D4B80423F1E-Running Gear Axles Steering

Service
Workshop Manual
Golf Sportsvan 2015 ➤
Golf Sportsvan 2018 ➤
Running gear, axles, steering
Edition 03.2018
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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 - Self-levelling suspension
44 - Wheels, tyres, vehicle geometry
48 - Steering
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Technical information should always be available to the foremen and mechanics, because their
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careful and constant adherence to the instructions is essential to ensure vehicle road-worthiness and
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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 © 2018 Volkswagen AG, Wolfsburg D4B80423F1E

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Contents
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00 - Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
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1 Safety information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
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1.1 Safety measures when working on vehicles with a start/stop system . . . . . . . . . . . . . . . . 1
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1.2 Safety precautions when working on subframe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
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2 Repair instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
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2.1 Leaks at shock absorbers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
2.2 Noises from shock absorbers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
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2.3 Checking shock absorbers when removed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
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2.4 Steering rack . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

2.5 Gaskets and seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
2.6 Nuts and bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
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2.7 Electrical components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

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2.8 Raising suspension to unladen position (vehicles with coil springs) . . . . . . . . . . . . . . . . . . 4
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3 Evaluating accident vehicles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
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3.1 Checklist for evaluating running gear on accident vehicles . . . . . . . . . . . . . . . . . . . . . . . . 9
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4 Waste disposal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
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4.1 Releasing gas and draining front gas-filled shock absorbers . . . . . . . . . . . . . . . . . . . . . . . . 11
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4.2 Releasing gas and draining rear gas-filled shock absorbers . . . . . . . . . . . . . . . . . . . . . . . . 13
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40 - Front suspension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
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1 Front axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
1.1 Overview of fitting locations - front axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
2 Subframe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
2.1 Assembly overview - subframe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
2.2 Fixing position of subframe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
2.3 Lowering subframe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
2.4 Removing and installing subframe without steering rack . . . . . . . . . . . . . . . . . . . . . . . . . . 25
2.5 Removing and installing subframe with steering rack . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
2.6 Repairing subframe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
2.7 Removing and installing anti-roll bar . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
2.8 Removing and installing coupling rod . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
2.9 Repairing thread in longitudinal member . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
3 Suspension strut, upper suspension link . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
3.1 Assembly overview - suspension strut, upper suspension link . . . . . . . . . . . . . . . . . . . . . . 54
3.2 Removing and installing suspension strut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
3.3 Repairing suspension strut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
4 Lower suspension link, swivel joint . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
4.1 Assembly overview - lower suspension link, swivel joint . . . . . . . . . . . . . . . . . . . . . . . . . . 66
4.2 Removing and installing lower suspension link . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
4.3 Checking swivel joint . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
4.4 Removing and installing swivel joint . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
4.5 Renewing front bonded rubber bush for lower suspension link . . . . . . . . . . . . . . . . . . . . . . 78
4.6 Renewing rear bonded rubber bush for lower suspension link . . . . . . . . . . . . . . . . . . . . . . 81
5 Wheel bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
5.1 Assembly overview - wheel bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
5.2 Removing and installing wheel bearing housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
5.3 Removing and installing wheel bearing unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
6 Drive shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
6.1 Overview - drive shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
6.2 Assembly overview - drive shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
6.3 Removing and installing drive shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
6.4 Loosening and tightening threaded connections of drive shaft . . . . . . . . . . . . . . . . . . . . . . 117
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Golf Sportsvan 2015 ➤ , Golf Sportsvan 2018 ➤
Running gear, axles, steering - Edition 03.2018
6.5 Removing and installing drive shaft heat shield . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119

6.6 Dismantling and assembling drive shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119
6.7 Checking outer constant velocity joint . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134
6.8 Checking inner constant velocity joint . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135
42 - Rear suspension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137

1 Rear axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137
1.1 Overview - rear axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137
1.2 Lowering rear axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140
1.3 Removing and installing rear axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 142
1.4 Removing and installing shield for rear axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149
2 Axle beam . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150
2.1 Assembly overview - axle beam . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150
2.2 Renewing bonded rubber bush for axle beam . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 151
3 Subframe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 158
3.1 Assembly overview - subframe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 158
3.2 Assembly overview - add-on parts for subframe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 159
3.3 Fixing position of subframe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 159
4 Anti-roll bar . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 164
4.1 Assembly overview - anti-roll bar . . . . . . . . . .ge. n. A. G. ..V.ol.ks. w. a.g.en. A. G. . . . . . . . . . . . . . . . . . . . . 164
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4.3 Removing and installing coupling rod ris . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . n.te.e. . . . . . . . . .
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5 Suspension link, track rod . . .s a.u. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .or.ac. . . . . . . .
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5.1 Assembly overview - transverse link . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 169
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5.2 Assembly overview - track rod . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 170
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5.3 Removing and installing upper transverse link . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 170
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5.4 Removing and installing lower transverse link . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 171
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5.5 Removing and installing track rod . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 173
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6 Suspension strut, shock absorber, spring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 175
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6.1 Assembly overview - suspension strut, shock absorber, spring . . . . . . . . . . . . . . . . . . . . . . 175
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6.2 Removing and installing shock absorbers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 177
6.3 Repairing shock absorber . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 182
6.4 Removing and installing spring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 184
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7 Wheel bearing assembly, trailing arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 191
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7.1 Assembly overview - wheel bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 191

7.2 Assembly overview - trailing arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 193
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7.3 Removing and installing wheel bearing housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 193

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7.4 Removing and installing wheel bearing unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 197

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7.5 Renewing bonded rubber bush for wheel bearing housing . . . . . . . . . . . . . . . . . . . . . . . . 204
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7.6 Removing and installing trailing arm with mounting bracket . . . . . . . . . . . . . . . . . . . . . . . . 207
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7.7 Repairing trailing arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 209

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43 - Self-levelling suspension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 213
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1 Electronically controlled damping system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 213
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1.1 Assembly overview - electronically controlled damping system . . . . . . . . . . . . . . . . . . . . . .
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1.2 Removing and installing electronically controlled damping control unit J250 . . . . . . . . . . 216
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1.3 Removing and installing front body acceleration senders G341 / G342 . . . . . . . . . . . . . . 217
1.4 Removing and installing rear left body acceleration sender G699 . . . . . . . . . . . . . . . . . . 218
2 Vehicle level sender . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 220
2.1 Assembly overview - front vehicle level senders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 220
2.2 Assembly overview - rear vehicle level senders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 221
2.3 Removing and installing front vehicle level senders G78 / G289 . . . . . . . . . . . . . . . . . . . . 222
2.4 Removing and installing rear vehicle level senders G76 / G77 . . . . . . . . . . . . . . . . . . . . . . 224
44 - Wheels, tyres, vehicle geometry . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 227
ii Contents
1 Wheel alignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 227

