vo
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Installation position: angle tolerance -a- is ±10°. The installation
position of the Front Body Acceleration Sensor may deviate
around this angle from the vehicle longitudinal axis.
– Perform the basic setting for the wheel damping electronics.
Refer to Vehicle Diagnostic Tester .
Front Body Acceleration Sen‐ 8 Nm
sor to body
1.4 Left Rear Body Acceleration Sensor -

G699- , Removing and Installing
Removing

AG. Volkswagen AG d
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Suspension,
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Wheels, Steering - Edition 03.2016 ra
c
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Panels; Luggage Compartment Side Trim Panel, Removingnl
pt
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and Installing .
itte
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– Release and disconnect the connector -1-.
ility
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– Remove the bolt -2- and then remove the Rear Body Acceler‐
h re
ation Sensor - G343- -3-.
hole
spec
es, in part or in w
Installing
t to the co
following:
rrectness of i
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nf
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orm
m
atio
m
– Insert the Rear Body Acceleration Sensor - G343- -1- so that

o
n in
c
the tab -arrow A- engages in the hole -arrow B-.

or
thi
te
sd
a
– Perform the basic setting for the wheel damping electronics.

iv
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Rear Body Acceleration Sensor Prote AG.
8 Nm
- G343- to body

2 Level Control System Sensor

page 277
page 278
⇒ “2.3 Left/Right Front Level Control System Sensor G78 / G289 ,
⇒ “2.4 Left/Right Rear Level Control System Sensor G76 / G77 ,
2.1 Overview - Front Level Control System Sensor
Note
A replacement Left Front Level Control System Sensor - G78- / Right Front Level Control Sensor - G289- only
comes complete with the coupling rod and the upper and lower retaining plate.
1 - Control Arm
AG. Volkswagen AG d
2 - Subframe agen oes
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3 - Connector rised
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4 - Left Front Level Control ss a ra
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System Sensor - G78- and
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un
pt
Right Front Level Control Sen‐
an
d
itte
sor - G289-
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erm
ab
❑ Complete with compo‐
ility
ot p
nents
wit
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❑ The lever must face to‐
ole,
ward outside of vehicle
spec

t to the co
ling. Refer to
rrectne

s
page 280
s o
cial p
❑ Perform the basic set‐

inform
ting of the headlamps.

mer
Refer to ⇒ Electrical
atio
m
Equipment; Rep. Gr.

o
n
c
94 ; Headlamp; Head‐
or
n thi
e
lamp, Adjusting .
t
sd
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pr
cum
5 - Bolt
r
fo
en
ng
t.
❑ 8 Nm
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Cop py
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6 - Nut
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❑ 8 Nm
lksw
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Prote AG.
2. Level Control System Sensor 277

2.2 Overview - Rear Level Control System

Sensor
⇒ “2.2.1 Overview - Rear Level Control System Sensor, Torsion
Beam Axle”, page 278
⇒ “2.2.2 Overview - Rear Level Control System Sensor, Multi-Link
Suspension”, page 279
⇒ “2.2.3 Overview - Rear Level Control System Sensor, Multi-Link
Suspension, AWD”, page 280
G. Volkswage
2.2.1 Overview - Rear Level Control
olks
waSystem
gen A Sensor,
n AG d
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t
Beam Axle
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Note s au ra
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un
A replacement Left Rear Level Control System Sensor - G76- only comes complete with the coupling rod and
pt
an
d
the upper and lower retaining plate.

itte
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erm
ab
ility
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1 - Connector
h re
ole,
spec
2 - Bolt
t to the co
❑ 5 Nm
3 - Left Rear Level Control Sys‐
tem Sensor - G76-
rrectne
ling. Refer to
ss
⇒ “2.4.1 Left Rear Level
o
cial p
f i
Control System Sensor
nform
G76 , Removing and In‐
mer
stalling, Torsion Beam
atio
m
Axle”, page 282

o
n
c
i
or
n thi
e
– Perform the basic set‐

t
sd
va
ting for the wheel damp‐

i
o
pr
cum
r
ing electronics. Refer to

fo
en
ng
Vehicle Diagnostic
t.
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op
Tester . C py
t. rig
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❑ Perform the basic set‐ cop Vo
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ting of the headlamps. cted agen
Prote AG.
Equipment; Rep. Gr.
lamp, Adjusting .
4 - Bolt
❑ 8 Nm
5 - Axle Beam

2.2.2 Overview - Rear Level Control System Sensor, Multi-Link Suspension
Note
A replacement level control system sensor only comes complete with the coupling rod and the upper and lower
retaining plate.
AG. Volkswagen AG d
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1 - Bolt d by V gu
ara
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❑ 5 Nm uthor eo
a ra
s c
2 - Left Rear Level Control Sys‐ s
ce
e
tem Sensor - G76-
nl
pt
du
an
❑ Complete with compo‐ itte
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erm
ab
nents
ility
ot p
❑ The lever must face to‐
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ward outside of vehicle
h re
hole
spec
es, in part or in w
ling. Refer to
t to the co
⇒ “2.4 Left/Right Rear
rrectness of i
page 282 .
l purpos

nform
ercia
ing electronics. Refer to

Vehicle Diagnostic
m
at
om
Tester .
ion
c
in t
r

o
his
e

at
do
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p
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or
Equipment; Rep. Gr.

f
en
ng
t.
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op
lamp, Adjusting .
C py
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3 - Internally Threaded Pop
cop Vo
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Rivet
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Prote AG.
4 - Connector
Rivet
6 - Bolt
❑ 5 Nm

2.2.3 Overview - Rear Level Control System Sensor, Multi-Link Suspension,

AWD
Note
A replacement level control system sensor only comes complete with the coupling rod and the upper and lower
retaining plate.

Rivet
2 - Connector
Rivet
4 - Bolt
❑ 5 Nm
5 - Rear Level Control System
Sensor
❑ Complete with compo‐
nents agen
AG. Volkswagen AG d
oes
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❑ The lever must face to‐ by Vo gu
ara
ward outside of vehicle rise
d
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❑ Removing and instal‐ s au ra
c
ling. Refer to s
ce
le
⇒ “2.4 Left/Right Rear

un
pt
an
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page 282 .
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es, in part or in w
ing electronics. Refer to t to the co

Vehicle Diagnostic
Tester .
rrectness of i

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Equipment; Rep. Gr.
nform
ercia
lamp, Adjusting .
m
a
com
6 - Bolt
tion in
❑ 5 Nm
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2.3 Left/Right Front Level Control System Cop py
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Sensor -G78- / -G289- , Removing and
ht
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Installing cted agen
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Caution


♦ Nut - Control Arm to Front Level Control System Sensor
Removing
G289- .
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– Remove nut -1-.
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te o
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– Remove the Left Front Level Control System Sensor - G78- or
Right Front Level Control Sensor - G289- .
Installing
following:
Note
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♦ The level control system sensor o lever must point toward svehi‐
lks ot g
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cle exterior. o
ir se
d ran
tee
th or
♦ The thread on thesslevel
au control system sensor must be instal‐ ac
led in the outer hole in the control arm. The tab on the level
ce
le
un
control system sensor must fit into the inner hole to assure that
pt
an
d
the installation position is correct.

itte
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erm
ab
ility
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• Perform the basic setting for the wheel damping electronics.
wit
is n
h re
ole,
spec
• If the control position was reprogrammed and if the vehicle has
lane assist, then the front camera for the driver assistance
t to the co
systems must be calibrated.
• Perform the basic setting of the headlamps. Refer to ⇒ Elec‐
rrectne
trical Equipment; Rep. Gr. 94 ; Headlamp; Headlamp, Adjust‐
ing .
ss
o
cial p
f in
♦ Refer to
form
mer

atio
m
page 277
o
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c
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2.4 Left/Right Rear Level Control System

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Sensor -G76- / -G77- , Removing and

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Installing
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⇒ “2.4.1 Left Rear Level Control System Sensor G76 , Removing yri
p by
co Vo
and Installing, Torsion Beam Axle”, page 282
by lksw
cted agen
Prote AG.
⇒ “2.4.2 Left Rear Level Control System Sensors G76 , Remov‐
ing and Installing, Multi-Link Suspension”, page 283
⇒ “2.4.3 Left Rear Level Control System Sensors G76 , Remov‐
ing and Installing, Multi-Link Suspension, AWD”, page 284
2.4.1 Left Rear Level Control System Sensor

- G76- , Removing and Installing, Tor‐
sion Beam Axle

Removing
– Remove the bolts -2 and 4-.
-3-.
Installing
following:
Note
G. Volkswagen
The Left Rear Level Control System wageSensor - G76- lever
nA AG do
emust
s no
olks
face opposite the directiond bofy travel.
V t gu
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• Perform the for the wheel damping electronics. basicausetting ac
ss
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♦ Refer to
es, in part or in w
⇒ “2.2.1 Overview - Rear Level Control System Sensor, Tor‐
t to the co
sion Beam Axle”, page 278
2.4.2 Left Rear Level Control System Sensors

- G76- , Removing and Installing, Multi- rrectness of i
l purpos
Link Suspension
nform
ercia

m
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or

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Removing
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– Remove the bolts -2 and 3-. ht. rig
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– Remove the Left Rear Level Control System Sensor - G76- by c lksw
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Installing
following:
The level control system sensor lever must point toward vehicle
exterior.
ing .
♦ Refer to
⇒ “2.2.2 Overview - Rear Level Control System Sensor, Multi-
Link Suspension”, page 279

2.4.3 Left Rear Level Control System Sensors

- G76- , Removing and Installing, Multi-
Link Suspension, AWD
Removing
-4-.
Installing
following:
The level control system sensor lever must point toward vehicle
exterior.
ing . wage
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olks s no
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Tightening Specifications edb ara
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♦ Refer to tho eo
au ra
⇒ “2.2.2 Overview - Rear LevelssControl System Sensor, Multi- c
Link Suspension”, page 279
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nl
pt
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or
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ate
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3 Special Tools
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44 – Wheels, Tires and Vehicle Alignment

1 Wheels and Tires
⇒ “1.2 Tires, Dismounting”, page 286
⇒ “1.3 Tires, Dismounting”, page 287
⇒ “1.4 Tires, Mounting”, page 287
⇒ “1.5 Wheel, Changing”, page 288
⇒ “1.6 Tire Sealant, Disposing”, page 292
⇒ “1.7 Vehicles with Tire Mobility Kit”, page 292
1.1 Wheel Bolt Tightening Specifications

Wheel bolt to wheel hub for all vehicles:
Tightening specification: 120 Nm
AG. Volkswagen
– Apply corrosion protection tolkthe wagwheel
en centeringAseat
G do before
es n
o s
mounting the wheel. Refer d by to
V ot g
ua
⇒ “1.5.1 Wheel Changing,
oris
e Protecting Wheel Centering Seat rante
Against Corrosion”,
au page 288 .
th eo
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♦ Positioning the anti-theft wheel bolts on steel wheels. Refer to
ce
le
un
pt
⇒ “1.5.5 Wheel Changing, Position of Anti-Theft Wheel Bolts

an
d
itte
on Steel Wheels”, page 291 .

y li
rm
ab
pe
ility
♦ Install the anti-theft wheel bolts using the Wheel Bolt Master
ot
wit
Set .
, is n
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hole
1.2 Tires, Dismounting

spec
es, in part or in w
t to the co
Note
rrectness of i
♦ Since MY 2005, all vehicles have new rims with revised con‐
l purpos
tour.
♦ When mounting tires, tire dismounting/mounting machine
nform
ercia
must be equipped with tire mounting fixture intended for these

rims.
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Otherwise the rim could get damaged.

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If the tire mounting unit has not been modified, contact the equip‐ py by
co Vo
lksw
ment manufacturer.
by
cted agen
Prote AG.
Safety Precautions for Removing and Installing Tires
• Always note the instructions and danger warnings identified in
the following description!
– Remove the nickel plated valve insert and let the air out of the
tire.
286 Rep. Gr.44 - Wheels, Tires and Vehicle Alignment

– Make sure the tire valve -arrow- is on the opposite side of the
press-off blade -1- when dismounting a tire using a tire dis‐
mounting/mounting machine.
The press-off blade must be applied at maximum 2 cm away from
rim flange.
– Remove the balance weight and any dirt from the rim.
– Press off both tire beads around circumference while thor‐

oughly applying tire mounting paste between tire andolrim
. V kswagen AG
flange -arrow-. swa
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1.3 Tires, Dismounting
t to the co
Tires which have been filled or sealed with tire sealant, must be
drained before removing from wheel.
rrectness of i
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Caution
nform
ercia
♦ Do not let tire sealant come in contact with your eyes or

skin.
m
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om
io
♦ It is harmful to health, can cause eye irritation and aller‐

n
c
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or
gies.
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ate
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♦ Wear safety gloves and protective eyewear.

p
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– Place the wheel on a flat surface.
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– Remove the valve insert.
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– Using a suitable drill bit or cutting bit, carefully drill a hole in
the bead seat area of tire.
– Hold the wheel over a catch tray and let the sealant flow out.
– Remove the tire from the rim.
– Clean the rim with a damp cloth.
1.4 Tires, Mounting

• Make sure wheel rim is clean.
1. Wheels and Tires 287

AG. Volkswagen AG d
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Golf 2015 ➤ , Golf Variant 2015 d ➤
by gu
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Suspension, Wheels, Steering thor - Edition 03.2016 eo
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– Using the Valve Fitting Tool - VAS6459- -1-, insert a new tire
ce
le
un
pt
valve.
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– Remove the valve insert.
erm
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ility
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– Inflate tire to approximately 3 to 4 bar (43 to 58 psi), tire bead
wit
is n
must slip audibly over rim hump when doing this.
h re
ole,
spec
– Install the valve insert.
t to the co
– Check the tire pressure for specified pressure.
– Balance the tire.
rrectness o
1.5 Wheel, Changing
cial p
f inform
mer
⇒ “1.5.1 Wheel Changing, Protecting Wheel Centering Seat
atio
m
Against Corrosion”, page 288

o
n
c
i
or
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⇒ “1.5.2 Wheel Changing”, page 289
thi
te
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⇒ “1.5.3 Wheel Changing Instructions”, page 290
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⇒ “1.5.4 Wheel Changing and Wheel Installation”, page 291

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⇒ “1.5.5 Wheel Changing, Position of Anti-Theft Wheel Bolts on
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Steel Wheels”, page 291
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1.5.1 Wheel Changing, Protecting Wheel
AG.
Centering Seat Against Corrosion

Applies to Light-Alloy and Steel Wheels
When a wheel is changed, the centering seat should be sprayed
with Wax Spray to prevent corrosion between the centering seat
and the wheel rim. Refer to the Parts Catalog.
– Thoroughly clean the centering seat on the wheel hub and the
centering surface on the rim.
– Apply wax in area of centering -arrow- using a brush.
Note
Always make sure that only centering -arrow- is waxed and not
rim contact surfaces. As a consequence, the brakes would be‐
come contaminated while driving and thereby result in poor brak‐
ing.
WARNING
Wheel bolts, contact surfaces of wheel/wheel hub and the

threads in the wheel hubs must not have wax applied to them.
Never apply lubricants or anti-corrosion treatment to threads
in wheel hubs.
– Install the wheel and tighten. Refer to

⇒ “1.1 Wheel Bolt Tightening Specifications”, page 286 .