1.1 Notes for wheel alignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 227
1.2 Conditions for testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 228
1.3 Test preparations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 228
1.4 Specifications for wheel alignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 230
1.5 Wheel alignment procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 233
1.6 Necessity of wheel alignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 234
1.7 Vehicle data sticker . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 236
1.8 Adjusting camber at front wheels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 237
1.9 Adjusting camber on rear axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 238
1.10 Adjusting toe at rear .axle olkswa. g.e.n .AG.............................................. 239
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1.11 Adjusting ofront kswagaxle toe . . . . . . . d.o.es. n.o. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 240
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1.12 Wheel ed brunout compensation . . . . . . . . . u.ar.a. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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1.13 Checking
utho maximum wheel lock . . . . . . . . . . e.e.or. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 241
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2 ss Adaptive cruise control . . . . . . . . . . . . . . . . . . . .c . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 243
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2.1 Calibrating adaptive cruise control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 243
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3 Front camera for assist systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 257
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3.1 Calibrating front camera for driver assist systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 257
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48 - Steering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 264
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1 Steering wheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 264
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1.1 Assembly overview - steering wheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 264
1.2 Removing and installing steering wheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 264
2 Steering column . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 267
rrectness of i
2.1 Assembly overview - steering column . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 267
l purpos
2.2 Checking steering column for damage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 268

2.3 Handling and transporting steering column . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 268
nf
ercia
2.4 Removing and installing steering column . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 269

orm
2.5 Removing and installing control unit for electronic steering column lock J764 . . . . . . . . . . 278
m
atio
om
3 Steering rack . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 280

n in
or c
thi
3.1 Assembly overview - steering rack . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 280

te
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3.2 Removing and installing steering rack . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 284

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3.3 Removing and installing bellows . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 299

f
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ng
t.
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3.4 Removing and installing track rod . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 302
Co
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t. rig
3.5 pyriRemoving and installing track rod ball joint . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
gh by
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305
3.6 Repairing steering rack . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 306
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4 Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 311
AG.
4.1 Removing and installing steering angle sender G85 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 311
Contents iii
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iv Contents
00 – Technical data
1 Safety information
(VRL011586; Edition 03.2018)
⇒ “1.1 Safety measures when working on vehicles with a start/
stop system”, page 1
⇒ “1.2 Safety precautions when working on subframe”,
page 1
1.1 Safety measures when working on vehicles with a start/stop system

Risk of injury due to unexpected motor start
If the vehicle’s start/stop system is activated, the engine can start
unexpectedly. A message in the dash panel insert indicates
whether the start/stop system is activated.
– Deactivate start/stop system by switching off the ignition.
1.2 Safety precautions when working on

subframe
♦ It is not permitted to weld or straighten load-bearing or wheel-
guiding components of the suspension.
♦ Always renew corroded nuts and bolts.
♦ Bonded rubber bushes can be twisted only to a limited extent.
Therefore, tighten the bolted connections of components with
bonded rubber bushes only when the wheel bearing housing
has been raised (unladen state) ⇒ page 4 . olksw n AG. V agen AG
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1. Safety information
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2 Repair instructions
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⇒ “2.1 Leaks at shock absorbers”, page 2
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⇒ “2.2 Noises from shock absorbers”, page 2
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⇒ “2.3 Checking shock absorbers when removed”, page 3
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⇒ “2.4 Steering rack”, page 3
es, in part or in w
t to the co
⇒ “2.5 Gaskets and seals”, page 4
⇒ “2.6 Nuts and bolts”, page 4
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⇒ “2.7 Electrical components”, page 4
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⇒ “2.8 Raising suspension to unladen position (vehicles with coil

springs)”, page 4
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2.1 Leaks at shock absorbers
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Shock absorbers are often replaced because of externally visible
or c
leakage. Inspections on the test rig and in the vehicle have shown
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that in the majority of cases this replacement is not justified.

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Slight loss of fluid (“sweating”) at the piston rod seal is not a rea‐
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son for replacing a shock absorber. An oil sweating shock ab‐
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sorber is deemed OK under the following conditions: t. C rig
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♦ Fluid seepage (as shown in the shaded part of the illustration)
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is visible, but the fluid is dull and possibly dried by dust.
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♦ The fluid seepage extends only from the top shock absorber
seal (piston rod seal) down to the bottom spring plate
-arrow-.
2.2 Noises from shock absorbers

Shock absorbers are often replaced because of noises (rumbling,
etc.) experienced by the customer. Inspections on the test rig and
in the vehicle have shown that in approx. 70% of these cases
there is no case for complaint. The replacement was not justified.
In the case of complaints regarding rumbling or knocking noises
please proceed as follows.
– Carry out a road test with the customer - if possible on a dry,
uneven road - to establish when, where and how the noises
occur.
Note
These noises are only very rarely caused by the shock absorbers.
2 Rep. gr.00 - Technical data

2.3 Checking shock absorbers when re‐

moved
Defective shock absorbers can be identified by loud rumbling
noises when driving, caused by wheel hopping, especially on bad
roads. Heavy fluid leakage is an additional visual indication.
Note
Shock absorbers are maintenance-free; shock absorber fluid can‐

not be topped up. G. Volkswagen
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After removal,
ed a shock absorber can be checked rby
by ua
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lows: thoris tee
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– Compress
ss shock absorber by hand.
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• The piston rod should move smoothly over the entire stroke
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– Release piston rod.
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• If the shock absorber has sufficient gas pressure the piston
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rod will return by itself to its original position.
spec
es, in part or in w
Note t to the co
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♦ If this is not the case, the shock absorber does not necessarily
need to be renewed. Provided there has been no major loss
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of fluid, it will still be as effective as a conventional shock ab‐

sorber.
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♦ Even without gas pressure, the shock absorber will provide full
damping effect as long as there has been no major loss of fluid.
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However, it may produce more noise.

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2.4 Steering rack

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steering rack it is important to work with the greatest possible care
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and cleanliness, and to use proper tools in good condition. Also
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note the basic rules on safety when performing repair procedures.
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A number of general notes on the individual repair procedures,
AG.
which can otherwise be found in the relevant sections of the

workshop manual, are summarised here. They apply for this par‐
ticular workshop manual.
The design and function of the electromechanical power steering
is described in the self-study programme ⇒ Self-study programme
No. 317 ; The electromechanical power steering with dual pinion .
♦ Thoroughly clean all unions and the adjacent areas before
disconnecting.
♦ When installing the steering rack, make sure that dowel
sleeves between bracket and steering rack are seated cor‐
rectly.
♦ Place removed parts on a clean surface and cover them to
prevent them from getting dirty. Use sheeting and paper for
this purpose. Use lint-free cloths only.
♦ Install only clean parts; do not remove new parts from pack‐
aging until immediately before installing.
♦ Use only the grease and sealants with specified part numbers.
2. Repair instructions 3
♦ If repair work cannot be performed immediately, cover new

parts which have been removed from their packing.
2.5 Gaskets and seals

♦ Always renew seals and gaskets.
♦ When seals have been removed, check contact surface on
housings or shafts for burrs and damage and rectify as nec‐
essary.
♦ Completely remove all residue from liquid sealants from the
sealing surfaces, making sure that no residual sealant gets
into the steering rack housing.
2.6 Nuts and bolts

♦ Loosen and tighten bolts and securing nuts for covers and
housings diagonally.
♦ Avoid canting sensitive parts, such as servo motor withncontrol
AG. Volkswagen AG d
unit. Loosen and tighten them diagonally in stages.
olks
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♦ Specified torques given are for unoiled nuts,
ris bolts and screws.
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♦ Always renew self-locking nuts andssbolts.
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2.7 Electrical components
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You have certainly felt an electric shock when you have touched
spec
something metallic. This is due to the electrostatic charge of the
es, in part or in w
t to the co
human body. This charge can cause malfunctions if you touch the
electric steering rack and steering column components.
– Before working on electrical components, touch an earned
rrectness of i
object, such as a water pipe or a lifting platform. Do not directly
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touch connector contacts.