1.5.2 Wheel Changing

Warm Up Cold Tires to the Minimum Mounting Temperature
Note
This applies also to ultra high performance tires (height- / width

ration smaller/same 45% and speed rating symbol larger than/
same as V).
WARNING
The minimum mounting temperature for a tire should be be‐

tween 15 °C and 30 °C (59 and 86 °F) in the center of the tire.
• For injury-free mounting, the upper sidewall and the upper

bead inside must be minimum 15 °C (59 °F).
• The internal temperature is called the core temperature.
• Rubber is a poor heat conductor, and for this reason, a cold
tire must exposed to a temperature controlled environment
until the inner rubber layers have warmed up to at least 15 °C
(59 °F).
• The temperature of the tire surface during the warm-up phase
should not be considered as the temperature on the inside of
the tire.
• So that the cold tires warm up quickly, never stack them one
on top of the other. They should be stored separated from each
other so that the warm air can “circulate” around them.
• Never use a room heater or a hot air gun to warm up tires
because the surface temperature will heat up very quickly to AG. Volkswagen A
n
a critical temperature. olks
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• Using warm water or warm air (maximum 50 °Cris(122
ed °F)) is ara
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the only way to warm a tire safely. utho eo
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• If cold tires (below 0 °C (32 °F)) are brought into a warm en‐
ce
e
nl
vironment (above 0 °C), then a layer of ice will form on the

pt
du
an
surface of the tire. This layer, caused by the condensation of

itte
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the humidity, shows that the tire has begun to absorb the
ab
ility
warmth.
ot p
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• Once the layer of ice starts to melt, wipe up the water with a
h re
hole
rag so that the warming up process will not be slowed down.

spec
es, in part or in w
Warm-Up Time
t to the co
♦ Tires warmer than 0 °C (32 °F) must be stored at minimum 19

°C (66.2 °F) for at least 2 hours.
rrectness of i
♦ Tires colder than 0 °C (32 °F) must be stored at minimum 19

l purpos
°C (66.2 °F) for at least 2.5 hours.

Recommendations:
nf
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or
♦ If possible, let the tires stand in the shop for 1 day before
m
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atio
mounting them
om
n in
or c
♦ Store them on an insulated surface, a wood pallet or some‐

thi
te
thing similar.
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♦ Position the tires so that they can be “surrounded” by the warm

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♦ Wipe off the sweat
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♦ Never heat the tires with a room heater or a hot air gun!
1.5.3 Wheel Changing Instructions olksw

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WARNING utho eo
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The secure seating of the wheel bolts and the wheels is only
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ensured if the instructions and checks below are followed.
an
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Note ole,
spec
After removing or installing one or multiple tires, the tire pressure
t to the co
monitoring system must be calibrated for vehicles with tire pres‐
sure monitoring system. Refer to ⇒ page 295 .
rrectne
– Make sure the contact surfaces -arrows- on the brake disc are
free from corrosion and dirt.
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– Make sure the contact surfaces -arrow- on the brake disc cen‐
Prote AG.
ter seat are free of corrosion and dirt.
– Make sure the contact surface -arrow- on the wheel inner side
(rim) as well as the central seat in the rim is free of corrosion
and dirt.
– The spherical caps * in the wheel bolt openings and the wheel
bolt threads must likewise be free of corrosion, dirt, oil or
grease.
* The spherical cap is the curved surface of a section of a sphere.

– Check whether the wheel bolts can be easily screwed in by

hand. The threads of the wheel bolts must not touch the holes
in the brake disc -arrow-.
If the thread of the wheel bolt touches the hole -arrow-, turn the
brake disc relative to the wheel accordingly.
. Volkswage n AG n AG d
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Remove Any Dirt or Corrosion
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♦ Oil or grease from
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♦ Oil or grease
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♦ Oil or grease from the threads on the wheel bolts
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WARNING
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Heavily corroded, difficult to turn or damaged wheel bolts must
hole
spec
be replaced.
es, in part or in w
t to the co
1.5.4 Wheel Changing and Wheel Installation
rrectness of i
– Coat the wheel centering seat with protective material. Refer
l purpos
to
⇒ “1.5.1 Wheel Changing, Protecting Wheel Centering Seat
nf
ercia
Against Corrosion”, page 288 .
orm
m
atio
1- When mounting a wheel, tighten all wheel bolts uniformly by
om
hand.
n in
or c
thi
e
2- Tighten the wheel bolts diagonally to approximately 30 Nm.

t
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3- Lower the vehicle to the ground. Tighten all the wheel bolts
o
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ng
diagonally to the tightening specification using the torque

t.
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wrench. Refer to Cop py
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⇒ “1.1 Wheel Bolt Tightening Specifications”, page 286 . opyri
gh by
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WARNING
AG.
Do not use an impact wrench to install the wheel bolts.
1.5.5 Wheel Changing, Position of Anti-Theft

Wheel Bolts on Steel Wheels
Caution
It is absolutely necessary to maintain the position of the anti-

theft wheels bolts to the tire valve on steel wheels.

The anti-theft wheel bolt must be installed either to the right or to

the left -arrows- of the valve -1- on steel wheels.
The decorative wheel hubcap can be installed on the steel wheel
securely only when the anti-theft wheel bolt is installed in this po‐
sition.
AG. Volkswagen AG d
agen oes
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1.6 Tire Sealant, Disposing
ol not
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or
♦ Tire sealant
aut or residue from it must not be mixed with other
h eo
ra
wastes/fluids
ss c
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nl
pt
♦ Accumulating fluid residue from tire sealant must be collected
du
an
itte
and placed in a plastic container. The plastic containers can
y li
erm
ab
be sent for recycling together with the tire sets (if the expiration
ility
ot p
date has passed).
wit
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♦ The return or recycling can take place using the existing shop
hole
disposal systems
spec
es, in part or in w
♦ Check with the company responsible for trash pickup for the t to the co
dealership.
1.7 Vehicles with Tire Mobility Kit

rrectness of i
l purpos
⇒ “1.7.1 Vehicles with Tire Mobility Kit, Golf”, page 292

⇒ “1.7.2 Vehicles with Tire Mobility Kit, Golf Wagon”, page 292
nform
ercia
1.7.1 Vehicles with Tire Mobility Kit, Golf

m
at
om
io
Depending on the vehicle equipment, the vehicles are equipped

n
c
in t
or
with a tire mobility kit.

his
ate
do
riv
The tire mobility kit is located in the tool compartment -3- in the
p
cum
or
luggage compartment on the right side.

f
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ng
t.
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op
The tire mobility kit contains a bottle of tire sealant -1- and a com‐ C py
t. rig
pressor -2-. gh ht
pyri by
Vo
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by c lksw
Tire sealant in the bottle has a limited storage life. Prote
cted AG.
agen
Therefore the minimum shelf life date -arrow- is marked on the

bottle -1-.
Replace tire sealant when minimum shelf life date has been
reached (tire sealant must not be older than 4 years).
If the bottle was opened, for example, for a punctured tire, it must
also be replaced.
Observe the disposal regulations. Refer to
⇒ “1.6 Tire Sealant, Disposing”, page 292 .
1.7.2 Vehicles with Tire Mobility Kit, Golf Wag‐

on
Depending on the vehicle equipment, the vehicles are equipped
with a tire mobility kit.

The tire mobility kit is located in the tool compartment -3- in the
luggage compartment on the left side.
The tire mobility kit contains a bottle of tire sealant -1- and a com‐
pressor -2-.
Tire sealant in the bottle has a limited storage life.
Therefore the minimum shelf life date is marked on the bottle
-1-.
Replace tire sealant when minimum shelf life date has been
reached (tire sealant must not be older than 4 years).
If the bottle was opened, for example, for a punctured tire, it must
also be replaced.
Observe the disposal regulations. Refer to
⇒ “1.6 Tire Sealant, Disposing”, page 292 .
lkswage es n
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t to the co
rrectness of i
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nform
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AG. Volkswagen AG d
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2 Tire Pressure Monitoring System
d by
Volksw not
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⇒ “2.1 Tire Pressure Monitoring
ut
ho System Description”, page 294 eo
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s
2.1 Tire Pressure Monitoring System De‐
ce
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un
pt
scription
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General Information
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The tire pressure monitoring system is included in the software in
h re
the ABS Control Module - J104- . The system will recognize a
hole
spec
slow and gradual decrease in tire pressure on a wheel. Diagnostic
es, in part or in w
Trouble Code (DTC) memory faults for tire pressure monitoring
t to the co
are stored in the ABS Control Module - J104- . With the help of
the ABS speed sensors, the Tire Pressure Monitoring System
(TPMS) compares the speed and rolling circumference of the in‐
rrectness of i
dividuals wheels.
l purpos
After the following work and/or changes and with the ignition
switched on, the Tire Pressure Monitoring Display Button - E492-
nform
ercia
must be pressed until the confirmation chime sounds:

m
♦ Change in the tire pressures
a
com
tion in
♦ A change in one or more tires
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♦ Changing a tire, for example, from front to rear
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♦ Removing or installing one or multiple tires en

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If the rolling circumference of a wheel changes, the Tire Pressure C py
t. rig
Monitoring Display Indicator Lamp - K220- lights up in the instru‐
gh ht
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ment cluster. The rolling circumference can change by:
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Prote AG.
♦ Insufficient tire pressure
♦ Structural damage on tires
♦ Vehicle is loaded heavily on one side
♦ High load on one axle, when towing trailer for example
♦ When snow chains are used
♦ Spare wheel is mounted
♦ One wheel is replaced

System Malfunction in the Anti-Lock Braking System

If a malfunction in the ABS is displayed by the ASR/ESP Indicator
Lamp - K155- , then the Tire Pressure Monitoring Display Indica‐
tor Lamp - K220- will also illuminate. A malfunction in the tire
pressure monitoring system has not been stored.
The indicator lamp cannot be turned off. In this case, perform the
following:
– Connect Vehicle Diagnostic Tester and select “Guided Fault
Finding” on the Vehicle Diagnostic Tester .
Follow the instructions on the screen to perform the basic setting.
Basic Setting with the Infotainment System, Performing
– Turn on the ignition.
– Switch on the Infotainment system.
– Press the Infotainment button CAR .
– Press Setup .
– Press Tires .
– Press Set .
– Press Confirm .
AG. Volkswagen AG d
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es, in part or in w
t to the co
rrectness of i
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nform
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tion in
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Cop py
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295
cop Vo
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Prote
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AG.
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3 Vehicle Alignment agen

AG. Volkswagen AG d
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⇒ “3.1 Axle Alignment Information”, page 296 d by gu
ara
rise nte
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⇒ “3.2 Test Prerequisites”, page 296 auth eo
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ss c
⇒ “3.3 Measurement Preparations”, page 297
ce
le
un
pt
an
d
⇒ “3.4 Axle Alignment Specified Values”, page 298
itte
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ab
⇒ “3.5 Axle Alignment Procedure”, page 302
pe
ility
ot
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⇒ “3.6 Evaluating Need for Axle Alignment”, page 304
h re
hole
spec
⇒ “3.7 Vehicle Data Label”, page 306
es, in part or in w
t to the co
⇒ “3.8 Front Axle Camber, Adjusting”, page 306
⇒ “3.9 Rear Axle Camber, Adjusting”, page 307
rrectness of i
⇒ “3.10 Rear Axle Toe, Adjusting”, page 308
l purpos
⇒ “3.11 Front Axle Toe, Adjusting”, page 309

⇒ “3.12 Wheel Run-Out Compensation”, page 309
nform
ercia
⇒ “3.13 Maximum Steering Angle, Checking”, page 310

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3.1 Axle Alignment Information
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Wheel alignment must only performed using VW/Audi-approved
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wheel alignment equipment.
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Wheel alignment checks must always include both the front and
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rear axles.
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– Perform the alignment using the wheel alignment computer. cop Vo
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The wheel alignment computer has all the information for the ve‐
hicle alignment.
Note
♦ An alignment should not be done until the vehicle has been

driven 1,000 to 2,000 km (621 to 1242 miles), since it takes
this long for the coil springs to settle.
♦ The individual specifications should be followed as exactly as
possible when making adjustments.
♦ If adjustments were performed on the suspension, check if the
driver assistance systems must be calibrated.
Vehicles pulling to one side and vehicles involved in an accident

The cause for this could be that steering rack in steering gear
does not stand exactly in the center when steering straight ahead.
The steering support may pull slightly to the left or to the right.
The result is a vehicle which pulls to the side.
If a vehicle is aligned due to a complaint “vehicle pulls to one side
or pulls askew”, center position of steering rack must always be
checked.
3.2 Test Prerequisites

• Check suspension, wheel bearing and steering for excessive
play and damage.
• Tread depth difference may be no more than 2 mm on an axle.
• Tires inflated to prescribed pressure

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• Vehicle curb weight
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• Fuel tank must be full.
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• Spare tire and vehicle tools are installed in appropriate posi‐
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tion in vehicle.
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spec
• The windshield washer fluid reservoir must be full.
es, in part or in w
t to the co
• Make sure that the sliding plates and turn tables are not touch‐
ing the end stop when checking the wheel alignment.
rrectness of i
Note
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The test equipment must be properly adjusted and attached to
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the vehicle; observe device manufacturer operating instructions.
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If necessary, contact the manufacturer of the alignment equip‐

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ment for familiarization with the proper use of the equipment.
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The vehicle alignment platforms and wheel alignment computer
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can lose their calibration over a period of time.
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Wheel alignment platforms and wheel alignment computers Cop py
should be serviced and calibrated at least once a year. ht. rig
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– Handle highly sensitive units with care.
by lksw
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3.3 Measurement Preparations

⇒ “3.3.1 Measurement Preparations, Axle Alignment without Driv‐
er Assistance Systems”, page 297
⇒ “3.3.2 Measurement Preparations, Axle Alignment with Driver
Assistance Systems”, page 298
3.3.1 Measurement Preparations, Axle Align‐

ment without Driver Assistance Systems
♦ Wheel Alignment Computer - VAG1813F- or VW/Audi ap‐
proved wheel alignment devices
♦ Brake Pedal Actuator - VAG1869/2- .
♦ Insert Tool - 18mm - T10179-
The lateral run-out of the wheel must be compensated for. Oth‐
erwise, measurement will result in false readings.
A correct toe-in adjustment will not be possible without performing
lateral run-out compensation!
Follow the operating instructions provided by the manufacturer of
the alignment equipment.
– Carry out wheel run-out compensation.
– Install the Brake Pedal Actuator - VAG1869/2- .
– Actuate the brake pedal using brake pedal actuator.
3. Vehicle Alignment 297

Preparation Work for Calibrating Driver Assistance Systems
3.3.2 Measurement Preparations, Axle Align‐

ment with Driver Assistance Systems
Perform the following steps using “quick access” if one or more
driver assistance systems on the vehicle will be calibrated (with‐
out a previous axle alignment):
• Before driving the vehicle onto the alignment stand, make sure
there is enough space between the vehicle and the calibrating
device. The distance between the calibrating device and the
vehicle: 120 cm ± 2.5 cm (47.2 ± 0.98 inches).
• If there is not enough space, back the vehicle onto the vehicle
alignment platform so that there will be enough space. agen
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• Check the Diagnostic Trouble Code (DTC) memory and ed cor‐
by ara
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rect any malfunctions before beginning the calibration.
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• Vehicle accurately aligned, suspension bouncedss and rocked c
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several times
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• Make sure that the sliding plate and turntable are not touching
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the end stop during the measurement.
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• Connect the battery charger. Refer to ⇒ Electrical Equipment
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General Information; Rep. Gr. 27 ; Battery, Charging .
hole
spec
• Position the front wheels so they are straight.
es, in part or in w
t to the co
• Connect Vehicle Diagnostic Tester to the vehicle and guide
the diagnostic cable through the open window.
rrectness of i
• The vehicle exterior lamps are off.
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• All the vehicle doors are closed.