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Prote AG.
2.8 Raising suspension to unladen position

(vehicles with coil springs)
⇒ “2.8.1 Raising wheel bearing assembly to unladen position (ve‐
hicles with coil springs), front axle”, page 4
⇒ “2.8.2 Raising wheel bearing assembly to unladen position (ve‐
hicles with coil springs), rear axle”, page 6
2.8.1 Raising wheel bearing assembly to unladen position (vehicles with coil
springs), front axle

Special tools and workshop

equipment required agen
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♦ Engine and gearbox jack - V.A.G 1383 A-

♦ Tensioning strap - T10038-
♦ Support - T10149-
Caution
All bolts on running gear components with bonded rubber

bushes may be tightened only when the component is in the
unladen position (normal position).
Bonded rubber bushes can be twisted only to a limited extent.
Axle components with bonded rubber bushes must therefore
be brought to a position equivalent to the unladen (normal) po‐
sition before being tightened.
Otherwise, the bonded rubber bush would be subject to torsion
loading, shortening its service life.
To simulate this position on the lifting platform, raise the respec‐

tive wheel suspension with the engine and gearbox jack - V.A.G
1383 A- and support - T10149- .
Before the respective wheel suspension is raised, the vehicle

must be strapped to the lifting platform arms usingagetensioning
es n
straps - T10038- . olksw ot g
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If the vehicle is not strapped down, there is a danger that the
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– Turn wheel hub until one of the wheel bolt holes is at the top.
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– Attach support - T10149- to wheel hub using wheel bolt.
es, in part or in w
t to the co
Respective nuts and bolts may be tightened only when dimension
-a- between the centre of wheel hub and edge of wheel housing
has been attained.
rrectness of i
The dimension -a- depends on the ride height of the installed run‐
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ning gear:
Running gear 1) Ride height -a- in mm
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Basic (G01/G02/G05/G07/ 383 ± 10 mm

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G18/G22 +2UA)
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Sport (G01/G02 +GM1/G06/ 368 ± 10 mm
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1)The type of running gear fitted to the vehicle is recorded on the
vehicle data sticker. The running gear is identified by the PR
number. Allocation of PR number to corresponding running gear
⇒ page 236 .
– Raise wheel bearing housing using engine and gearbox jack
- V.A.G 1383 A- until dimension -a- is attained.
WARNING
♦ Do not raise or lower the vehicle while the engine and

gearbox jack is positioned under the vehicle.
♦ Do not leave engine and gearbox jack - V.A.G 1383 A-
under vehicle longer than necessary.
– Tighten respective nuts and bolts.

– Lower wheel bearing housing.
– Pull engine and gearbox jack - V.A.G 1383 A- out from under
vehicle.
– Detach support - T10149- .
2.8.2 Raising wheel bearing assembly to unladen position (vehicles with coil
springs), rear axle


equipment required
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bushes may be tightened only when the component is in the py by
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unladen position (normal position).
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Bonded rubber bushes can be twisted only to a limited extent.
Axle components with bonded rubber bushes must therefore
be brought to a position equivalent to the unladen (normal) po‐
sition before being tightened.
Otherwise, the bonded rubber bush would be subject to torsion
loading, shortening its service life.
To simulate this position on the lifting platform, raise the axle on

one side using the engine and gearbox jack - V.A.G 1383 A- and
support - T10149- .
Before the axle on one side is raised, both sides of the vehicle
must be strapped to the lifting platform arms with tensioning wagen AG. Volkswagen AG does
straps - T10038- . olks not
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1- Tensioning strap - T10038- thoris e or
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If the vehicle is not strapped down, there is a danger that the
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– Turn wheel hub until one of the wheel bolt holes is at the top.
es, in part or in w
t to the co
– Attach support - T10149- with a wheel bolt.
Respective nuts and bolts may be tightened only when dimension
rrectness of i
-a- between the centre of wheel hub and edge of wheel housing
has been attained.
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The dimension -a- depends on the ride height of the installed run‐
ning gear:
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Running gear 1) Ride height -a- in mm
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Basic (G01/G02/G05/G07/ 385 ± 10 mm

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Sport (G01/G02 +GM1/G06/ 370 ± 10 mm

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Raised running gear (G01/G02/ 400 ± 10 mm
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Blue Motion (G01G02 +2UP 370 ± 10 mm
AG.
+GM1 G07+2UC/ G21/G26)

1)The type of running gear fitted to the vehicle is recorded on the
vehicle data sticker. The running gear is identified by the PR
number. Allocation of PR number to corresponding running gear
⇒ page 236 .
– Raise wheel bearing housing using engine and gearbox jack
until dimension -a- is attained.
WARNING

gearbox jack is positioned under the vehicle.
♦ Do not leave engine and gearbox jack under vehicle lon‐
ger than necessary.
– Tighten respective nuts and bolts.

– Lower wheel bearing housing.
vehicle.
– Remove support - T10149- .

3 Evaluating accident vehiclesswagen AG. Volkswagen AG does

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⇒ “3.1 Checklist for evaluating running gear on edaccident vehicles”,
by ara
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page 9 thoris eo
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3.1 Checklist for evaluating running gear on
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nl
pt
accident vehicles
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Damage to running gear may go unnoticed during repairs to load-
ility
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bearing and suspension parts of accident vehicles. Under certain
wit
, is n
circumstances, this undiscovered damage could lead to serious
h re
consequential damage during later vehicle operation. Therefore,
hole
spec
the following parts of accident vehicles must be examined in the
es, in part or in w
manner and order described independent of wheel alignment
t to the co
which may have to be performed. If no deviations from specifica‐
tions are measured during wheel alignment, there are no defor‐
mations of the running gear.
rrectness of i
Visual and functional examination of steering system
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♦ Visual examination for deformation and cracks
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♦ Examination for play in track rod joints and steering rack

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♦ Visual examination for tears in boots
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♦ Examine electrical and hydraulic lines and hoses for chafing,

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cuts and kinks.

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♦ Check hydraulic lines, threaded connections and steering rack
for
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for leaks.
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♦ Check steering rack and lines for secure seating
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♦ Check for flawless function from lock to lock by moving the
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steering from stop to stop. In the process, the steering wheel
Prote AG.
must turn with a constant force without resistance.

Visual inspection and functional check of running gear
• Adhere to the sequence of the following inspection steps!
♦ Check all components shown in the assembly overviews for
deformation, cracks and other damage.
♦ Renew damaged parts
♦ Align wheels on a Volkswagen AG-approved wheel alignment
stand
Visual and functional check of wheels and tyres
♦ Check for true running and imbalance.
♦ Check tyres for cuts and impact damage in the tread and on
the flanks ⇒ Wheels and Tyres Guide; Rep. gr. 44 ; Evaluating
tyres .
♦ Check tyre inflation pressure; information on mandatory tyre
inflation pressure can be found on a sticker attached to B-pillar
on driver side or to inside of tank flap.
If rim of wheel and/or tyre is damaged, renew tyre. This also ap‐
plies if the circumstances of the accident and the damage to the
vehicle indicate possible damage which is not visible.
A further factor in the decision is the age of the tyre. Tyres should
not be older than 6 years.
If in doubt, the following always applies:
• Whenever a safety risk cannot be excluded, the tyre(s) must
be renewed.
3. Evaluating accident vehicles 9

Complete vehicle
Also check other vehicle systems such as:
♦ Brake system including ABS
♦ Visual and functional examination of exhaust system and pas‐
senger protection
Specifications for testing and adjusting can be found in the re‐
spective workshop manual in ELSA.
The accident vehicle check described here applies to the running
gear. This makes no claim to completeness for the overall vehicle.
Electronic vehicle systems
Safety-relevant systems such as ABS/EDL; airbags; electronical‐
ly regulated suspension systems; electromechanical
n AG. Volkswageor
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hydraulic steering and other driver Vo assist systems must be read
lks es n
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with the ⇒ Vehicle diagnosticsedtester for possibly stored fault mes‐ uaran
b
sages. If faults are savedthino the event memories of the systems
ir tee
or
mentioned above, repairss
au
them according to instructions in work‐ ac
shop manuals in ELSA. Following repairs, read event memories
ce
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nl
of the affected systems again to ensure that complete function
pt
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has been restored.
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4 Waste disposal
⇒ “4.1 Releasing gas and draining front gas-filled shock absorb‐
ers”, page 11
⇒ “4.2 Releasing gas and draining rear gas-filled shock absorb‐
ers”, page 13 gen AG
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4.1 Releasing gas and draining front gas-fil‐ ed
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⇒ “4.1.1 Releasing gas and draining front gas-filled shock ab‐
ce
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pt
sorbers, conventional shock absorbers”, page 11
du
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⇒ “4.1.2 Releasing gas and draining front gas-filled shock ab‐
ab
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sorbers, DCC shock absorbers”, page 12
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4.1.1 Releasing gas and draining front gas-fil‐
h re
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spec
led shock absorbers, conventional
es, in part or in w
t to the co
shock absorbers
– Clamp gas-filled shock absorber vertically in vice, with piston
rrectness of i
rod pointing downwards.
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WARNING
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Safety goggles must be worn when drilling.

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– Drill a 3 mm hole -A- through outer tube of shock absorber.
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– Continue drilling until the inner tube has been penetrated (ap‐
Prote AG.
prox. 25 mm deep).
– Drill a 6 mm hole -B- through outer and inner tube of shock
absorber.
– Hold shock absorber over an oil drip tray. Move the piston rod
back and forth over its full extension until no further oil es‐
capes.
4. Waste disposal 11
4.1.2 Releasing gas and draining front gas-fil‐

led shock absorbers, DCC shock ab‐
sorbers
– Clamp gas-filled shock absorber vertically in vice.
WARNING
Note
Gas escapes upon penetration.
prox. 25 mm deep).
absorber. AG. Volkswagen AG d
agen oes
olksw not
– Hold shock absorber over an oil drip tray. Move the piston rod d by V gu
ara
back and forth over its full extension until no further oil es‐ oris e nte
eo
capes. aut
h
ra
ss c
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nl
pt
du
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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
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nf
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orm
m
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om
n in
or c
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Cop py
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rig ht
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AG. Volkswagen AG d
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4.2 Releasing
by
Vol
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oes
not rear gas-fil‐
gu
is led shock absorbers
d ara
e nte
r
ho
t e or
au a
⇒ “4.2.1
ss Releasing gas and draining rear gas-filled shock absorb‐
c
ers, conventional shock absorbers”, page 13
ce
le
un
pt
an
d
itte
⇒ “4.2.2 Releasing gas and draining rear gas-filled shock absorb‐
y li
erm
ab
ers, DCC shock absorbers”, page 14
ility
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4.2.1 Releasing gas and draining rear gas-fil‐
wit
is n
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ole,
led shock absorbers, conventional
spec
shock absorbers
t to the co
rrectne
WARNING
ss
o
cial p
f inform
mer
atio
om
n
c
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or
n thi
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sd
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Note
iv
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pr
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t.
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p by
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prox. 25 mm deep).
lksw
cted agen
Prote AG.
absorber.
capes.
4. Waste disposal 13
4.2.2 Releasing gas and draining rear gas-fil‐

led shock absorbers, DCC shock ab‐
sorbers
WARNING
Note
prox. 25 mm deep).
absorber.
capes.
AG. Volkswagen AG d
agen oes
olksw not
V gu
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or eo
h
aut ra
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le
un
pt
an
d
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ab
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spec
t to the co
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cial p
f inform
mer
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t.
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Prote AG.

40 – Front suspension
1 Front axle
⇒ “1.1 Overview of fitting locations - front axle”, page 15
1.1 Overview of fitting locations - front axle
I - ⇒ “2 Subframe”, page 16
II -
⇒ “3 Suspension strut, upper
suspension link”, page 54
III -
⇒ “4 Lower suspension link,
swivel joint”, page 66
IV - wage
es n
⇒ “5 Wheel bearing”,y Volks ot g
ua
page 85 ised b ran
r tee
ho
aut or
ac
ss
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es, in part or in w
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nform
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c
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ate
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1. Front axle 15
2 Subframe
⇒ “2.1 Assembly overview - subframe”, page 16
⇒ “2.2 Fixing position of subframe”, page 17
⇒ “2.3 Lowering subframe”, page 21
⇒ “2.4 Removing and installing subframe without steering rack”,
page 25
⇒ “2.5 Removing and installing subframe with steering rack”, page
29
⇒ “2.6 Repairing subframe”, page 41
⇒ “2.7 Removing and installing anti-roll bar”, page 48
⇒ “2.8 Removing and installing coupling rod”, page 52
⇒ “2.9 Repairing thread in longitudinal member”, page 53
2.1 Assembly overview - subframe
1 - Anti-roll bar with rubber

bush
❑ Removing and installing
⇒ page 48
2 - Nut
❑ When tightening, coun‐
terhold on multipoint
socket of joint stub.
❑ Renew after removal
❑ 65 Nm
AG. Volkswagen AG d
agen oes
3 - Suspension strut Volksw not
gu
d by ara
e
4 - Coupling rod horis nte
eo
ut
❑ Removing and installing ss a ra
c
⇒ page 52
ce
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un
pt
an
d
5 - Subframe
itte
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ab
❑ Fixing position
pe
⇒ page 17 ility
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❑ Lowering ⇒ page 21 h re
hole
spec
es, in part or in w
without steering rack

t to the co
⇒ page 25
with steering rack
rrectness of i
⇒ page 29
l purpos
6 - Bolt
nform
ercia
❑ 70 Nm +180°
m
a
com
ti
7 - Bolt
on in
r
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thi
s
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❑ 20 Nm +180°
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8 - Left support
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9 - Bolt
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❑ 50 Nm +90°
agen
Prote AG.
16 Rep. gr.40 - Front suspension