• Using the screen, turn on the calibration on the wheel align‐
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ment computer.
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3.4 Axle Alignment Specified Values
om
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thi
⇒ “3.4.1 Axle Alignment Specified Values, Torsion Beam Axle,
te
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Golf”, page 298

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⇒ “3.4.2 Axle Alignment Specified Values, Torsion Beam Axle,

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Co
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⇒ “3.4.3 Axle Alignment Specified Values, Multi-Link Suspension,
rig ht
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Golf”, page 300 by c lksw
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⇒ “3.4.4 Axle Alignment Specified Values, Multi-Link Suspension,
3.4.1 Axle Alignment Specified Values, Torsion Beam Axle, Golf

Specified values valid for all engine versions.
PR number explanations. Refer to
⇒ “3.7 Vehicle Data Label”, page 306 .
Front Axle Basic Suspen‐ Sport Suspension Raised Suspen‐ DCC Suspension
sion sion
PR numbers G03, G01+0N4 G04, G01+0N4 G10, G01+0N4 G04, G03+2UH
+2UA, +2UA +2UF,
G12, G07+0N4 G14, G07+0N4
+2UA +2UF
Total toe (wheels not pressed) 10′ ± 10′ 10′ ± 10′ 10′ ± 10′ 10′ ± 10′
Camber (wheels in straight- -30′ ± 30′ -41′ ± 30′ -16′ ± 30′ -36′ ± 30′
ahead position). Refer to 1).

Front Axle Basic Suspen‐ Sport Suspension Raised Suspen‐ DCC Suspension
sion sion
+2UA, +2UA +2UF,
G12, G07+0N4 G14, G07+0N4
+2UA +2UF
Maximum permissible differ‐ maximum 30' maximum 30' maximum 30' maximum 30'
ence between both sides
Toe differential angle at 20° 1° 19′ ± 20′ 1° 30′ ± 20′ 1° 09′ ± 20′ 1° 26′ ± 20′
steering angle. Refer to 2).
Caster 7° 23′ ± 30′ 7° 38′ ± 30′ 7° 09′ ± 30′ 7° 33′ ± 30′
olkswagen AG
en AG. V
Maximum permissible differ‐ maximum 30' olks
wag maximum 30' doemaximum
s no 30' maximum 30'
ence between both sides db
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Standing height 383 ut
ho± 10 mm 368 ± 10 mm 398 ± 10 mm eo
ra
373 ± 10 mm
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1) Camber corrections are not possible. It can only be slightly corrected by push‐
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ing the subframe.
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2) The toe angle difference can also be indicated negatively in alignment com‐
ot
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puter, depending on manufacturer.
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Rear Axle Basic Suspen‐ Sport Suspension Raised Suspen‐ DCC Suspension
spec
es, in part or in w
sion sion
t to the co
Camber -1° ± 10′ -1° ± 10′ -1° ± 10′ -1° ± 10′
rrectness of i
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Total toe (at specified camber) 20′ ± 12′ 24′ ± 12′ 16′ ± 12′ 23′ ± 12′
Maximum permissible devia‐ maximum 20′ maximum 20′ maximum 20′ maximum 20′
tion from direction of rotation
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ercia
Standing height 385 ± 10 mm 370 ± 10 mm 400 ± 10 mm 375 ± 10 mm

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3.4.2 Axle Alignment Specified Values, Torsion Beam Axle, Golf Wagon
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⇒ “3.7 Vehicle Data Label”, page 306 . cop Vo
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Front Axle Basic Suspen‐ Sport Suspen‐ Raised Suspen‐ DCC Suspension
sion sion sion
+2UA, +2UA +2UF,
G12, G07+0N4 G14, G07+0N4
+2UA +2UF
Total toe (wheels not pressed) 10′ ± 10′ 10′ ± 10′ 10′ ± 10′ 10′ ± 1 0′
Caster 7° 23′ ± 30′ 7° 38′ ± 30′ 7° 09′ ± 30′ 7° 33′ ± 30′
3) Camber corrections are not possible. It can only be slightly corrected by pushing the subframe.

4) The toe angle difference can also be indicated negatively in alignment computer, depending on manufacturer.
Rear Axle Basic Suspen‐ Sport Suspen‐ Raised Suspen‐ DCC Suspension
sion sion sion
Camber -1° ± 10′ -1° ± 10′ lkswage± 10′
-1° -1° ±es10′
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Maximum permissible differ‐ maximum 30' maximum 30' ris
ed maximum 30' maximum 30' rante
ence between both sides utho eo
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Total toe (at specified camber) 20′ ± 12′ 24′ ± 12′
s 26′ ± 12′ 23′ ± 12′
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Maximum permissible devia‐ maximum 20′ maximum 20′ maximum 20′ maximum 20′
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3.4.3 Axle Alignment Specified Values, Multi-Link Suspension, Golf
es, in part or in w
t to the co
rrectness of i
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+2UA +2UA +2UF,
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G15, G07+0N4 G17, G07+0N4
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+2UA +2UF
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Maximum permissible differ‐ maximum 30' maximum 30' gh
maximum 30' maximum 30'
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ence between both sides cop Vo
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Caster 7° 23′ ± 30′ 7° 38′ ± 30′ 7° 09′ ± 30′ 7° 33′ ± 30′

Front Axle GTI GTI Heavy Duty
PR numbers G05, G06+2UC G06, G06+2UN
G09, G06+2UJ
Total toe (wheels not pressed) 10′ ± 10′ 10′ ± 10′
Camber (wheels in straight- -41′ ± 30′ -30′ ± 30′
Maximum permissible differ‐ maximum 30' maximum 30'
Toe differential angle at 20° 1° 30′ ± 20′ 1° 19′ ± 20′
Caster 7° 38′ ± 30′ 7° 23′ ± 30′

Front Axle GTI GTI Heavy Duty

PR numbers G05, G06+2UC G06, G06+2UN
G09, G06+2UJ
Standing height 368 ± 10 mm 383 ± 10 mm
ing the subframe.
sion sion sion
Camber -1° 20′ ± 30′ -1° 20′ ± 30′ -1° 20′ ± 30′ -1° 20′ ± 30′
Maximum permissible differ‐ genmaximum
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gen maximum
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ence between both sidesVolkswa es n
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Total toe (at specified db
ise camber) 10′ ± 10′ 10′ ± 10′ 10′ ± 10′ 10′ ± 10′
ran
or tee
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Maximum permissible
s au devia‐ maximum 20′ maximum 20′r ac maximum 20′ maximum 20′
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Rear Axle GTI GTI Heavy Duty
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spec
Camber -1° 45′ ± 30′ -1° 20′ ± 30′
es, in part or in w
t to the co
Total toe (at specified camber) 16′ ± 10′ 10′ ± 10′
rrectness of i
Maximum permissible devia‐ maximum 20′ maximum 20′

l purpos

Standing height 370 ± 10 mm 385 ± 10 mm
nform
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3.4.4 Axle Alignment Specified Values, Multi-Link Suspension, Golf Wagon

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+2UA, +2UA +2UF,
G15, G07+0N4 G17, G07+0N4
+2UA +2UF
Caster 7° 23′ ± 30′ 7° 38′ ± 30′ 7° 09′ ± 30′ 7° 33′ ± 30′

ing the subframe.
sion sion sion
Camber -1° 20′ ± 30′ -1° 20′ ± 30′ -1° 20′ ± 30′ -1° 20′ ± 30′
AG. Volkswagen AG d
Maximum permissible differ‐ maximum 30' maximum
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maximum 30'
ence between both sides yV
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Total toe (at specified camber) 10′ ± 10′ ho
ris 10′ ± 10′ 10′ ± 10′ tee 10′ ± 10′
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Maximum permissible devia‐ maximum
ss 20′ maximum 20′ maximum 20′ maximum 20′
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3.5 Axle Alignment Procedure
hole
spec
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Observe the following work sequence!
t to the co
Note
rrectness of i
Vehicle may only be measured in the curb weight position.
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– Note the information in the alignment equipment.
nform
ercia
Measuring Procedure
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Start → Perform wheel run-out com‐ → Bounce vehicle
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pensation.
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↓
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Turn the steering wheel in‐ ← Measure vehicle height ←
op
Install the Brake Pedal Actuator -
C py
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to the straight ahead posi‐ gh
VAG1869/2- .
ht
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tion and secure it. Refer to
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↓
Check camber at front axle → Is actual value within toler‐ → No
ance?
↓ ↓
↓ ← ← Yes Adjust. Refer to
⇒ “3.8 Front Axle Camber, Adjust‐
ing”, page 306 .
↓ ↓
↓ ← ← ← ← ←
↓
Check rear axle camber → Is actual value within toler‐ → No
ance?
↓ ↓

↓ ← ← Yes Check (torsion beam axle). Refer

to
⇒ “3.9.1 Rear Axle Camber, Ad‐
justing, Torsion Beam Axle”, page
307 .
Adjust (multi-link suspension). Re‐
fer to
⇒ “3.9.2 Rear Axle Camber, Ad‐
justing, Multi-Link Suspension”,
page 307 .
↓ ↓
↓ ← ← ← ← ←
↓
Check toe at rear axle → Is actual value within toler‐ → No
ance? gen AG. Volkswagen AG d
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↓ ← ← ris Yes Check (torsion beam
nte
axle). Refer
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s ⇒ “3.10.1 Rear Axle Toe, Adjust‐
ce
e
ing, Torsion Beam Axle”,

nl
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page 308 .
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Adjust (multi-link suspension). Re‐
erm
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fer to
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⇒ “3.10.2 Rear Axle Toe, Adjust‐
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ing, Multi-Link Suspension”,
hole
page 308 .
spec
es, in part or in w
↓ ↓
t to the co
↓ ← ← ← ← ←
↓
rrectness of i
Check caster at front axle → Is actual value within toler‐ → No
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ance?
↓ ↓
nform
ercia
↓ ← ← Yes Check the axle components and

assembly
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↓ ↓ n
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↓ ← ← ← ← ←
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Check toe at front axle → →

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Is actual value within toler‐ No

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ance? t. Cop py
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↓ ↓
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agen
⇒ “3.11 Front Axle Toe, Adjusting”,
page 309 .
↑ ↓
↑ ← ← ← ← ←
9) If the steering wheel is crooked, it must be straightened at the end of the axle alignment. Then perform a basic setting on the Steering
Angle Sensor - G85- using the Vehicle Diagnostic Tester

Note
♦ If adjustments were made to the suspension during the axle

alignment on vehicles with ESP or ABS, a calibration of the
Steering Angle Sensor - G85- must be performed using the
Vehicle Diagnostic Tester .
♦ If the rear axle setting was changed, the following driver as‐
sistance systems must be calibrated:
♦ Lane assist. Refer to
page 327 , AG. Volkswagen AG d
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♦ Adaptive Cruise Control (ACC). Refer to by ara
d
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⇒ “5.1.1 Adaptive Cruise Control (ACC), Calibrating”,thor eo
page 321 . ss au ra
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3.6 Evaluating Need for Axle Alignment
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⇒ “3.6.1 Evaluating Need for Axle Alignment, Torsion Beam Axle”,
pe
ility
ot
page 304
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⇒ “3.6.2 Evaluating Need for Axle Alignment, Multi-Link Suspen‐
hole
spec
sion”, page 305
es, in part or in w
t to the co
3.6.1 Evaluating Need for Axle Alignment,
Torsion Beam Axle
rrectness of i
When Vehicle Alignment is Necessary
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♦ Vehicle shows handling problems.
nform
ercia
♦ There is an accident damage and components were replaced.

m
♦ Axle components have been removed or replaced.
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♦ Tire wear patterns are uneven.
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Components Replaced
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Front Axle Component Re‐ Wheel Alignment Rear Axle Component Re‐ Wheel Alignment
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placed Check Required placed Check Required
Co
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Yes No Yes No
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Lower Control Arm X Shock Absorber cted X
agen
Prote AG.
Bonded rubber bushings X Coil Spring X
for control arm
Wheel bearing housing X Axle Beam X
Tie rod/tie rod end X
Steering Gear X
Subframe X
Suspension Strut X
Stabilizer Bar X 10))
10) Requirement: Subframe and brackets were secured before removal.
Components Removed and Installed

Components Of Front Axle Wheel Alignment Components Of Rear Axle Wheel Alignment
Removed And Installed Check Required Removed And Installed Check Required
Yes No Yes No
Lower Control Arm X 11)) Shock Absorber X
Wheel bearing housing X Coil Spring X

Yes No Yes No
Tie rod/tie rod end X Axle Beam X
Steering Gear X
Subframe X 11))
Suspension Strut X
Stabilizer Bar X 11))
3.6.2 Evaluating Need for Axle Alignment,

Multi-Link Suspension
When Vehicle Alignment is Necessary
♦ Vehicle shows handling problems.
♦ There is an accident damage and components were replaced.
♦ Axle components have been removed or replaced.
♦ Tire wear patterns are uneven.
Components Replaced agen
AG. Volkswagen AG d
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Front Axle Component Re‐ Wheel Alignment
ised b Rear Axle Component Re‐
ara
nte Wheel Alignment
placed Check thor
Required placed e o Check Required
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Yes
ss No Yes
c
No
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Lower Control Arm X Lower transverse link X
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Bonded rubber bushings X Upper Transverse Link X
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Wheel bearing housing X Tie rod X

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Tie rod/tie rod end X Wheel bearing housing X

spec
es, in part or in w
Steering Gear X Subframe X t to the co
Subframe X Coil Spring X

Suspension Strut X Shock Absorber X
rrectness of i
Stabilizer Bar X 12)) Stabilizer Bar X

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Trailing Arm X
nform
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Components Removed and Installed

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Yes No Yes No
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Lower Control Arm X 13))gh
Lower transverse link X
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Wheel bearing housing X Upper Transverse Link X
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Tie rod/tie rod end X Tie rod X
Steering Gear X Wheel bearing housing X
Subframe X 13)) Subframe X
Suspension Strut X Coil Spring X
Stabilizer Bar X 13)) Shock Absorber X
Stabilizer Bar X

Yes No Yes No
Trailing Arm X
3.7 Vehicle Data Label

Explanation of “PR numbers” on the Vehicle Data Label
Depending on engine and equipment, various suspensions are
installed. They are identified by the PR numbers.
The PR numbers are needed for the allocation of vehicle specified
values.
Suspension version installed in vehicle is indicated on vehicle
data plate by corresponding PR number for the front axle.
There is a vehicle data label in the spare wheel well and also one
in the customer Maintenance booklet.
Sample Vehicle Data Label AG. Volkswagen AG d
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In this example, the vehicle is equipped with the sport chassis by
Vol not
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G03 -arrow-. rised ara
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3.8 Front Axle Camber, Adjusting
rrectness of i
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Note
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atio
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♦ Correct the camber according to Body Collision only. Camber

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corrections are not possible. The camber is not adjustable,

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e
however it can be rearranged by sliding the subframe!

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♦ Slide subframe only toward left or right, under no circumstan‐

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ces in or against direction of travel!

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– Remove the noise insulation. Refer to ⇒ Body Exterior; Rep. pyri by
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– Remove the bolt -1- and loosely install a new bolt.