10 - Bolt
❑ Renew after removal agen
AG. Volkswagen AG d
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❑ 70 Nm +180° d by
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ise nte
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11 - Right support ut
ho eo
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12 - Lower bonded rubber bush for pendulum support s
ce
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nl
pt
❑ Renewing ⇒ page 41
du
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itte
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13 - Upper bonded rubber bush for pendulum support
ab
ility
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14 - Nut
hole
spec
❑ When tightening, counterhold on multipoint socket of joint stub.
es, in part or in w
t to the co
❑ 65 Nm
rrectness of i
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2.2 Fixing position of subframe
nf
ercia
orm
Note
m
atio
om
n in
c
♦ Certain repairs on vehicles require the removal of the sub‐

or
thi
e
frame or the entire front axle.

t
sd
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cu
♦ The original position of the subframe relative to the body can
o
m
f
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ng
be retained with the aid of qty. 4 locating pins - T10486/1- .

t.
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Cop py
♦ Qty. 2 locating pins - T10486/1- are a part of locating device -
t. rig
gh ht
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T10486- . When locating device - T10486- is already being
p by
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by c lksw
employed, then only the addition of qty. 2 locating pins - Prote
cted AG.
agen
T10486/1- are required.
♦ If the locating device - T10486- is not being employed, then
use locating device - T10486 A- . This contains qty. 4 locating
pins - T10486/1- and qty. 2 locating pins - T10486/2- . The
locating pins - T10486/2- are not required for the following
process.
2. Subframe 17

equipment required
AG. Volkswagen AG d
agen oes
olksw not
y V gu
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rise nte
tho eo
au ra
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ce
♦ Qty. 4 locating pins - T10486/1-

e
nl
pt
du
an
itte
♦ Engine and gearbox jack - V.A.G 1383 A- with gearbox support

y li
erm
ab
- V.A.G 1359/2- .
ility
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♦ Torque wrench - V.A.G 1332-

, is n
h re
hole
– Remove front and rear noise insulation ⇒ General body re‐

spec
pairs, exterior; Rep. gr. 66 ; Noise insulation; Assembly over‐

es, in part or in w
t to the co
view - noise insulation .

– Unbolt pendulum support bolts -1- from gearbox.
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
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t.
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Cop py
t. rig
gh ht
pyri by
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co lksw
by
cted agen
Prote AG.

– Position engine and gearbox jack - V.A.G 1383 A- -1- under

subframe
– If necessary, clean thread of locating pins - T10486/1- .
AG. Volkswagen AG d
agen oes
olksw not
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rise nte
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• To fix position of subframe, locating pins - T10486/1- must be ss c
ce
le
screwed one after the other into positions -3-, -5-, -7- and un
pt
-8-.
an
d
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pe
ility
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Note
wit
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hole
The locating pins - T10486/1- must NOT be tightened to more
spec
es, in part or in w
than 20 Nm, otherwise the threads of the locating pin will be dam‐
t to the co
aged.
Fixing position of subframe at rear
rrectness of i
l purpos
– Unscrew bolts -1-.
nform
ercia
– Remove bolt -3- and remove support -4-.

m
a
com
tion in
r
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s
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fo
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t.
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Cop py
t. rig
gh ht
pyri by
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co lksw
by
cted agen
Prote AG.
– Insert locating pins - T10486/1- -1- and tighten to 20 Nm.
2. Subframe 19

– Remove bolt -5- and remove support -6-.
– Insert locating pins - T10486/1- and tighten to 20 Nm.
Fixing position of subframe at front
AG. Volkswagen AG d
– Remove screw -8-. olksw
agen oes
not
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un
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d
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spec
t to the co
– Insert locating pins - T10486/1- -1- and tighten to 20 Nm.
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
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fo
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t.
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Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

. Volkswage
AG n AG d
agen oes
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– Remove screw -7-. db
yV gu
ara
rise nte
– Insert locating pins - T10486/1- anduthtighten
o to 20 Nm. eo
ra
s a c
s
• The fixing of the subframe is completed when all the above
ce
le
un
mentioned bolts have been replaced consecutively with the
pt
an
d
locating pins - T10486/1- .
itte
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rm
ab
pe
• The position of the subframe is now fixed.
ility
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Remove locating pins - T10486/1-
h re
hole
spec
Removal is carried out in the reverse sequence, noting the fol‐
es, in part or in w
lowing:
t to the co
– Always only unscrew one locating pin at a time and replace it
with a new bolt.
rrectness of i
– On vehicles with vehicle level sender, carry out basic setting
l purpos
⇒ Vehicle diagnostic tester.

Specified torques
nform
ercia
♦ ⇒ “2.1 Assembly overview - subframe”, page 16

m
a
com
ti
♦ Bolts for pendulum support ⇒ Rep. gr. 10 ; Assembly mount‐
on in
ings; Assembly overview - assembly mountings .
r
te o
thi
s
iva
♦ Bolts for noise insulation ⇒ General body repairs, exterior;
do
r
rp
c
Rep. gr. 66 ; Noise insulation; Assembly overview - noise in‐
um
fo
en
g
sulation .
n
t.
yi Co
op py
If the steering wheel is found to be off centre during the road test
t. C rig
gh ht
yri
even though locating pins - T10486/1- were used, check wheel p by
co Vo
alignment. In this case the wheel alignment test results must be
by lksw
cted agen
Prote
archived in the vehicle files.
AG.
2.3 Lowering subframe

Special tools and workshop equipment required
2. Subframe 21
Removing
wage es n
– Turn steering wheel to straight-ahead
yV
olk s position and remove oig‐
t gu
nition key so that the steering
ised b lock engages. ara
nte
or eo
h
Vehicles with keylesss aentry
ut and start system “Keyless Access” ra
c
s
– Switch off ignition and open driver’s door so that the steering
ce
e
nl
pt
du
lock engages.
an
itte
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erm
ab
– Disconnect battery ⇒ Electrical system; Rep. gr. 27 ; Battery;
ility
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Disconnecting and reconnecting battery .
wit
, is n
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For left-hand drive models only
hole
spec
– Unscrew bolt -1- and fold footwell covering -2- in direction of
es, in part or in w
t to the co
arrow towards vehicle interior.
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
te
For right-hand drive models only

a
do
priv
cum
or
– Unscrew bolt -1-.

f
en
ng
t.
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– Press foot rest -2- upwards in direction of -arrow- and remove. ht. Cop py
rig
rig ht
– Fold floor covering to the rear. py by
co Vo
by lksw
cted agen
Continued for all vehicles Prote AG.
– Unscrew bolt -1- from universal joint -2- and pull off universal
joint in -direction of arrow-.
Caution
The following work must not be performed while the universal

joint is separated from the steering rack:
♦ Connect battery
♦ Switch on ignition
♦ Turn steering mechanism
♦ Turn steering column
These points must absolutely be heeded because otherwise,
irreparable damage may be caused.
– Remove lower noise insulation ⇒ General body repairs, ex‐

terior; Rep. gr. 66 ; Noise insulation; Assembly overview -
noise insulation .

For vehicles with natural gas engines

– Unclip natural gas line -1- from clip -arrow-.
Continued for all vehicles
– Detach exhaust system bracket from subframe -arrows-.
AG. Volkswagen AG d
agen oes
olksw not
V gu
– Remove bolts -1- for pendulum support.
d by ara
rise nte
tho eo
au ra
ss c
ce
e
nl
pt
du
an
itte
y li
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
– Remove hexagon nut -1- from coupling rod -3- (left and right
sides).
l purpos
– Pull coupling rod -3- out of anti-roll bar -2- on left and right side.
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
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cu
o
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.
2. Subframe 23
Vehicles with vehicle level sender.