– Remove the bolt -4- and loosely install a new bolt. agen
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Adjusting the camber is limited by the tolerances in the ed bysubframe ara
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bores. If the specification is not attained by sliding horthe
is
subframe, eo
then the camber and the assembly must be checked. aut ra
ss c
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le
– By moving the subframe, only the specified value of the cam‐
un
pt
ber can be adjusted.
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– Slide the subframe -5- to the side until the camber is even on
ility
both sides. Refer to ot p
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⇒ “3.4 Axle Alignment Specified Values”, page 298 .
h re
ole,
spec
– Tighten the subframe bolts -1, 2, 3, and 4-.
t to the co
After moving the subframe, check the clearance between the
steering column universal joint and the cutout in the plenum
chamber bulkhead.
rrectne
– Remove the bolt -1- and fold the footwell trim panel -2- in the
s
s o
cial p
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mer
atio
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There must be at least 5 mm of free space all around between Cop py
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universal joint -1- and cutout of bulkhead -2-. opyri
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Prote AG.
3.9 Rear Axle Camber, Adjusting

⇒ “3.9.1 Rear Axle Camber, Adjusting, Torsion Beam Axle”, page
307
⇒ “3.9.2 Rear Axle Camber, Adjusting, Multi-Link Suspension”,
page 307
3.9.1 Rear Axle Camber, Adjusting, Torsion

Beam Axle
Camber cannot be adjusted.
If measured values are not within the specified range, check the
axle beam for damage and replace if necessary.
3.9.2 Rear Axle Camber, Adjusting, Multi-Link

Suspension


– Loosen nut -A- of threaded connection of upper transverse link
at subframe.
– Adjust camber by turning hex of eccentric bolt -arrow-.
Note
olksw
The maximum adjustment range is 90° to leftswor
ageright of center
n AG. V agen AG
does
position. by Volk not
gu
a
ed ran
oris tee
th or
au ac
ss
ce
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un
pt
an
d
itte
– Tighten the nut -A-.
y li
rm
ab
pe
ility
ot
wit
, is n
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hole
spec
es, in part or in w
t to the co
rrectness of i
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nform
ercia
– Use the Insert Tool - 18mm - T10179- for this.

m
a
com
Tighten the nut to 80 Nm using the Insert Tool - 18mm - T10179- . tion in
r
te o
thi
– Check the camber value again after tightening the nut -A-.
s
iva
do
r
rp
– After the nut -A- is tightened, check the camber value once
um
fo
more. Refer to
en
ng
t.
yi Co
⇒ “3.4 Axle Alignment Specified Values”, page 298 . t. Cop py
rig
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Tightening Specifications pyri by
Vo
co lksw
by
cted agen
♦ Refer to ⇒ “5.1 Overview - Transverse Link”, page 181 Prote AG.
3.10 Rear Axle Toe, Adjusting

⇒ “3.10.1 Rear Axle Toe, Adjusting, Torsion Beam Axle”,
page 308
⇒ “3.10.2 Rear Axle Toe, Adjusting, Multi-Link Suspension”, page
308
3.10.1 Rear Axle Toe, Adjusting, Torsion Beam

Axle
The toe cannot be adjusted.
If measured values are not within the specified range, check the
axle beam for damage and replace if necessary.
3.10.2 Rear Axle Toe, Adjusting, Multi-Link

Suspension


– Loosen nut -1-.
– Turn the eccentric bolt -2- until the specified value is reached.
Note
The maximum adjustment range is 90° to left or right of center

position.

– After the nut -A- is tightened, check the toe value once more.
Refer to ⇒ “3.4 Axle Alignment
en AG. V
olSpecified
kswagen AG Values”, page 298 .
ag does
lksw not
by
Vo gu
ara
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ise nte
♦ Refer tout⇒
ho “5.1 Overview - Transverse
r
Link”, page 181 eo
a ra
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un
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3.11 Front Axle Toe, Adjusting
wit
is n
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ole,
spec

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♦ Torque Wrench 1332 Insert - Open Ring Wrench - 24mm -
VAG1332/9-
rrectne
– To loosen or tighten the lock nut -2-, counterhold at the tie rod
end -1- with a suitable tool.
ss o
– Loosen the lock nut -2-.

cial p
f inform
– Adjust toe on left and right–hand wheels at hex -arrow-.

mer
atio
om
n
c
i
or
Note
thi
te
sd
iva
o
pr
♦ Make sure that boot on steering gear is not damaged or twis‐

um
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fo
en
ted. Twisted boots wear out quickly.

ng
t.
yi Co
op py
♦ Only tighten the lock nuts when the vehicle is resting on the
t. C rig
gh ht
ground - the tie rod end must be parallel to the suspension
pyri by
Vo
co
strut steering lever.
by lksw
cted agen
Prote AG.
– Tighten the lock nut -2- and check the toe-in value again.
After tightening the lock nut -2-, it is possible that the value devi‐
ates slightly.
If the measured toe nevertheless lies within the tolerance, the
adjustment is correct. Refer to
⇒ “3.4 Axle Alignment Specified Values”, page 298 .
♦ Refer to ⇒ “3.6 Steering Gear, Servicing”, page 363
3.12 Wheel Run-Out Compensation

A correct toe-in adjustment will not be possible without performing
lateral run-out compensation!
The lateral run–out of the wheel must be compensated for. Oth‐
erwise, measurement will result in false readings.

Permissible axial run-out of the wheel rims can exceed the speci‐
fied toe setting tolerance. If compensation for wheel run-out is not
performed, it will not be possible to obtain a correct toe-in adjust‐
ment.
Follow the operating instructions provided by the manufacturer of
the alignment equipment.
3.13 Maximum Steering Angle, Checking

The wheel alignment computer determines the maximum steering
angle.
– If the value for the maximum steering angle is outside of the
tolerance, then observe the following parameters:
. Volkswagen AG
a gen AG d
♦ Is there damage to or distortion
Vol of steering- and suspension
ksw
oes
not
gu
components? ed by ara
n is tee
or
♦ Are the tie rods visually
au
th OK? or
ac
ss
♦ Is the tie rod symmetry correct?
ce
e
nl
pt
du
an
Damaged components are to be replaced.
itte
y li
erm
ab
– If the steering wheel is crooked, then observe the following
ility
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parameters:
wit
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♦ Check the steering components for damage and distortion. If
hole
spec
necessary, the damaged parts are to be replaced.
es, in part or in w
t to the co
♦ Check the suspension components for damage and distortion.
If necessary, the damaged parts are to be replaced.
rrectness of i
♦ Check the tie rod symmetry as well.
l purpos
– Measure the dimension -a- on the “shorter” tie rod end. Short‐
en the “longer” tie rod end to the same dimension. To do this,
install the tie rod end -1- deeper on the tie rod -2-.
nform
ercia
The dimension -a- must be the same on the right and left tie rod
m
at
end.
om
ion
c
in t
r
The maximum permitted difference between the right and left

o
his
te
must be < 2.5 mm.

a
do
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cum
or
– When the steering wheel returns to its center position, let the
f
en
g
steering wheel “come to its center” using even movements.

n
t.
yi Co
Cop py
t. rig
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pyri by
Vo
o
by c lksw
cted agen
Prote AG.

4 Wheel/Tire Vibration, Causes and

Solution
⇒ “4.1 Vibration Causes”, page 311
⇒ “4.2 Road Test, Performing Before Balancing”, page 311 .
⇒ “4.3 Wheel, Balancing”, page 312
⇒ “4.4 Vibration Control System”, page 316
⇒ “4.5 Tire and Wheel Radial and Lateral Run-Out, Checking”,
page 316
⇒ “4.6 Rim Radial and Lateral Run-Out, Checking”, page V317
olkswa AG. gen AG
agen does
⇒ “4.7 Wheels and Tires, Matching”, page 318
Vol
ksw not
gu
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ed
⇒ “4.8 Flat Spots in Tires From Standing,
ho
ris Determining”, nte
eo
page 319 aut ra
c
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4.1 Vibration Causes
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There are many causes for vibration. Vibration can also be
erm
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caused by tire wear, among other things. Tire wear caused by
ility
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driving does not always develop evenly over the entire tread. Due
wit
is n
to this, a slight imbalance develops which disturbs the smooth‐
h re
ole,
ness of the formerly accurately balanced wheel.
spec
This slight imbalance cannot yet be felt in the steering wheel, but
t to the co
it is present. It increases the tire wear and consequently reduces
the service life of the tire.
rrectne
Recommendation
In order to guarantee over the entire service life of a tire a
ss o
cial p
• Optimal safety,
f inform
mer
• Optimal smoothness and
atio
m
• Uniform wear
o
n
c
i
or
n thi
e
It is recommended that wheels/tires be balanced at least two

t
sd
va
times within the tire's service life.

i
o
pr
cum
r
fo
en
4.2 Road Test, Performing Before Balanc‐

ng
t.
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op
ing
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pyri by
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If a vehicle comes to the shop with the complaint “vibration”, a
c by lksw
cted agen
road test must be performed before balancing the wheels.
Prote AG.
♦ That way, information about the type of vibration can be ob‐

tained.
♦ Observe at which speed range the disturbance takes place.
– Raise the vehicle on the platform immediately after the road
test.
– Mark the component location on the tire.
Component Location of Tire Identification with ...
Left front tire LF
Right front tire RF
Left rear tire LR
Right rear tire RR
– Remove the wheels from the vehicle.
– Balance the wheels.
4. Wheel/Tire Vibration, Causes and Solution 311

4.3 Wheel, Balancing

⇒ “4.3.1 Wheel, Balancing”, page 312
⇒ “4.3.2 Wheel, Balancing on Stationary Balancing Machine”,
page 312
⇒ “4.3.3 Wheel, Balancing with Finish Balancer”, page 315
4.3.1 Wheel, Balancing

Before beginning balancing, the following requirements must be
fulfilled.
• The tire pressure must be OK.
• The tire tread must not be worn down on one side and should
be at least 4 mm deep.
• The tires must not have any damage such as cuts, holes, for‐
eign bodies, etc.
• The suspension and steering, including the shock absorber,
must be in perfect condition.
• A road test has been performed.
4.3.2 Wheel, Balancing on Stationary Balanc‐

ing Machine
• Test drive performed. Refer to
⇒ “4.2 Road Test, Performing Before Balancing”, page 311 .
Tension Wheel on Balancing Machine
Note lkswage es n
o ot g
byV ua
d ran
ir se
Please keep in mind that cleanliness is the most th important when
o tee
or
balancing as well, just as for any other repairs
ss
au
you perform. Only ac
then can a proper result be obtained!
ce
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nl
pt
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an
itte
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Dirt and rust in the area of the contact surfaces and centering of
erm
ab
the wheel distorts the result.

ility
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wit
– Clean contact surfaces, centering seat and wheel disc using

, is n
h re
the Pneumatic Brush Grinder Set - VAS6446- before tension‐

hole
spec
ing wheel on balancing machine. Refer to Workshop Equip‐

es, in part or in w
ment, Catalog.
t to the co
Note
rrectness of i
l purpos
It is very important that the wheel balancing machine uses the

correct system for centering and tensioning the tires. Reference
the information for the Wheel Balancing Machine Centering Sys‐
nform
ercia
tem before beginning any work. Refer to Workshop Equipment,

Catalog.
m
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
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Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

lkswage es n
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o
Golf
ot g
ua 2015 ➤ , Golf Variant 2015 ➤
ran
ho
ir se Suspension, Wheels, teeSteering - Edition 03.2016
ut or
a ac
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– Tension the wheel with the tire on the balancing machine.
ce
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nl
pt
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an
itte
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erm
ab
ility
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wit
, is n
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hole
spec
es, in part or in w
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rrectness of i
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nform
mercia
at
om
ion
c
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or
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ate
do
priv
cum
for
en
ng
t.
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Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

Note
♦ To mount wheel on wheel balancer, use for example Wheel

Centering System Adapter - VAS5271- .
♦ This way a 100% centering of the wheel and gentle mounting
is possible!
♦ It is not possible to center it 100% on balancing machine with
conical tensioners.
♦ With a deviation of 0.1 mm outside the center, there is an im‐
balance of 10 grams on the wheel/tire.
Wheel/Tire Balancing Procedure

– Let the wheel/tire turn on the balancing machine.
– Check the run of the characteristic lines on the sidewall of the
tire in the area of the rim flange. en AG. V
olkswagen AG
ag does
lksw not
– Check the tire wear pattern while the
by wheel/tire is turning.
Vo gu
ara
ed nte
ris
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au ra
Note ss c
ce
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nl
pt
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an
In the event of one-sided wear, flat spots from braking or severe
itte
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wear spots, smooth running cannot be achieved by balancing. In
erm
ab
this case, the tire must be replaced.
ility
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wit
, is n
h re
– Check the run-out on the wheel/tire. If the wheel with tire runs
hole
spec
untrue although there are no flat spots, a radial or lateral run-
es, in part or in w
out may be the cause.
t to the co
– Check wheel with tire for radial- and lateral run-out. Refer to
⇒ “4.5.2 Wheels and Tires, Radial and Lateral Run Out, rrectness of i
Checking with Tire Dial Gauge”, page 317 .
l purpos
– If the radial and lateral run-out are within the specified toler‐
ance, balance the wheel and tire.
nf
ercia
orm
m
Note
atio
om
n in
or c
♦ Do not use more than 60 grams of weight per wheel.

thi
te
sd
iva
♦ If more weight is necessary, a smoother running can achieved

o
r
rp
cu
by matched mounting of the tire. Tires matching. Refer to

o
m
f
en
ng
⇒ “4.7 Wheels and Tires, Matching”, page 318 .

t.
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Cop py
. rig
♦ The display in the balancing machine should show 0 grams.
t
gh ht
pyri by
Vo
co
♦ Hunter RFT33VAG Road Force Touch™ Wheel Balancer -
by lksw
cted agen
Prote
VAS6230B4- can be inserted as an alternative to matching.
AG.
Refer to ⇒ “4.4 Vibration Control System”, page 316 .
– Install the wheel on the vehicle.

– First, tighten the lowest wheel bolt hand-tight to approximately
30 Nm.
– Tighten the remaining wheel bolts diagonally to approximately
30 Nm. This process centers the wheel on the wheel hub.
– Lower vehicle onto its wheels.
– Now use a torque wrench to tighten the wheel bolts diagonally
to the specified tightening specification.

Road Test, Performing

– Perform a road test after balancing the wheel/tires.
If a vibration is still detected during the road test, the cause may
be due to tolerance in the wheel centering.
The component tolerances of wheels and wheel hubs can be ad‐
ditive in unfavorable cases. Vibration can result from this. This
can be eliminated using a finish balancer. Refer to
⇒ “4.3.3 Wheel, Balancing with Finish Balancer”, page 315 .
4.3.3 Wheel, Balancing with Finish Balancer
Note
♦ Working with a Finish Balancer requires instruction from the

manufacturer of the balancer.
♦ When balancing, place the wheels of the driven axle on the
turntable sensors. On a FWD vehicle, the front wheels must
be on the sensors. On AWD vehicles, all four wheels must be
on the sensors.
If it is determined when balancing on the vehicle the remaining

imbalance is more than 20 grams, the wheel should be rotated on
the wheel hub.
– Mark the point at which the imbalance is indicated.
– Afterwards, unbolt the wheel andagrotate its
n AG. V olkposition
swagen AGon the
w e does
wheel hub so that the marking
yV
o lkspoints downward. not
g b ua
ed ran
oris tee
th or
Note au ac
ss
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nl
pt
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The wheel hub must not turn during this procedure.

an
itte
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erm
ab
ility
– First, tighten the lowest wheel bolt hand-tight to approximately

ot p
30 Nm.
wit
, is n
h re
hole
– Tighten the remaining wheel bolts diagonally to approximately

spec
30 Nm. This process centers the wheel properly on the wheel

es, in part or in w
hub.
t to the co
– Check again whether the imbalance is less than 20 grams us‐

ing the finish balancer.
rrectness of i
l purpos
Note
nf
ercia
The imbalance should not be smaller than 20 grams under any

orm
circumstances before changing balance weight.

m
atio
om
n in
or c
– Loosen the wheel bolts again, if necessary.

thi
te
sd
iva
– Rotate the wheel relative to the wheel hub once more by one
o
r
rp
cu
o
or two wheel bolt holes.

m
f
en
ng
t.
yi Co
– Tighten the wheels according to the method described above. Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted
Note
agen
Prote AG.
Only if the imbalance is less than 20 grams should the imbalance

be reduced by changing the balance weight.

– Balance the wheels until the imbalance is below 5 grams.

– Tighten the wheel bolts to the specified tightening specification
if you have not already done so.
WARNING
Always tighten the wheel bolt to the tightening specification and

using the torque wrench.
4.4 Vibration Control System

Expanded functions can be performed using Hunter RFT33VAG
Road Force Touch™ Wheel Balancer - VAS6230B4- in addition
to the previously known balancers.
A special characteristic of this system is testing the radial force of
wheel/tire during rolling.
For this purpose, a roller presses a force of approximately 635 kg
(1400 lbs) against the wheel. This simulates the tire contact force
against the street surface while driving.
Tire contact forces fluctuate due to radial- and lateral run-out and
differing rigidity in the tires.
The Hunter RFT33VAG Road Force Touch™ Wheel Balancer - . Volkswage
VAS6230B4- detects and stores the position of the maximum agen
AG n AG d
oes
lksw not
measured radial force in the tires. After that, the position by Voof small‐ gu
ara
est dimension between rim flange and disc wheel rcenter ise
d
is meas‐ nte
ured. autho eo
ra
ss c
ce
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nl
pt
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itte
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erm
ab
ility
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4.5 Tire and Wheel Radial and Lateral Run-
wit
, is n
h re
Out, Checking
hole
spec
es, in part or in w
⇒ “4.5.1 Tire and Wheel Radial and Lateral Run-Out, Checking,

t to the co
Tolerances”, page 316
⇒ “4.5.2 Wheels and Tires, Radial and Lateral Run Out, Checking
rrectness of i
with Tire Dial Gauge”, page 317

l purpos
4.5.1 Tire and Wheel Radial and Lateral Run-

Out, Checking, Tolerances
nform
ercia
Radial and lateral run-out occur when the wheel and tire are not
m
at
running precisely true.

om
ion
c
in t
r
For technical reasons, 100% true running is not possible.

o
his
ate
do
riv
Therefore the manufacturers of these components allow a pre‐

p
cum
cisely specified tolerance.

for
en
ng
t.
yi Co
Mounting the tire in a unfavorable position on the wheel can be Cop py
the cause for exceeding the maximum allowed tolerance for
t. rig
gh ht
yri
wheel with tire.
p by
co Vo
by lksw
cted agen
The table shows the maximum permissible tolerance values for
Prote AG.
the wheel with mounted tire.

Tolerances for Radial and Lateral Run-Out of Rim with Tire
Rim with Tire Radial Run-Out (mm) Lateral Run-Out (mm)
Passenger vehicle 0.9 1.1
(1.3 near the lettering)

4.5.2 Wheels and Tires, Radial and Lateral

Run Out, Checking with Tire Dial Gauge
Checking Lateral Run-Out
AG. Volkswagen AG d
– Preload the Tire Dial Gauge approximately
lksw
agen 2 mm. oes
not
Vo gu
by
– Position the Tire Dial Gaugerison
ed the side wall of the tire. ara
nte
tho eo
– Rotate the wheel slowly.s au ra
c
s
ce
e
– Note the smallest and the largest dial readings.

nl
pt
du
an
itte
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erm
ab
Note
ility
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wit
, is n
h re
If the difference is greater than 1.3 mm, the lateral run-out is too
hole
great.
spec
es, in part or in w
t to the co
In this case, lateral run-out can be reduced by matched mounting
of the tire. Refer to
rrectness of i
Peak values on the Tire Dial Gauge due to small irregularities in
l purpos
the rubber may be disregarded.

Checking Radial Run-Out
nf
ercia
orm
– Preload the Tire Dial Gauge approximately 2 mm.
m
atio
om
n in
or c
– Position the Tire Dial Gauge on the tread of the tire.
thi
te
sd
iva
– Rotate the wheel slowly.

o
r
rp
cu
o
m
f
en
ng
– Note the smallest and the largest dial readings. yi

t.
Co
Cop py
t. rig
gh ht
yri by
Note
op Vo
by c lksw
cted agen
Prote AG.
If the difference is greater than 1 mm, the radial run-out is too
great.
In this case, radial run-out can be reduced by matched mounting

of the tire. Refer to
4.6 Rim Radial and Lateral Run-Out,

Checking
– Mount the rim on the Balancing Machine .
– Use the Wheel Centering System Adapter - VAS5271- .
– Preload the Tire Dial Gauge approximately 2 mm.
– Turn the rim slowly.

– Note the smallest and the largest dial readings.

S - Lateral Run-Out
H - Radial Run-Out
– Compare determined value with specifications in the table.
Refer to ⇒ page 318 .
Note wage
es n
olks ot g
byV ua
Peak values on the Tire Dial Gauge due to small irregularities may ir se
d ran
tee
be disregarded. autho
or
ac
ss
ce
e
nl
pt
du
Specified Values for Radial and Lateral Run-Out on the Rim
an
itte
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erm
ab
Rim Radial Run-Out (mm) Lateral Run-Out (mm)
ility
ot p
wit
Steel wheel 0.5 0.5
, is n
h re
hole
Light alloy wheel 0.5 0.8
spec
es, in part or in w
t to the co
Note
rrectness of i
If the measured value exceeds the specified value, no acceptable
smooth running can be attained.
l purpos
nform
ercia
4.7 Wheels and Tires, Matching

m
at
om
ion
c
in t
r
General Information
o
his
ate
do
riv
If radial or lateral run-out from rim or tire meet each other, the
p
cum
untrue running of the wheel and tire is increased.
for
en
ng
t.
yi Co
For technical reasons, 100% true running is not possible. Refer Cop py
to
t. rig
gh ht
yri
⇒ “4.5.1 Tire and Wheel Radial and Lateral Run-Out, Checking,
p by
co Vo
by lksw
Tolerances”, page 316 . Prote
cted AG.
agen
Drive the tires until they are warm before matching them to the
tires already on the vehicle. This eliminates flat spots from stand‐
ing which may exist. Refer to
⇒ “4.8 Flat Spots in Tires From Standing, Determining”,
page 319 .
Work Procedure for Match-Mounting
– Let the air out of the tire.
– Remove the tire bead from the wheel rim flange.
– Coat the tire bead all the way around with Tire Mounting
Paste .
– Turn the tire 180° against the rim.
– Inflate the tire to approximately 4 bar (58 psi).
– Tension the wheel with the tire on the balancing machine.
– Check the run-out or the radial and lateral run-out, as neces‐
sary.

Note
♦ If the radial and lateral run-out value is not exceeded, the

wheel can be balanced to 0 grams. Specifications. Refer to
⇒ page 316 .
♦ If the radial and lateral run-out lies outside the specified val‐
ues, the tire must be turned again.
– Let the air out and remove the tire beads from the wheel rim
flanges.
– Rotate the tire 90° (one quarter of a turn) relative to the rim.
– Inflate the tire to 4 bar (58 psi) again and check the run-out.
Note
♦ If the radial and lateral run-out value is not exceeded, the

wheel can be balanced to 0 grams.
♦ If the radial and lateral run-out is still outside the specified val‐
ues, the wheel must be turned again.
AG. Volkswagen AG d
agen oes
– Press the tire beads
yV
oloff
ksw the rim flanges. not
gu
e db ara
– Rotate the tire
horis 180° (half a turn) relative to the rim. nte
eo
aut ra
If the valuess for radial or lateral run-out are still outside the speci‐
s c
fied values, check the rim for radial and lateral run-out. Refer to
ce
e
nl
pt
du
⇒ “4.6 Rim Radial and Lateral Run-Out, Checking”, page 317 .

an
itte
y li
erm
ab
If the measured values for radial and lateral run-out of the rim are
ility
ot p
within the specified values, then the tire has excessive radial or
wit
lateral run-out. In this case, the tire must be replaced.

, is n
h re
hole
spec
es, in part or in w
Note
t to the co
♦ Assembly paste from mounting tires is located between tires

and rim flanges.
rrectness of i
♦ Avoid strong braking or acceleration maneuvers during the

l purpos
first 100 to 200 km. Otherwise, the tires can rotate on the rims
and the work done would then be undone!
nform
ercia
4.8 Flat Spots in Tires From Standing, De‐

m
at
om
ion
termining
c
in t
or
his
ate
What is a Flat Spot from Standing?

do
priv
cum
or
Terms like flat portion, flattening, are also used as a term for flat
f
en
ng
t.
yi
spots from standing.
Co
Cop py
t. rig
gh
Flat spots from standing cause vibration, like an incorrectly bal‐
ht
pyri by
Vo
anced wheel. It is important to recognize a flat spot in the tread
o
by c lksw
cted agen
from standing as such! Prote AG.
Flat spots from standing cannot be corrected by balancing, and

can occur again at any time under various circumstances. Flat
spots from standing can be corrected without complicated special
tools, providing that the flat spot was not caused by wheel lock
during hard braking. Refer to ⇒ Wheel and Tire Guide - General
Information; Rep. Gr. 44 ; Tires, Rolling Noises, Wear Spots .

Note
Wear spots due to wheel lock

wageare irreparable! Tires
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Causes of FlatauSpots
t from Standing or
ac
ss
♦ The vehicle stands for several weeks in a location without be‐
ce
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pt
ing moved.
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♦ Tire pressure is too low.
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♦ The vehicle was placed in a paint system drying cabinet after
wit
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painting.
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♦ The vehicle was parked with warm tires in a cold garage or
similar for a long time. In this case, a flat spot can develop
t to the co
overnight.
Flat Spots, Correcting
rrectne
♦ Flat spots cannot be removed from tires with shop equipment.
ss
♦ Such flat spots can be "driven out" only by driving the car until
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the tires are warm.
inform
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♦ We do not recommend the following method during cold or

atio
winter weather.
om
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Requirements/Conditions
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– Check the tire pressure and correct, if necessary.

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– If possible, drive the vehicle on an expressway.

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– If the traffic and road conditions permit, drive at a speed of 120
t. C rig
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to 150 km/h (75 to 93 mph) for a distance of 20 to 30 km (12.4 p by
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to 18.6 miles).
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WARNING
♦ Do not endanger yourself or other persons during this road

test.
♦ Follow all traffic regulations and speed limits when per‐
forming the road test.
– Lift the vehicle immediately after the performing the road test.
– Remove the wheels from the vehicle.
– Balance the wheels on the stationary balancing machine. Re‐
fer to
⇒ “4.3.2 Wheel, Balancing on Stationary Balancing Machine”,
page 312 .

5 Adaptive Cruise Control (ACC)

⇒ “5.1 Adaptive Cruise Control (ACC), Calibrating”, page 321
5.1 Adaptive Cruise Control (ACC), Cali‐

brating
⇒ “5.1.1 Adaptive Cruise Control (ACC), Calibrating”, page 321
AG. Volkswagen AG d
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5.1.1 Adaptive Cruise Control (ACC), Cali‐by Volksw oes
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♦ Setting Device Basic Set - VAS6430/1-
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♦ ACC Reflector Mirror - Audi - VAS6430/3-
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Note
♦ Before adjusting the ACC, check the sensor, its mounts, and
rrectness of i
securing elements for damage, external influences and secure
l purpos
fit. Repair any damaged components, if necessary.

♦ Prior to adjusting the adaptive cruise control (ACC), check the
nform
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event memory and correct any malfunctions.

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♦ The ACC control module “adjustment angle measured value”
om
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shows whether the sensor is misaligned.
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♦ The ACC adjustment may only be set using a VW/Audi-ap‐

at
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proved wheel alignment device and adjustment equipment!

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♦ A new adjustment is necessary if:

♦ The rear axle toe was adjusted.
♦ The Distance Regulation Control Module - J428- was removed
and installed.
♦ The front bumper carrier was removed and installed.
♦ The front bumper carrier was loosened or moved.
♦ The adjustment angle is greater than -0.8° to +0.8°.
♦ The vehicle was moved to the service position.
5. Adaptive Cruise Control (ACC) 321

Note
♦ Before driving the vehicle onto the alignment stand, make sure
there is enough space between the vehicle and the Setting
Device Basic Set - VAS6430/1- . The distance between the
ACC Reflector Mirror - Audi - VAS6430/3- and the sensor must
be 120 cm ± 2.5 cm (47.2 ± 0.98 inches).
♦ If there is not sufficient space, drive the vehicle backward onto
the alignment stand in order to use the corresponding space.
♦ If the ACC Reflector Mirror - Audi - VAS6430/3- is repositioned
on the calibration beam during the adjustment, the Setting
Device Basic Set - VAS6430/1- setting must always be
checked (for example bubble levels, individual toe settings at
the calibration beam, etc.).
• Before beginning the adjustment, check the Diagnostic Trou‐

ble Code (DTC) memory and correct any malfunctions
present.
The adjustment procedure is described here using the Setting
Device Basic Set - VAS6430/1- .
Follow the sequence for adjusting:
1- Establish a distance of 120 cm ± 2.5 cm between the cen‐
trally positioned ACC Reflector Mirror - Audi - VAS6430/3-
and the sensor in the air grille,
2- Attach the ACC Reflector Mirror - Audi - VAS6430/3- in the
center of the calibration beam,
3- Adjust the Distance Regulation Control Module - J428-
Do not perform the steps under “Calibration procedure without a
previous axle alignment” if an axle alignment has already been
performed.
Calibration Procedure without Previous Axle Alignment
agen
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– Select the ACC calibration button on thed balignment
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– Follow the test requirements for anuthaxle
o alignment. Refer to eo
ra
⇒ “3.2 Test Prerequisites”, pagess296
a
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– Drive the vehicle onto the vehicle alignment platform.

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– Connect the battery charger. Refer to ⇒ Electrical Equipment

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– Connect Vehicle Diagnostic Tester (Guide the diagnostic ca‐

h re
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ble through the open window.)

spec
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Note
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During the adjustment procedure, make sure all the vehicle doors
remain closed and the vehicle exterior lamps are switched off.
ss o
– Position the front wheels so they are straight.

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– Install the quick-action clamps on the rear wheels.

mer
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– Install the measurement sensor on the rear wheels.

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– Perform a wheel run-out compensation and the rear wheels.

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Rep. Gr.44 - Wheels, Tires and Vehicle Alignment
Calibration Procedure with or without Previous Axle Alignment

– Remove the trim -1-.
– Remove the trim -1-. AG. Volkswagen AG d
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– Remove any dirt that may be on the sensor d bylens.
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– Position the Setting Device Basic Set - VAS6430/1- at a dis‐
t to the co
tance -a- from the centrally positioned ACC Reflector Mirror -
Audi - VAS6430/3- in the center and parallel with respect to
the Distance Regulation Control Module - J428- .
rrectness of i
a - 120 cm ± 2.5 cm (47.2 ± 0.98 inches)
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Note
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The Setting Device Basic Set - VAS6430/1- must not be moved
com
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on the calibration beam.
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– Position the front wheel measuring sensors -1- on the calibra‐
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– In area -A-, bring item -2- on the rotary knob into alignment
with the marking on the mirror (number 2 on the rotary knob
must face the vehicle).

– Level the bubble levels -A and B- on the ACC Reflector Mirror

- Audi - VAS6430/3- using the adjusting screws -1, 2, and 3-.
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– Adjust the mirror -4- ksvia
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doesthat the laser
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– Position the mirror on the side of the calibration beam so that
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the laser beam is in the center of the sensor lens.

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– Level the bubble levels -2- of the measurement sensor -1-.

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– Turn the precision adjustment screw -5-orisuntil the display on
e
tee
the wheel alignment computer is located
au
th within the tolerance or
ac
range. ss
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– Level the bubble levels -2- of the measurement sensor -1-.
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– Using the laser beam -3- on the ACC Reflector Mirror - Audi -
p
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VAS6430/3- , check whether the bubble level is level and the
en
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laser beam is in the center of the sensor lens.
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Note
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If the laser beam does not meet the sensor lens, the ACC Re‐
flector Mirror - Audi - VAS6430/3- must be aligned again.
– On the Vehicle Diagnostic Tester , press GO TO and select the

function Function/Component Selection .
Selection on the Vehicle Diagnostic Tester for the adjustment of
the Distance Regulation Control Module - J428- :
– Press the following buttons one after another on the screen:
♦ Chassis (Repair Group 01; 40 - 49)
♦ 13 - Distance Control
♦ 01 - OBD-Capable System
♦ 13 - Distance Control
♦ 13 - Distance Control, Functions
♦ 13 - Calibrate
Follow the instructions on the screen to perform the adjustment.

Designation of the Distance Regulation Control Module - J428-

adjusting screws
1- Adjusting screw 1
2- Adjusting screw 2
3- Must not be turned - functions only as a pivot point
WARNING
The ACC adjustment is only applied when “Output diagnostic

test complete” is displayed on the Vehicle Diagnostic Tester .
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6 Driver Assistance Systems Front

Camera
page 327
6.1 Driver Assistance Systems Front Cam‐

era, Calibrating
♦ Calibration Board For Lane Guard System - VAS6430/4-
♦ Wheel Alignment Computer
Note
If the camera can no longer recognize the lane markingsedue

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♦ The camera visual field is dirty or icy. Ifuththat
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♦ The camera view field in fogged over.