– Disconnect connector -1- on front left vehicle level sender -
G78- and/or front right vehicle level sender - G289- , as
applicable.

subframe
– Fix position of subframe ⇒ page 17 and lower approx. 10 cm.
Note
AG. Volkswagen AG d
agen oes
ksw
Be sure to observe the electrical by wiring of the steering and the guar
Vol not
wiring of oil level and oil temperature
ris
ed
senders - G266- to avoid an
tee
overstretching them. autho or
ac
ss
ce
e
Installing
nl
pt
du
an
itte
Carry out installation in the reverse sequence, noting the follow‐ y li

erm
ab
ing: ility
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, 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
gh ht
pyri by
Vo
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by c lksw
cted agen
Prote AG.

– Renew seal -1-.

– Slide seal -1- over collar of steering rack -2- so that rubber lip
makes contacts with collar all round -arrows-.
– Make sure that seal -1- is firmly seated.
– Coat seal with lubricant e.g. soft soap from above.
Note
♦ After fitting the steering rack to the universal joint ensure that
the seal is not kinked against the assembly plate on the steer‐
ing rack. The opening to the footwell must be sealed correctly.
Otherwise, this can result in water leaks and/or noise.
♦ Ensure sealing surfaces are clean.
AG. Volkswagen AG d
agen oes
olksw not
V
– Removing locating pins - T10486/1- ⇒ page 21 . ed b y gu
ara
ris nte
o eo
– On vehicles with vehicle level sender, carryauout
th basic setting ra
⇒ Vehicle diagnostic tester. ss c
ce
e
nl
pt
Specified torques
du
an
itte
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erm
ab
ility
ot p
♦ ⇒ “3.1 Assembly overview - steering rack”, page 280
wit
, is n
h re
♦ ⇒ “2.1 Assembly overview - steering column”, page 267
hole
spec
es, in part or in w
t to the co
rrectness of i
sulation .
l purpos
♦ Exhaust system to subframe ⇒ Rep. gr. 26 ; Exhaust pipes/

silencers; Assembly overview - silencer .
nform
ercia
m
at
even though locating pins - T10486/1- were used, check wheel
om
io
n
c
in t
or

his
ate
do
priv
cum
or
2.4 Removing and installing subframe with‐

f
en
ng
t.
yi
out steering rack
Co
Cop py
t. rig
gh ht
yri
p by
co Vo
by lksw
cted agen
Prote AG.
2. Subframe 25
Removing
Note
The subframe is removed together with the suspension links.
– Loosen wheel bolts.

– Raise vehicle.
– Remove wheels.
terior; Rep. gr. 66 ; Noise insulation; Assembly overview - wagen AG. Volkswagen AG doe
noise insulation . yV
olks s no
t gu
b ara
ed
For vehicles with natural gas engines thoris nte
e or
au ac
– Unclip natural gas line -1- from clip -arrow-. ss
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
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.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

sides).
– Remove nuts -arrows- on left and right sides of vehicle.
AG. Volkswagen AG d
agen oes
olksw not
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rise nte
tho eo
au ra
ss c
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

applicable.
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
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
2. Subframe 27
– Pull wiring harness -3- clips -1- and -2- off subframe and steer‐
ing rack.
– Remove bolts -1- for steering rack.

– Prise steering rack out of dowel sleeves of subframe.

subframe
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
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aut ra
ss c
ce
le
un
pt
an
d
itte
y li
erm
– Pull out spreader clip -arrow-. ab

ility
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wit
– Lower subframe with engine and gearbox jack - V.A.G 1383
is n
h re
A- .
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
t.
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Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

– Secure subframe on engine and gearbox jack - V.A.G 1383

A- .
– Secure steering rack to body.
Installing
Carry out installation in the reverse sequence, noting the follow‐
ing:
– Tighten nuts -arrows-.

Specified torques
♦ ⇒ “2.1 Assembly overview - subframe”, page 16 agen
AG. Volkswagen AG d
oes
olksw not
♦ ⇒ “3.1 Assembly overview - steering rack”, page 280ed by V gu
ara
ris nte
o
♦ Bolts for pendulum support ⇒ Rep. gr. 10 ; Assembly
aut
h mount‐ eo
ra
ings; Assembly overview - assembly mountings s .
s c
ce
le
un
pt
an
d
itte
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erm
ab
sulation .
ility
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wit
is n
h re
ole,
spec
♦ Wheel bolts ⇒ Wheels and Tyres Guide; Rep. gr. 44 ; Wheels,
t to the co
tyres; Specified torque for wheel bolts
rrectne
ss o
cial p
f
2.5 Removing and installing subframe with
inform
mer
steering rack
atio
om
n
c
⇒ “2.5.1 Removing and installing subframe with steering rack, i

or
n thi
LHD”, page 29
te
sd
iva
o
r
⇒ “2.5.2 Removing and installing subframe with steering rack,

p
cum
r
fo
RHD”, page 36
en
ng
t.
yi Co
op py
2.5.1 Removing and installing subframe with
. C rig
ht ht
rig by
steering rack, LHD copy Vo
by lksw
cted agen
Prote AG.
2. Subframe 29
♦ Ball joint puller - T10187-
AG. Volkswagen AG d
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olksw not
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d by ara
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or eo
h
aut ra
ss c
ce
le
un
pt
an
d
itte
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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
Removing
en
ng
t.
yi Co
op
– Turn steering wheel to straight-ahead position and remove ig‐
C py
t. rig
gh
nition key so that the steering lock engages.
ht
pyri by
Vo
o
by c lksw
Vehicles with keyless entry and start system “Keyless Access”
cted agen
Prote AG.
lock engages.
– Unscrew bolts -1- and fold footwell trim -2- in
-direction of arrow- towards vehicle interior.

Caution

AG. Volkswagen AG d
♦ Connect battery olksw
agen oes
not
V gu
by
♦ Switch on ignition rised ara
nte
ho eo
♦ Turn steering mechanism aut ra
ss c
ce
e
nl
pt
du
an
itte
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erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
– Raise vehicle.
t to the co
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nut.
1- Ball joint puller - T10187-


applicable.
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sender - G266- .
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subframe
2. Subframe 33
– Unscrew bolts -arrows- and remove heat shield -1- from steer‐
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A- .

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with the appropriate strap.
Installing
Install in reverse order. During this procedure, observe the fol‐
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– Renew seal -1-.