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If there is a lot of dirt on the inside of the glass in the camera view
erm
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window, this must be cleaned off by hand. To do this, remove the
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control module and the lens and clean the glass with washer fluid.
wit
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To remove the control module and lens. Refer to ⇒ Electrical
h re
hole
Equipment; Rep. Gr. 96 ; Driver Assistance Systems Front Cam‐
spec
era; Driver Assistance Systems Front Camera, Removing and
es, in part or in w
Installing .
t to the co
The calibration must be correct for the Driver Assistance Systems
Front Camera - R242- to function correctly.
rrectness of i
The Driver Assistance Systems Front Camera - R242- must be
l purpos
calibrated again for the following reasons:

♦ “No or incorrect basic setting/adaptation” is stored in the event
nf
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memory.
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♦ The Driver Assistance Systems Front Camera - R242- was

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replaced.
or
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♦ The windshield was replaced or removed.

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♦ The rear axle toe was adjusted.

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♦ The vehicle level sensor was readapted on vehicles with
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damping regulation.
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6. Driver Assistance Systems Front Camera 327

Note
♦ Before calibrating the driver assistance systems front camera,

check the Diagnostic Trouble Code (DTC) memory and cor‐
rect any faults.
♦ The driver assistance systems front camera may only be cali‐
brated using alignment equipment approved by VW/Audi.
♦ Only the Setting Device Basic Set - VAS6430/1- may be used
to calibrate the driver assistance systems front camera.
Note
♦ The Driver Assistance Systems Front Camera - R242- must fit

correctly in the retainer.
♦ The camera viewing range must be clean and unobstructed.
♦ Before driving the vehicle onto the vehicle alignment platform,
make sure there is sufficient space between the center of the
wheel hub on the front wheels and the Setting Device Basic
Set - VAS6430/1- . AG. Volkswagen AG d
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The distance between the Setting Device Basic Set - l not
♦ by
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VAS6430/1- and the center of the wheel hub on the front
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wheels must be 1,500 mm ± 25 mm (59 ± 0.98 in). aut ho eo
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♦ If there is not sufficient space, drive the vehicle backward onto
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the alignment stand in order to use the corresponding space.
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♦ The calibration board must be positioned in the center of the
rm
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setting device.
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♦ Before beginning the calibration, check the DTC memory. If
h re
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necessary, erase any existing entries.
spec
es, in part or in w
t to the co
– Follow the test requirements for an axle alignment. Refer to
⇒ “3.2 Test Prerequisites”, page 296 .
– Drive the vehicle onto the vehicle alignment platform.
rrectness of i
– Connect the battery charger. Refer to ⇒ Electrical Equipment
l purpos
nform
– Connect Vehicle Diagnostic Tester (Guide the diagnostic ca‐
ercia
ble through the open window.)

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During the calibration procedure, make sure all the vehicle doors
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remain closed and the vehicle exterior lamps are switched off.
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– Position the front wheels so they are straight. yri
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– Select calibrating the driver assistance systems front camera
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in the wheel alignment computer.
– Install the quick-action clamps on all four wheels.
– Install the measuring sensors on the wheels.
– Perform a wheel run-out compensation and the rear wheels.
– Bounce the vehicle.

– Measure and record the height at all four wheels.

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♦ The Setting Device Basic Set - VAS6430/1- must snot
s a
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♦ The alignment stand must be in the lowest level position for
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the next step.
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– Rotate the Setting Device Basic Set - VAS6430/1- upward just
enough so that the calibration beam is parallel to the center of
the measuring sensors on the front wheels, so that it is possi‐
rrectness of i
ble to correctly measure the distance measuring unit -1-.
l purpos
1- Distance measuring unit with spring tape measure and

mounting pin
nf
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– Position the Setting Device Basic Set - VAS6430/1- at a dis‐
or
tance -a- of 1,500 mm ± 25 mm (59 ± 0.98 in) from the center
m
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of the wheel hub on the front wheels to the beam on the Setting
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♦ Distance -a- 1,500 mm ± 25 mm (59 ± 0.98 in) must be Cop py
measured on both side of the vehicle and then the Setting
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Device Basic Set - VAS6430/1- must be aligned.
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♦ Distance -a- must be the same on both sides of the vehi‐
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cle.
– Mount the front wheel measuring sensors -1- to the Setting

– Determine the height value -a- between the Setting Device

Basic Set - VAS6430/1- contact area and the wheel contact
surface on the vehicle alignment platform. Enter it in the align‐
ment computer.

– Loosen the clamping bolt -arrow- and place the measuring bar
-1- on the floor.
– Turn the crank -1- to adjust the Calibration Board For Lane
Guard System - VAS6430/4- to the height specification -2- and
then make a note of it.
If the specified height was reached, then

G. Volkthe
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must be pushed slightly forward gen Asecured
aand with the
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330
AG.
Rep. Gr.44 - Wheels, Tires and Vehicle Alignment
– Slide the Setting Device Basic Set - VAS6430/1- to the side

-arrows B-, until the display in the wheel alignment computer
is in the tolerance range.
AG. Volkswagen AG d
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– By gently turning the adjustment screws -2 and 3-, the Setting
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Device Basic Set - VAS6430/1- is secured from rolling away.
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– Turn the precision adjustment screw -1- until the display on
atio
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the wheel alignment computer is located within the tolerance

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– Level the bubble level -A- using the adjusting screw -1-.
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– Level the bubble level -B- using the adjusting screws
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-2 and 3-.
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– Loosen the clamping bolt -arrow- and place the measuring bar yri
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-1- on the floor.
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– Check specified height -2- one more time and adjust if neces‐
sary.
If the specified height was reached, then the measuring bar -1-
must be pushed slightly forward and secured with the locking bolt
-arrow-.
Perform Any Subsequent Work Using Vehicle Diagnostic Tester .
– Turn on the ignition.
– Select “Guided Fault Finding” on the Vehicle Diagnostic Test‐
er .
Body (Repair Groups 01, 27 and 50 through 97)
Electrical System (Repair Groups 01, 27 and 90

through 97) olkswagen AG
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Driver Assistance Systems Front Camera -R242- e or
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Driver Assistance System Camera, Functions

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A5 - Calibrate the Control Module (Repair Group 44)

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Follow the instructions on the screen to perform the calibration.

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Note
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Next, in guided fault finding, determine the height of the body.

rrectness of i
– Enter the recorded ride heights.

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7 Special Tools

equipment required
♦ Wheel Alignment Comput‐
er - VAG1813F- or VW/Au‐
di approved wheel align‐
ment devices
♦ Brake Pedal Actuator -
VAG1869/2- .
♦ Insert Tool - 18mm -
T10179-
♦ Shock Absorber Set -
T10001-
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AG. Volkswagen AG d
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tee - Edition 03.2016
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♦ Torque Wrench 1332 Insert - Open Ring Wrench - 24mm -
nform
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VAG1332/9-
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♦ ACC Reflector Mirror - Audi - VAS6430/3-

AG. Volkswagen AG d
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⇒ “1.1 Overview - Steering Wheel”, page 336
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⇒ “1.2 Steering Wheel, Removing and Installing”, page 336
wit
, is n
h re
1.1 Overview - Steering Wheel
hole
spec
es, in part or in w
t to the co
1 - Steering Column
rrectness of i
ling. Refer to
⇒ “2.4 Steering Column,
l purpos

ling”, page 340 .
nf
ercia
❑ The punch points
orm
-arrows- on the steering
m
atio
m
wheel and steering col‐

o
n in
c
umn must be aligned

or
thi
with each other when
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positioning. Several
o
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steering columns are
o
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not equipped with a

t.
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punch point at the facto‐ Cop py
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ry. For these steering
ht ht
rig by
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columns, an appropriate co Vo
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punch point must be set
cted agen
Prote AG.
before removing the
steering wheel. Refer to
⇒ “1.2 Steering Wheel,
ling”, page 336 .
2 - Steering Wheel
ling. Refer to
⇒ “1.2 Steering Wheel,
ling”, page 336 .
sions. For allocation.
Refer to the Parts Cata‐
log.
❑ The punch points
-arrows- on the steering
wheel and steering col‐
umn must be aligned
with each other when
positioning. Several
steering columns are not equipped with a punch point at the factory. For these steering columns, an
appropriate punch point must be set before removing the steering wheel. Refer to
⇒ “1.2 Steering Wheel, Removing and Installing”, page 336 .
3 - Bolt
❑ 30 Nm + 90°
1.2 Steering Wheel, Removing and Instal‐

ling
336 Rep. Gr.48 - Steering


Removing
WARNING
Before performing work on the electrical system and removing

the steering wheel, the following conditions must be met:
♦ Disconnect the battery. Refer to ⇒ Electrical Equipment;
Rep. Gr. 27 ; Battery; Battery, Disconnecting and Con‐
necting .
AG. Volkswagen AG d
agen
♦ The wheels must be in the straight position. olksw
oes
not
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The airbag system may fail during future operation
oris if these
e nte
warnings are not followed! h eo
aut ra
ss c
ce
le
un
pt
an
d
– Move the steering column to the center height position.

itte
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erm
ab
– Remove the airbag unit. Refer to ⇒ Body Interior; Rep. Gr.
ility
ot p
69 ; Overview - Driver Side Airbag .
wit
is n
h re
– Bring wheels in the straight position.
ole,
spec
t to the co
Note
Removal and installation of steering wheel must take place in
rrectne
center position (wheels in straight-ahead position).
ss o
– If equipped disconnect the steering wheel heating connector.
cial p
f inform
mer
atio
m
– Check if the steering column is equipped with a punch point

o
n
c
on the steering column height marking.
i
or
n thi
te
sd
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– If that is not the case, then the steering wheel/steering column

iv
o
pr
position must be marked with a punch point on the steering
cum
r
fo
column.
en
ng
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op
– Remove the steering wheel -2- from the steering column.
C py
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Installing co Vo
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cted agen
Prote AG.
Make sure the wheels are in the straight-ahead position before
installing the steering wheel.
– When installing a removed steering wheel, ensure that the
markings on the steering column/steering wheel are aligned.
– When installing a new steering wheel (without a marking):
mount the steering wheel in its center position (the steering
wheel spokes must be horizontal and the wheels must be in
the straight-ahead position).
– Install steering wheel.
– Install the airbag unit. Refer to ⇒ Body Interior; Rep. Gr. 69 ;
Driver Side Airbag; Overview - Driver Side Airbag .
– Perform a road test.
– If steering wheel is crooked, remove it again and rotate it on
steering column splines.
♦ Refer to ⇒ “1.1 Overview - Steering Wheel”, page 336
1. Steering Wheel 337

2 Steering Column
⇒ “2.1 Overview - Steering Column”, page 338
⇒ “2.2 Steering Column, Checking for Damage”, page 339
⇒ “2.3 Steering Column, Handling and Transporting”, page 339
⇒ “2.4 Steering Column, Removing and Installing”, page 340
⇒ “2.5 Electronic Steering Column Lock Control Module J764 ,
2.1 Overview - Steering Column
Note
♦ Always replace self-locking nuts.

♦ Always replace corroded bolts/nuts.
♦ Always replace the bolts and nuts, which are tightened with an
additional tightening angle.
1 - Instrument Panel Central

Tube
2 - Shear Bolt
ing. Refer to
⇒ “2.5 Electronic Steer‐
ing Column Lock Con‐ AG. Volkswagen AG d
trol Module J764 , Re‐ lksw
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not
moving and Installing”, d by Vo gu
ara
page 348 orise nte
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u ra
3 - Right Retainer ss a c
ce
le
❑ For knee airbag

un
pt
an
d
itte
4 - Electronic Steering Column

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ab
Lock Control Module - J764-
pe
ility
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❑ For vehicles with “Key‐ wit

, is n
less Access” keyless h re

hole
locking and starting sys‐

spec
tem
es, in part or in w
t to the co

ling. Refer to
⇒ “2.5 Electronic Steer‐
rrectness of i
ing Column Lock Con‐

trol Module J764 , Re‐
l purpos

page 348
nform
ercia
5 - Bolt
m
❑ 20 Nm
com
tion in
❑ Follow the tightening se‐

r
te o
thi
quence. Refer to
s
iva
do
⇒ page 346
r
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fo

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op
6 - Left Retainer
C py
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❑ For knee airbag p by
co Vo
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7 - Bolt Prote AG.
❑ 20 Nm

❑ Replace after removal AG. Volkswagen AG d
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8 - Bolt olksw not
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❑ 20 Nm + 90° orise nte
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ut
❑ Replace after removal ss a ra
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9 - Steering Column
nl
pt
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an
itte
❑ Removing and installing. Refer to ⇒ “2.4 Steering Column, Removing and Installing”, page 340 .
y li
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❑ The steering column must be engaged on the instrument panel central tube bracket when installing
ility
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(assembly aid).
wit
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❑ There are different versions. Refer to the Parts Catalog.
hole
spec
es, in part or in w
t to the co
2.2 Steering Column, Checking for Damage
rrectness of i
Visual Check
l purpos
– Check whether steering column parts show signs of damage.

Functional Check
nform
ercia
– Check that the steering column turns easily without jerking.

m
at
om
– Check whether steering column can be easily adjusted later‐
ion
c
ally and vertically.
in t
or
his
ate
2.3 Steering Column, Handling and Trans‐
do
priv
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or
porting
f
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Cop py
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WARNING
rig by
copy Vo
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cted agen
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♦ The correct handling of the steering column must always
AG.
be observed.
♦ Incorrect handling of steering column may cause damage
to steering column and therefore lead to a safety risk.
Correct Handling and Transport of Steering Column

♦ Transport the steering column with two hands.
♦ Hold the steering column by the upper outer steering column
tube and in the area of the upper universal joint.
2. Steering Column 339

Golf 2015 ➤ , Golf Variant 2015 a➤
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Incorrect Handling of Steering
au Column
th or
ac
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Transporting at the clamping lever leads to pre-damage to the
ce
le
un
pt
steering column.
an
d
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t to the co
rrectne
Incorrect Handling of Steering Column with Safety Risk
ss o
The following handling techniques can lead to damage of the uni‐
cial p
f in
versal joint bushings, the lower steering column bearing and the
form
mer
steering column:
atio
om
♦ Transporting steering column with one hand on joint shaft.
n
c
i
or
n thi
e
♦ Bending joints more than 90°.

t
sd
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cum
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t.
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Cop py
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2.4 Steering Column, Removing and Instal‐

ling
Caution


♦ Bolts - Left Retainer to Steering Column
♦ Bolts - Right Retainer to Steering Column
♦ Shear Bolts - Steering Column to Electronic Steering Column
Lock Control Module
♦ Bolt - Steering Column to Steering Gear
Removing
The steering column is delivered only as a complete replacement
part. Service is not possible.

Vehicles with Ignition Switch

The steering lock housing can be replaced. Refer to ⇒ Electrical
Equipment; Rep. Gr. 94 ; Steering Column Switch Module; Steer‐
ing Column Switch Module, Removing and Installing .
tem
The Electronic Steering Column Lock Control Module - J764- can
be removed and installed. Refer to
⇒ “2.5 Electronic Steering Column Lock Control Module J764 ,
Removing and Installing”, page 348 .
WARNING
Before starting work on electrical equipment and removing

steering wheel, the following conditions must be fulfilled:
♦ The technician must electrostatic discharge. This is done
by touching a grounded metal part, for example, water
lines, heater pipe, metal carriers or a workshop hoist .
If this not done, the Electronic Steering Column Lock Control
Module - J764- could fail later.
♦ Disconnect the battery. Refer to ⇒ Electrical Equipment;
Rep. Gr. 27 ; Battery; Battery, Disconnecting and Con‐
necting .
♦ The wheels must be straight.
The airbag system may fail at a later time if these warnings are
not followed!
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
– Straighten the wheels. orise nte
th eo
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– Pull the lever on the side of the steering column downward.
ss a c
ce
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nl
– Push the steering column as far down as possible and remove
pt
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it.
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– Push lever under steering column upward again.
ility
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– Remove the airbag unit. Refer to ⇒ Body Interior; Rep. Gr.
h re
69 ; Driver Side Airbag; Overview - Driver Side Airbag .
hole
spec
es, in part or in w
– Remove the steering wheel. Refer to

⇒ “1.2 Steering Wheel, Removing and Installing”, page 336 . t to the co
– Remove the upper steering column trim panel. Refer to ⇒
rrectness of i
Body Interior; Rep. Gr. 68 ; Storage Compartments and Cov‐

ers; Upper Steering Column Trim Panel, Removing and In‐
l purpos
stalling .
– Remove the lower steering column trim panel. Refer to ⇒ Body
nf
ercia
Interior; Rep. Gr. 68 ; Storage Compartments and Covers;

orm
Lower Steering Column Trim Panel, Removing and Installing .

m
atio
om
– Remove the steering column switch module. Refer to ⇒ Elec‐

n in
or c
trical Equipment; Rep. Gr. 94 ; Steering Column Switch Mod‐

thi
te
sd
a
ule; Steering Column Switch Module, Removing and Instal‐

iv
o
r
rp
ling .
cu
o
m
f
en
ng
t.
– Remove the knee airbag. Refer to ⇒ Body Interior; Rep. Gr.
yi Co
op
69 ; Knee Airbags; Overview - Knee Airbag .
C py
t. rig
gh ht
pyri by
Vo
co lksw
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cted agen
Prote AG.


– Remove the connector -1- from the Anti-Theft Immobilizer
Reader Coil - D2- .
– Remove the connector -2- from the ignition/starter switch -1-.

tem
– Unclip the wire from the retainer on the Electronic Steering
Column Lock Control Module - J764- -arrow-.gen AG. Volkswagen AG d
wa oes
olks not
Continuation for All Vehicles d byV gu
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– or steering column. Refer to
Remove the footwell vent underuththe eo
ra
⇒ Heating, Ventilation and Air
ss Conditioning; Rep. Gr. 87 ; Air
a c
Routing; Overview - Air Routing and Air Distribution in Pas‐
ce
le
un
pt
senger Compartment .
an
d
itte
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erm
ab
ility
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– Release the tab in direction of -arrow- using a small screw‐
wit
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driver.
h re
ole,
spec
– Remove the wiring guide -1- forward from the metal tab.
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
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sd
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cum
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fo
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t.
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Cop py
ht. rig
rig ht
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co Vo
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cted agen
Prote AG.

– Release the tabs -arrows- on the wiring guide -1- with a small
screwdriver.
– Remove the wiring guide
gen AG -1- downward
. Volkswagen AG from the steering col‐
does
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umn. yV
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– Release
tho
risthe lower cable bracket -2- and remove it tdownward.
ee
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– Setssthe wire for the steering column aside. c
ce
le
un
pt
an
d
itte
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erm
ab
ility
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wit
is n
h re
ole,
spec
t to the co
rrectness o
– Remove the bolt -1- and fold the footwell trim panel -2- in the
cial p
f in
form
mer
atio
om
n
c
i
or
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te
sd
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pr
cum
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fo
en
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t.
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Cop py
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gh ht
pyri by
Vo
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by c lksw
cted agen
Prote AG.
– Remove the bolt -1- from the universal joint -2-. Then remove
Caution

♦ Switch on the ignition.
♦ Turning the steering column


– Remove the left bracket for the knee airbag -3-.
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss
ce
le
un
pt
an
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– Remove the right bracket for the knee airbag -3-.

itte
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erm
ab
ility
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wit
is n
h re
ole,
spec
t to the co
rrectness o
– Remove the bolt -1- and hold the steering column -2-.
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
– Disengage the steering column -1- upward from the tabs

-2 and 3- on the mounting bracket and remove it.
Caution
For correct handling and transport of steering column. Refer to

⇒ “2.3 Steering Column, Handling and Transporting”,
page 339 .
Installing

– Engage the steering column -1- in the assembly aids on the

mounting bracket at the bottom -2- and at the top -3-.
– Align the steering column -2- to the mounting bracket. Install

the bolt -1- hand-tight.
AG. Volkswagen AG d
agen oes
olksw not
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nl
pt
du
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itte
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ab
ility
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wit
– Install the right bracket for the knee airbag -3-.
, is n
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hole
– Install the bolts -1 and 2- hand-tight.
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
– Install the left bracket for the knee airbag -3-.

thi
te
sd
iva
– Install the bolts -1 and 2- hand-tight.

r
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m
f
en
ng
t.
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Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

– Tighten the bolts -1, 2, 3, and 4- one after the other to the
tightening specification.
– The flat side of the steering column -1- must be positioned on

the flat side of the steering gear -2-. At the same time, the
opening on the steering gear must align precisely with the hole
for the bolt -arrows-.
AG. Volkswagen AG d
agen oes
olksw not
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ho eo
aut ra
ss c
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nl
pt
du
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itte
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– Install the universal joint -2- on the steering pinion in the op‐
ility
ot p
posite direction of the -arrow-.

wit
, is n
h re
– Install and tighten the new hex bolt -1-.

hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
orm
m
atio
m
– Fold the footwell trim panel -2- forward and secure it with the
o
n in
c
bolt -1-.
or
thi
te
sd
iva
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o
m
f
en
ng
t.
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Cop py
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rig ht
py by
co Vo
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cted agen
Prote AG.


– Connect the connector -arrow- with the Anti-Theft Immobilizer
Reader Coil - D2- .
– Connect the connector -2-.

tem
– Connect the connector -1-.
– Clip the wire into the retainer on the Electronic Steering Col‐
umn Lock Control Module - J764- -arrow-.
– Install the steering column switch module. Refer to ⇒ Electri‐
cal Equipment; Rep. Gr. 94 ; Steering Column Switch Module;
Steering Column Switch Module, Removing and Installing .
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss
ce
e
nl
pt
du
an
itte
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erm
ab
ility
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wit
, is n
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hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
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Cop py
t. rig
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– Insert the lower wiring bracket -2- so that the tabs engage in
the guide on the steering column.
– Insert the wiring guide -1-. The tabsn A-arrows-
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the steering column. wage does
olks no
V t gu
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– Install the footwell vent
ris under the steering column. Refer to ⇒ ntee
ed ra
Heating, Ventilation
au
tho and Air Conditioning; Rep. Gr. 87 ; Air or
ac
Routing; Overviewss - Air Routing and Air Distribution in Pas‐
senger Compartment .
ce
le
un
pt
an
d
itte
– Install the knee airbag. Refer to ⇒ Body Interior; Rep. Gr. 69 ;
y li
rm
ab
Knee Airbags; Overview - Knee Airbag .
pe
ility
ot
– Install the lower steering column trim panel. Refer to ⇒ Body
wit
, is n
h re
hole
Lower Steering Column Trim Panel, Removing and Installing .
spec
es, in part or in w
– Install the upper steering column trim panel. Refer to ⇒ Body
t to the co
Upper Steering Column Trim Panel, Removing and Installing .
rrectness of i
– Install the steering wheel. Refer to
⇒ “1.2 Steering Wheel, Removing and Installing”, page 336 .
l purpos
– Install the driver side airbag unit. Refer to ⇒ Body Interior; Rep.
Gr. 69 ; Driver Side Airbag; Overview - Driver Side Airbag .
nform
ercia
– Perform a basic setting on the Steering Angle Sensor - G85-

m
a
com
ti
using the ⇒ Vehicle diagnostic tester.
on in
r
te o
thi
Tightening Specifications s
iva
do
r

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cum
fo
en
ng
♦ Refer to ⇒ Heating, Ventilation and Air Conditioning; Rep. Gr.

t.
yi Co
op
87 ; Air Routing; Overview - Air Routing and Air Distribution in
C py
ht. rig
Passenger Compartment . rig ht
py by
co Vo
by lksw
♦ Refer to ⇒ Electrical Equipment; Rep. Gr. 94 ; Steering Col‐
cted agen
Prote AG.
umn Switch Module; Steering Column Switch Module, Re‐
moving and Installing .
♦ Refer to ⇒ Body Interior; Rep. Gr. 69 ; Knee Airbags; Over‐
view - Knee Airbag
♦ Refer to ⇒ Body Interior; Rep. Gr. 69 ; Driver Side Airbag;
Overview - Driver Side Airbag .
♦ Refer to ⇒ Body Interior; Rep. Gr. 68 ; Storage Compartments
and Covers; Lower Steering Column Trim Panel, Removing
and Installing .
♦ Refer to ⇒ Body Interior; Rep. Gr. 68 ; Storage Compartments
and Covers; Upper Steering Column Trim Panel, Removing
and Installing .
2.5 Electronic Steering Column Lock Con‐

trol Module - J764- , Removing and In‐
stalling
♦ 7/16 Inch Extractor - T10424US-
Caution



♦ Shear Bolts - Steering Column to Electronic Steering Column
Lock Control Module
AG. Volkswagen AG d
agen
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not
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If the control module
ut
hor
is being replaced, select the function Re- eo
r
place for thess respective control module in the mode “Guided ac
a
Fault Finding” or “Guided Functions” on the Vehicle Diagnostic
ce
e
nl
pt
Tester .
du
an
itte
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erm
ab
Removing
ility
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wit
, is n
– Remove the steering column switch module. Refer to ⇒ Elec‐
h re
trical Equipment; Rep. Gr. 94 ; Steering Column Switch Mod‐
hole
spec
ule; Steering Column Switch Module, Removing and Instal‐
es, in part or in w
ling .
t to the co
– Disconnect the connector -2- by sliding the retainer -1- toward
the rear and pressing the release down.
rrectness of i
– Remove the shear bolt -3- using the 7/16 Inch Extractor -
l purpos
T10424US-
– Remove the Electronic Steering Column Lock Control Module
nf
ercia
- J764- -4-
orm
m
atio
om
n in
c
Note
or
thi
te
sd
iva
o
r
If the shear bolt cannot be removed using the 7/16 Inch Extractor
rp
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o
- T10424US- , it must be drilled out using an angle drill and an 8.5

f
en
ng
t.
yi
mm diameter drill bit.
Co
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Installing co Vo
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AG.
– Tighten the new bolts -arrows- until the head break off.

Suspension, Wheels, Steering - Edition 03.2016 agen
AG. Volkswagen AG d
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3 Steering Gear or eo
h
aut ra
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⇒ “3.1 Overview - Steering Gear”, page 350
ce
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nl
pt
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an
⇒ “3.2 Steering Gear, Removing and Installing”, page 351
itte
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erm
ab
⇒ “3.3 Boot, Removing and Installing”, page 357
ility
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wit
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⇒ “3.4 Tie Rod, Removing and Installing”, page 359
h re
hole
spec
⇒ “3.5 Tie Rod End, Removing and Installing”, page 362
es, in part or in w
t to the co
⇒ “3.6 Steering Gear, Servicing”, page 363
3.1 Overview - Steering Gear
rrectness of i
l purpos
Caution
nf
ercia
o
rm
m
atio
m

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c

or
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te
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en
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t.
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1 - Expanding Clip
Co
Cop py
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2 - Steering Column
ht
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Vo
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cted
3 - Bolt
agen
Prote AG.
tion. Refer to
⇒ “2.1 Overview - Steer‐
ing Column”, page 338
4 - Steering Gear
ling. Refer to
⇒ “3.2 Steering Gear,
ling”, page 351
sions. Refer to the Parts
Catalog.
❑ With Power Steering
Control Module - J500-
❑ Can be checked in “Gui‐
ded Fault Finding” using
the Vehicle Diagnostic
Tester
5 - Nut
❑ 20 Nm + 90°
6 - Left Wheel Bearing Housing
7 - Bolt
❑ 70 Nm + 90°

8 - Subframe
9 - Right Wheel Bearing Hous‐
ing
10 - Heat Shield
❑ Depending on the engine installed, there are different versions. Refer to the Parts Catalog.
11 - Bolt
❑ 8 Nm
❑ Depending on the engine installed, three or four are installed. Refer to the Parts Catalog.
12 - Wire
3.2 Steering Gear, Removing and Installing

Removing agen
AG. Volkswagen AG d
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– Turn the steering wheel by V in the straight position and remove gu
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– Remove the bolts -1- and fold the footwell trim panel -2- in the
spec
direction of the arrow into the vehicle interior.

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3. Steering Gear 351

– Remove the bolt -arrow- from the universal joint -1-, and then
remove the universal joint in the direction of the -arrow-.
Caution

♦ Switching on the ignition
♦ Turning the steering column.
These points must be observed since performing these actions
could cause irreparable damage.


-arrows-.
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To protect the thread, screw the nut on the pin a few turns.
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– Remove the tie rod end from the wheel bearing housing and
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– Disconnect the connector -1- for the Oil Level Thermal Sensor
- G266- .
– If equipped, disconnect the connector -2- from the After-Run
Coolant Pump - V51- . To do so, open the catch -3- in the
direction of the -arrow- and release the connector.
– Remove the clips -1- and -2- for the wiring harness -3- from
the subframe and the steering gear.
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– Remove the boltsr-arrows-
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Different heat shields -1- are installed depending on the engine.
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– Disconnect the connectors -1 and 2- from the steering gear.
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– Unclip the wiring harness -1- from the steering gear -2- cted agen
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-arrows-.

– Pry the steering gear off of the subframe, for example, using
a large screwdriver and remove it toward the rear.

– Set the steering gear down as illustrated.

Avoid damage to the control module -1-.
Installing
The steering gear threaded sleeves must be seated in the sub‐
frame holes.
– Connect the connectors -1 and 2- so that they audibly click into

place.
Note
AG. Volkswagen A
♦ Coat the seal on theolksteering
swa
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♦ After attaching
utho steering gear to drive axle, make sure thateseal
or
on steering
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a
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and kinks and is sealed correctly. The opening to the foot well
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– Attach the bolts for the steering gear and the stabilizer bar.
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Note

– Install the lower noise insulation. Refer to ⇒ Body Exterior;

Note
Make sure the ball joint boot is not damaged or twisted.
– Bolt the universal joint to the steering gear.

– Connect the battery. Refer to ⇒ Electrical Equipment; Rep.
– Perform the Steering Angle Sensor - G85- basic setting using
the ⇒ Vehicle diagnostic tester.
It is necessary to adapt the electro-mechanical power steering
using the Vehicle Diagnostic Tester ⇒ Vehicle diagnostic tester if
new steering gear was installed.
♦ Refer to
page 54 olks
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♦ Refer to
ris ⇒ “2.1 Overview - Subframe”, page 16 nte
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♦ Refer
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3.3 Boot, Removing and Installing

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Caution


Removing
Note
♦ If the boot is faulty, moisture and dirt will penetrate into steering
gear. There must be a noticeable grease film present on steer‐
ing rack in area of splines. If grease film is not present, steering
gear must be replaced.
♦ Replace the steering gear:
♦ If there is corrosion.
♦ If it is damaged. agen
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⇒ “3.5 Tie Rod End, Removing and Installing”, page 362 .
rrectness of i
– Clean outside of steering gear in area of boot.

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While doing this, no dirt must enter the steering gear through the
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♦ If no grease film is visible on steering rack, steering gear must Prote
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Installing
Caution
Do not lubricate the steering rack.

– Guide new clamp and boot onto tie rod.