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2. Subframe 35
2.5.2 Removing and installing subframe with

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subframe
2. Subframe 39
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– Secure subframe to engine and gearbox jack - V.A.G 1383 A-

with the appropriate strap.
Installing
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sulation .
2.6 Repairing subframe
2. Subframe 41
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♦ Assembly tool - T10205A-

♦ Hydraulic cylinder - VAS 6178-
♦ Foot pump - VAS 6179-
♦ Assembly tool - VAS 6779-
♦ Thrust plate - VW 401-

♦ Press tool - VW 412-
Renewing bonded rubber bushes for pendulum support

– Remove front noise insulation ⇒ General body repairs, exte‐
rior; Rep. gr. 66 ; Noise insulation; Assembly overview - noise
insulation .
sides).
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ings; Removing
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Pressing out bonded rubber bush

– Fit assembly tool - VAS 6779- to subframe as shown in illus‐
rrectne
tration.
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ss
rubber bush so that flattened side -arrow- faces to direction of

o
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inform
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2. Subframe 43
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1 - Thrust piece for removal - VAS 6779/1-

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2 - Tube - VAS 6779/4-

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spec
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5 - Hexagon nut - VAS 6779/3-

t to the co
6 - Threaded spindle - VAS 6779/2-

rrectness of i
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– Press out both bonded rubber bushes until upper bonded rub‐
ber bush -2- is visible in pendulum support opening -arrow- in
subframe.
– Carry out visual check of outer ring of upper bonded rubber
bush -2-.
• If outer ring of upper bonded rubber bush -2- is deformed, de‐
stroy it through opening of pendulum support -arrow- in pen‐
dulum support.
– Using a chisel or similar -1-, create a break in the outer ring of
the upper bonded rubber bush -2-.
Note
This process is necessary to prevent the canting of the outer ring wagen AG. Volkswagen AG doe
of the upper bonded rubber bush in the area of the opening ofythe
Vol
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Preparing bonded rubber bush for pressing in

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hole
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es, in part or in w
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– Insert bonded rubber bushes -1- into larger diameter of tube -

m
VAS 6779/6- -2- with bolt head facing upwards.
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r
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s
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2. Subframe 45
AG. Volkswagen AG d
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3- Bonded rubber bush
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spec
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6- Pressure plate - VW 401-
rrectness of i
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– Insert counterhold - VAS 6779/7- -1- into subframe.
n
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– Insert counterhold attachment - VAS 6779/7-1A- -2- into pen‐

at
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Pressing in bonded rubber bush

– Screw threaded spindle - VAS 6779/2- -7- into counterhold -
VAS 6779/7- -1-
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tration.

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3 - Thrust piece - VAS 6779/9-
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4 - Stepped ring - VAS 6779/8- ; mark -I- on stepped ring must

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6 - Hexagon nut - VAS 6779/3-
7 - Threaded spindle - VAS 6779/2-
– Press in both bonded rubber bushes together.
– Remove assembly tool - VAS 6779- from subframe and check
pressed-in bonded rubber bushes are properly seated.
– Bolt anti-roll bar to subframe and coupling rods.
– Install pendulum support ⇒ Rep. gr. 10 ; Assembly mountings;
Removing and installing pendulum support .
– Install front noise insulation ⇒ General body repairs, exterior;
sulation .
2. Subframe 47
Specified torques
sulation .
2.7 Removing and installing anti-roll bar

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Removing
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mer
atio
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noise insulation .
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Continued for all vehicles cted agen
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2. Subframe 49

applicable.
– Unscrew nut -1-.

– Pull bracket -2- for front left vehicle level sender - G78- or front
right vehicle level sender - G289- out of suspension link -3-.

– Remove front left vehicle level sender - G78- -2- and/or front
right vehicle level sender - G289- , as applicable.
Continued for all vehicles AG. Volkswagen AG d
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ing rack.
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– Prise steering rack
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– Lower subframe using engine and gearbox jack - V.A.G 1383 cop Vo
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Installing
ing:
2. Subframe 51
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♦ The lever of the vehicle level sender
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in suspension link. Retaining lug for vehicle level sender must
an
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Specified torques
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♦ ⇒ “2.1 Assembly overview - front vehicle level senders”, page
ss
220
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2.8 Removing and installing coupling rod

Removing
– Raise vehicle.

– Unscrew nut -arrow- and pull coupling rod -1- off suspension
strut.
– Unscrew hexagon nut -1- from coupling rod -3-.

– Pull coupling rod -3- out of anti-roll bar -2-.
Installing
ing:
• Tighten nuts of coupling rod on suspension strut/anti-roll bar,
if necessary, counterhold at multi-point socket head.
Specified torques
2.9 Repairing thread in longitudinal member

Repairing the thread in welded nuts in the longitudinal member is
possible under certain conditions; Body repair ⇒ Body Repairs;
Rep. gr. 50 . . Volkswag AG en AG
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es, in part or in w
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2. Subframe 53
3 Suspension strut, upper suspension

link
⇒ “3.1 Assembly overview - suspension strut, upper suspension
link”, page 54
⇒ “3.2 Removing and installing suspension strut”, page 55
⇒ “3.3 Repairing suspension strut”, page 62
3.1 Assembly overview - suspension strut, upper suspension link
1 - Spring seat
❑ Observe installation po‐
sition
2 - Shock absorbers
❑ Different versions avail‐
able ⇒ Electronic parts
catalogue “ETKA”
3 - Bolt
❑ Tip of bolt must point in
direction of travel.
❑ 70 Nm +180°
4 - Wheel bearing housing
5 - Nut
6 - Protective cover
❑ Different versionsksavail‐ n AG. Volkswagen AG do
l wage es n
able ⇒ Electronic
by V parts
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catalogueris“ETKA”
ed ran
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7 - Coil spring
ss
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un
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⇒ page 62
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❑ Surface of spring coil

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ility
must not be damaged.

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t to the co
8 - Deep groove ball thrust

bearing
rrectne
9 - Buffer stop
❑ Different versions available ⇒ Electronic parts catalogue “ETKA”
ss
10 - Suspension strut mounting

o
cial p
f in
❑ Note correct installation position ⇒ page 60 .

form
mer
11 - Nut
atio
om

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❑ 60 Nm
t
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Rep. gr.40 - Front suspension
agen
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12 - Body - front
13 - Bolt
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❑ Renew after removal agen oes
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❑ 15 Nm +90° d by ara
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14 - Cover aut ra
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3.2 Removing and installing suspension strut
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♦ Spreader - 3424-
3. Suspension strut, upper suspension link 55

♦ Ejector - T10520-
Removing
– Loosen drive shaft bolt at wheel hub ⇒ page 117 .
Caution
Wheel bearings must not be subjected to load after bolt secur‐

ing drive shaft to wheel hub has been loosened.
If wheel bearings are loaded with weight of vehicle, bearing will
be damaged. This reduces the service life of the wheel bearing.
It is not permissible to loosen drive shaft bolt more than 90° if
vehicle is standing on its wheels.
Do not attempt to move the vehicle without the drive shafts
fitted as this would damage the wheel bearing. If a vehicle must
nevertheless be moved, comply with the following:
♦ Install an outer joint instead of the drive shaft.
♦ Tighten outer joint to 120 Nm.
– Loosen wheel bolts. AG. Volkswagen AG d

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– Raise vehicle. by
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– Remove wheel. hor eo
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– Unscrew nut -arrow- and pull coupling rod -1- off suspension ss c
ce
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strut.
un
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– Detach wire for ABS speed sensor from suspension strut.