– Lightly grease the sealing surface of the boot to the tie rod with
grease from the repair kit.
– Slide the boot -2- onto the tie rod -1- as illustrated.
– Secure spring clamp on boot using Hose Clip Pliers -
VAG1275A- .
– Lightly grease the sealing surface of the boot to the steering
gear housing with grease from the repair kit.
– Push the boot all the way onto the steering gear housing.
– Tighten the new clamp using the Locking Pliers - VAS6199- to

the extent depicted in the illustration.
– Install the tie rod end up to the marking made earlier during
the removal. Refer to
⇒ “3.5 Tie Rod End, Removing and Installing”, page 362 .
– Install the front wheel and tighten the bolts.
– Perform vehicle alignment. agen
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3.4 Tie Rod, Removing and Installing

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♦ Clamps - Tie Rod
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remove the nut.

1- Puller - Ball Joint - T10187-
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– Open the clamps and push back boot.

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Note
♦ If corrosion, damage, wear-out or first signs of soiling on steer‐

ing rack can be seen, complete steering gear must be re‐
placed.
♦ If no grease film is visible on steering rack, steering gear must
also be replaced completely.
Installing
following:
Caution
Do not lubricate the steering rack.

– Make sure the correct tie rod end is installed on each side.
I - Right tie rod end identified with an “A”
II - Left tie rod end identified with a “B”
– Guide new clamp and boot onto tie rod.
– Twist tie rod far enough into tie rod end until dimension -a- is
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2- Torque Wrench 1332 40-200Nm - VAG1332- rrectness of i
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– Lightly grease the sealing surface of the boot to the tie rod with
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gear housing with grease from the repair kit.
– Push the boot all the way onto the steering gear housing.

– Tighten new clamp using Locking Pliers - VAS6199- to the

extent depicted in the illustration.
– Install wheel and tighten.
– Perform vehicle alignment.
– If both tie rods were replaced, then the basic setting for the
Steering Angle Sensor - G85- must be performed using the
Vehicle Diagnostic Tester .
– Then perform the basic setting to the steering using the Vehi‐
cle Diagnostic Tester .
♦ Refer to
3.5 Tie Rod End, Removing and Installing

Caution


♦ Clamps - Tie Rod
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– Mark the position of the tie rod end on the tie rod.
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h re
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Caution
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rrectne
– Remove the tie rod from the wheel bearing housing and re‐
ss
move the nut.

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1- Puller - Ball Joint - T10187-

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– Remove the tie rod end from the tie rod.

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Rep. Gr.48 - Steering
AG.
– Make sure the correct tie rod end is installed on each side.
I - Right tie rod end identified with an “A”
II - Left tie rod end identified with a “B”
– Turn the tie rod end to marking made earlier on the tie rod and
secure it with a locking nut.
– Install the tie rod end into the wheel bearing housing.
– Install the tie rod end with a new nut.
– Install wheel and tighten.
– Perform vehicle alignment.
♦ Refer to
3.6 Steering Gear, Servicing
1 - Right Tie Rod End

❑ Identified with “A”. Refer
to ⇒ page 361
ling. Refer to
⇒ “3.5 Tie Rod End, Re‐
page 362
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3 - Clamp
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4 - Boot
❑ Must not be twisted after
toe is adjusted
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⇒ “3.3 Boot, Removing
and Installing”,
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page 357 .
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⇒ page 359
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8 - Left Tie Rod End
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❑ Identified with “B”. Refer to ⇒ page 361
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9 - Nut
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❑ 70 Nm
❑ Nut must be counterheld on tie rod end using a wrench when loosening and tightening.
rrectness of i
10 - Spring Clamp
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11 - Boot
❑ Removing and installing. Refer to ⇒ “3.3 Boot, Removing and Installing”, page 357 .
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❑ Check for damage
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❑ Must not be twisted after toe is adjusted
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13 - Tie Rod
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❑ Removing and installing. Refer to ⇒ “3.4 Tie Rod, Removing and Installing”, page 359

4 Sensors
⇒ “4.1 Steering Angle Sensor G85 , Removing and Installing”,
page 365
4.1 Steering Angle Sensor - G85- , Remov‐

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Note
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ce
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sor - G85- is faulty. Refer to
pt
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⇒ “3.2 Steering Gear, Removing and Installing”, page 351 .

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4. Sensors 365
5 Special Tools

equipment required
40-200Nm - VAG1332-
♦ Torque Wrench Insert -
Open Jaw - VAG1923-
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♦ Hose Clip Pliers -

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♦ Open Ring Wrench - 24mm
- VAG1332/11-
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♦ 7/16 Inch Extractor - T10424US-

AG. Volkswagen Golf 2015 ➤ , Golf Variant 2015 ➤
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6 Revision History ut or
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DRUCK NUMBER: K0059241421
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Fac‐ Edit Job Fee Notes Quality
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tory Edi‐ Type dba Checke
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016 8/20 tory 378 axle.
16 Up‐ 3
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6. Revision History 369

Cautions & Warnings
Please read these WARNINGS and CAUTIONS before proceeding with maintenance
and repair work. You must answer that you have read and you understand these
WARNINGS and CAUTIONS before you will be allowed to view this information.
•= If you lack the skills, tools and equipment, or a suitable workshop for any procedure described in this manual, we
suggest you leave such repairs to an authorized Volkswagen retailer or other qualified shop. We especially urge
you to consult an authorized Volkswagen retailer before beginning repairs on any vehicle that may still be covered
wholly or in part by any of the extensive warranties issued by Volkswagen.
•= Disconnect the battery negative terminal (ground strap) whenever you work on the fuel system or the electrical
system. Do not smoke or work near heaters oragother
en AG. fire
Volkshazards.
wagen AG Keep an approved fire extinguisher handy.
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•= Volkswagen is constantly improving ris
eits
d vehicles and sometimes these changes, ran both in parts and specifications,
tee
o
are made applicable to earlier models.
uth Therefore, part numbers listed in this manual
or are for reference only. Always
a ac
check with your authorized Volkswagen
ss retailer parts department for the latest information.
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•= Any time the battery has been disconnected on an automatic transmission vehicle, it will be necessary to
itte
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reestablish Transmission Control Module (TCM) basic settings using the VAG 1551 Scan Tool (ST).
ility
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•= Never work under a lifted vehicle unless it is solidly supported on stands designed for the purpose. Do not support
h re
ole,
a vehicle on cinder blocks, hollow tiles or other props that may crumble under continuous load. Never work under a
spec
vehicle that is supported solely by a jack. Never work under the vehicle while the engine is running.
t to the co
•= For vehicles equipped with an anti-theft radio, be sure of the correct radio activation code before disconnecting the
battery or removing the radio. If the wrong code is entered when the power is restored, the radio may lock up and
rrectne
become inoperable, even if the correct code is used in a later attempt.
s
•=
s
If you are going to work under a vehicle on the ground, make sure that the ground is level. Block the wheels to
o
cial p
f
keep the vehicle from rolling. Disconnect the battery negative terminal (ground strap) to prevent others from inform
starting the vehicle while you are under it.
mer
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•= Do not attempt to work on your vehicle if you do not feel well. You increase the danger of injury to yourself and
n
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or
others if you are tired, upset or have taken medicine or any other substances that may impair you or keep you from
thi
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being fully alert.

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•= Never run the engine unless the work area is well ventilated. Carbon monoxide (CO) kills.
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•= Always observe good workshop practices. Wear goggles when you operate machine tools or work with acid. Wear copy
rig by
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goggles, gloves and other protective clothing whenever the job requires working with harmful substances. by lksw
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•= Tie long hair behind your head. Do not wear a necktie, a scarf, loose clothing, or a necklace when you work near
machine tools or running engines. If your hair, clothing, or jewelry were to get caught in the machinery, severe
injury could result.
•= Do not re-use any fasteners that are worn or deformed in normal use. Some fasteners are designed to be used
only once and are unreliable and may fail if used a second time. This includes, but is not limited to, nuts, bolts,
washers, circlips and cotter pins. Always follow the recommendations in this manual - replace these fasteners with
new parts where indicated, and any other time it is deemed necessary by inspection.
Page 1 of 3
© 2002 Volkswagen of America, Inc.
All rights reserved. Information contained in this document is based on the latest information available at the time of printing and is subject to the copyright and other intellectual property rights of
Volkswagen of America, Inc., its affiliated companies and its licensors. All rights are reserved to make changes at any time without notice. No part of this document may be reproduced, stored in a
retrieval system, or transmitted in any form or by any means, electronic, mechanical, photocopying, recording, or otherwise, nor may these materials be modified or reposted to other sites, without
the prior expressed written permission of the publisher.
Version 1.0
Cautions & Warnings
•= Illuminate the work area adequately but safely. Use a portable safety light for working inside or under the vehicle.
Make sure the bulb is enclosed by a wire cage. The hot filament of an accidentally broken bulb can ignite spilled
fuel or oil.
•= Friction materials such as brake pads and clutch discs may contain asbestos fibers. Do not create dust by
grinding, sanding, or by cleaning with compressed air. Avoid breathing asbestos fibers and asbestos dust.
Breathing asbestos can cause serious diseases such as asbestosis or cancer, and may result in death.
•= Finger rings should be removed so that they cannot cause electrical shorts, get caught in running machinery, or be
crushed by heavy parts.
•= Before starting a job, make certain that you have all the necessary tools and parts on hand. Read all the
instructions thoroughly; do not attempt shortcuts. Use tools that are appropriate to the work and use only
replacement parts meeting Volkswagen specifications. Makeshift tools, parts and procedures will not make good
repairs.
•= Catch draining fuel, oil or brake fluid in suitable containers. Do not use empty food or beverage containers that
might mislead someone into drinking from them. Store flammable fluids away from fire hazards. Wipe up spills at
once, but do not store the oily rags, which can ignite and burn spontaneously.
•= Use pneumatic and electric tools only to loosen threaded parts and fasteners. Never use these tools to tighten
fasteners, especially on light alloy parts. Always use a torque wrench to tighten fasteners to the tightening torque
listed.
•= Keep sparks, lighted matches, and open flame away from the top of the battery. If escaping hydrogen gas is
ignited, it will ignite gas trapped in the cells and cause the battery to explode.
•= Be mindful of the environment and ecology. Before you drain the crankcase, find out the proper way to dispose of
the oil. Do not pour oil onto the ground, down a drain, or into a stream, pond, or lake. Consult local ordinances that
govern the disposal of wastes.
•= The air-conditioning (A/C) system is filled with a chemical refrigerant that is hazardous. The A/C system should be
n AG. Volkrecovery/recycling
serviced only by trained automotive service technicians using approved refrigerant swagen AG equipment,
wage doe
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trained in related safety precautions, and familiar with regulations ygoverning the discharging ands ndisposal
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automotive chemical refrigerants. db ran
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•= Before doing any electrical welding on vehicles equippedsswith
anti-lock brakes (ABS), disconnect the battery
ce
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negative terminal (ground strap) and the ABS control module connector.
un
pt
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•= Do not expose any part of the A/C system to high temperatures such as open flame. Excessive heat will increase ab
ility
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system pressure and may cause the system to burst. wit

is n
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ole,
•= When boost-charging the battery, first remove the fuses for the Engine Control Module (ECM), the Transmission
spec
Control Module (TCM), the ABS control module, and the trip computer. In cases where one or more of these
t to the co
components is not separately fused, disconnect the control module connector(s).
•= Some of the vehicles covered by this manual are equipped with a supplemental restraint system (SRS), that
rrectne
automatically deploys an airbag in the event of a frontal impact. The airbag is operated by an explosive device.
Handled improperly or without adequate safeguards, it can be accidentally activated and cause serious personal
ss
injury. To guard against personal injury or airbag system failure, only trained Volkswagen Service technicians
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should test, disassemble or service the airbag system.

inform
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Page 2 of 3
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All rights reserved. Information contained in this document is based on the latest information available at the time of printing and is subject to the copyright and other intellectual property rights of Co
Cop
Volkswagen of America, Inc., its affiliated companies and its licensors. All rights are reserved to make changes at any time without notice. No part of this document may be reproduced, stored in a py
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Cautions & Warnings
•= Do not quick-charge the battery (for boost starting) for longer than one minute, and do not exceed 16.5 volts at the
battery with the boosting cables attached. Wait at least one minute before boosting the battery a second time.
•= Never use a test light to conduct electrical tests of the airbag system. The system must only be tested by trained
Volkswagen Service technicians using the VAG 1551 Scan Tool (ST) or an approved equivalent. The airbag unit
must never be electrically tested while it is not installed in the vehicle.
•= Some aerosol tire inflators are highly flammable. Be extremely cautious when repairing a tire that may have been
inflated using an aerosol tire inflator. Keep sparks, open flame or other sources of ignition away from the tire repair
area. Inflate and deflate the tire at least four times before breaking the bead from the rim. Completely remove the
tire from the rim before attempting any repair.
•= When driving or riding in an airbag-equipped vehicle, never hold test equipment in your hands or lap while the
vehicle is in motion. Objects between you and the airbag can increase the risk of injury in an accident.
I have read and I understand these Cautions and Warnings.
AG. Volkswagen AG d
agen oes
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Page 3 of 3
AG.

All rights reserved. Information contained in this document is based on the latest information available at the time of printing and is subject to the copyright and other intellectual property rights of
Volkswagen of America, Inc., its affiliated companies and its licensors. All rights are reserved to make changes at any time without notice. No part of this document may be reproduced, stored in a
the prior expressed written permission of the publisher.
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Volkswagen Golf Variant 2015 Repair Manual - Suspension, Wheels, Steering PDF

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Service

Service Department. Technical Information

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Copyright © 2016 Volkswagen AG, Wolfsburg D4B80416633

3.1 Shock Absorber Leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

3.3 Shock Absorbers, Checking when Removed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

3.6 Bolts and Nuts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

3.7 Electrical Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

6.3 Drive Axle, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85

1.2 Rear Axle, Lowering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 136

2.1 Overview - Axle Beam . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150

4.1 Overview - Stabilizer Bar . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 177

4.3 Coupling Rod, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . orm 179

5 Control Arm, Tie Rod . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 181

5.1 Overview - Transverse Link . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 181

5.2 Overview - Tie Rod . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 184

5.3 Upper Transverse Link, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 185

5.4 Lower Transverse Link, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 187

6.3 Shock Absorber, Servicing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 200

43 - Level Control System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 267

1.1 Overview - Electronic Damping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 267

44 - Wheels, Tires and Vehicle Alignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 286

3.2 Test Prerequisites . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 296

3.4 Axle Alignment Specified Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 298

3.9 Rear Axle Camber, Adjusting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 307

3.11 Front Axle Toe, Adjusting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 309

3.12 Wheel Run-Out Compensation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 309

3.13 Maximum Steering Angle, Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 310

4 Wheel/Tire Vibration, Causes and Solution . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 311

4.1 Vibration Causes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 311

4.2 Road Test, Performing Before Balancing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 311

1.2 Steering Wheel, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 336

3.4 Tie Rod, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 359

3.5 Tie Rod End, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 362

6 Revision History . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 369

manner and sequence, independent of performing an axle align‐

during an axle alignment, then no deformations of the chassis are

Visual and Function Check of Steering System

♦ Check of hydraulic lines, threaded connections and steering

♦ Check proper function through entire steering angle by turning

steering wheel from stop to stop. Steering wheel must be ro‐

tary without hitching at equal force.

formation, cracks and other damages

1. Evaluating Vehicles in Collisions 1

spective repair manuals/ELSA.

Electronic Vehicle Systems

Safety related systems, such as: ABS/EDS; Airbag; electronically

2 Rep. Gr.00 - Technical Data

2.1 Start/Stop System Safety Precautions

Risk of injury due to the engine automatically starting on vehi‐

2.2 Subframe Safety Precautions

3.1 Shock Absorber Leaks

3.2 Shock Absorber Noises

Shock absorbers are frequently rejected and exchanged because

of rumbling noises. Examinations on the test stand and vehicle

of the rejected shock absorbers and the replacement was not

With complaints that are interpreted as rumbling or knocking

sounds, proceed as follows.

– Determine where, when and how the sounds change during a

road test on a dry stretch of road with irregularities.

4 Rep. Gr.00 - Technical Data

large loss of oil.

– Push the shock absorber together by hand.