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AG. Volkswagen AG d
– Remove nuts -arrows- agen oes
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– Pull wheel bearing housing
orise with swivel joint out of suspension nte
link. aut
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– Pull outer joint of drive shaft out of wheel hub.
ce
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nl
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If the drive shaft cannot be pulled out of the wheel bearing by
itte
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hand, use ejector - T10520- .
erm
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Before using press tool - T10520- ensure that thrust piece -1- is
rrectness of i
inserted.
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Using ejector - T10520- :

– To press out drive shaft -3-, secure ejector - T10520- -1- to
wheel hub using 3 wheel bolts -2-.

Golf Sportsvan 2015 ➤ , Golf Sportsvan 2018 ➤ AG. Volkswagen
n AG do
Running gear, axles, steering - Edition 03.2018wage es n
olksV o t gu
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– It is essential to follow specified sequence.
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I- Tighten knurled nut -1- hand-tight. ss c
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nl
pt
II - Turn only bolt -2- using a spanner in order to press out drive
du
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shaft with ejector - T10520- .
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Note
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spec
At the end of the procedure or for pressing out drive shaft further,
es, in part or in w
t to the co
the spindle must be moved to its original position in order to apply
the hydraulic force.
rrectness of i
– Secure drive shaft to body with wire.
l purpos
Caution
nform
ercia
Do not allow the drive shaft to hang down under its own weight,
m
at
for this would allow the inner joint to bend too far and be dam‐
om
io
aged.
n
c
in t
or
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ate
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Vehicles with adaptive chassis control DCC

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

air on the contacts on the shock absorber and the connector.
– Insert a screwdriver -1- into brake disc between brake caliper

and brake carrier.
– Secure engine and gearbox jack - V.A.G 1383 A- with support
- T10149- -2- to wheel hub using a wheel bolt.
WARNING

gearbox jack - V.A.G 1383 A- is positioned under the ve‐
hicle. The vehicle could slip off the lifting platform.

– Separate threaded connection between wheel bearing hous‐

ing and suspension strut -arrow-.
– Insert spreader - 3424- in slot in wheel bearing housing.
Note
Make sure that the spreader - 3424- is only inserted into the wheel
bearing housing. Insert sufficiently to ensure that the metal tab
swaof
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does
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– Turn ratchet handle through 90° and detach afrom
ut spreader - or
ac
3424- . ss
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un
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– Press brake disc towards suspension strut by hand.
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Otherwise the shock absorber tube can cant in the bore of the
ility
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wheel bearing housing.
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– Lower wheel bearing housing -1- in -direction of arrow- using
spec
engine and gearbox jack - V.A.G 1383 A- .
t to the co
– Lower wheel bearing housing -1- until shock absorber is hang‐
ing free -arrow-.
rrectne
– Bolt swivel joint to suspension link again and tighten wheel
bearing housing to subframe.
ss
o
cial p
f
support - T10149- .
inform
mer
atio
WARNING
om
n
c
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– Pull seal off entire length of plenum chamber cover.
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– Detach clips. cop Vo
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– Remove bulkhead ⇒ General body repairs, exterior; Rep. gr.
50 ; Bulkhead; Removing and installing bulkhead .

– Unscrew bolts -1- for upper shock absorber mounting and re‐
move suspension strut.
Installing
– Position suspension strut so that the arrows -1- are always on

the inner side.
– One of the two arrows -1- on the spring plate -2- must point in
direction of travel.
– Insert suspension strut and bolt bolts -1- to body.
AG. Volkswagen AG d
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ab
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– Position engine and gearbox jack - V.A.G 1383 A- under sup‐

ot p
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port - T10149- and secure wheel bearing housing.

is n
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– Untie wheel bearing housing from subframe.

spec
t to the co
rrectness o
cial p
f inform
mer
atio
om
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c
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Golf
AG. VolkswagenSportsvan
AG do 2015 ➤ , Golf Sportsvan 2018 ➤
agen
olksw Running egear,
s no axles, steering - Edition 03.2018
t gu
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– Remove nuts -arrows- uthor eo
a ra
s c
– Pull wheel bearing housing
s with swivel joint out of suspension
ce
e
link.
nl
pt
du
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itte
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erm
ab
ility
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hole
spec
es, in part or in w
t to the co
rrectness of i
– Lower wheel bearing housing -1- in -direction of arrow- using
l purpos
engine and gearbox jack - V.A.G 1383 A- .

– Press wheel bearing housing upwards using engine and gear‐
nform
ercia
box jack - V.A.G 1383 A- , guide into suspension strut in the

m
process.
at
om
ion
c
– Bolt swivel joint to suspension link again and continue to press
in t
or
his
e
wheel bearing housing upwards until final position is reached

at
do
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on suspension strut.
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– Remove spreader - 3424- .
– Insert new bolts, tip of bolt must point in direction of travel.

– Attach wheel bearing housing to suspension strut using new
nut -arrow-.
Continue installation in reverse order of removal. During this pro‐
cedure, observe the following:

lkswage es n
Golf Sportsvan 2015d ➤ by , Golf Sportsvan 2018 ➤
Vo ot g
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ran
horise
steering - Edition 03.2018 tee
ut or
a ac
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Note
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♦ The lever of the vehicle level sender must point towards the
h re
outside of the vehicle.
hole
spec
es, in part or in w
t to the co
position.
rrectness of i
l purpos
– Install bulkhead ⇒ General body repairs, exterior; Rep. gr.

50 ; Bulkhead; Removing and installing bulkhead .
nf
ercia
or
m
m
atio
m
Specified torques
o
n in
or c
thi
e
♦ ⇒ “3.1 Assembly overview - suspension strut, upper suspen‐

t
sd
iva
sion link”, page 54
o
r
rp
cu
o
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f
♦ ⇒ “4.1 Assembly overview - lower suspension link, swivel
en
ng
t.
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joint”, page 66 t. Cop py
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♦ ⇒ “2.1 Assembly overview - subframe”, page 16 yri
p by
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220
♦ ⇒ “6.2 Assembly overview - drive shaft”, page 95
♦ Bulkhead nuts ⇒ General body repairs, exterior; Rep. gr. 50 ;
Bulkhead: Assembly overview - bulkhead
3.3 Repairing suspension strut


equipment required
AG. Volkswagen AG d
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d by ara
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♦ Torque wrench - V.A.G 1332- ss a c
ce
le
♦ Spring compressor - V.A.G 1752/1-

un
pt
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♦ Spring retainer - V.A.G 1752/4-

rm
ab
pe
ility
♦ Shock absorber tool set - T10001-

ot
wit
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♦ Commercially available ratchet handle

hole
spec
es, in part or in w
♦ Ring spanner insert - V.A.G 1332/7-

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.
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– Remove coil spring strut ⇒ page 56 .
Co
Cop py
t. rig
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pyri by
Vo
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by c lksw
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63
agen
Prote AG.
3. Suspension strut, upper suspension link
AG. Volkswagen AG d
agen oes
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d by ara
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Golf Sportsvan 2015 ➤ , Golf Sportsvan horis
2018 ➤ eo
ut
Running gear, axles, steering - Edition
ss a 03.2018 ra
c
ce
e
nl
pt
Removing spring
du
an
itte
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erm
– Clamp suspension strut support clamp - V.A.G 1752/20- -4- in
ab
ility
a vice.
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– Clamp suspension strut in suspension strut support clamp -
h re
hole
V.A.G 1752/20- -4-.
spec
es, in part or in w
– Pre-tension coil spring with spring compressor - V.A.G 1752/1-
t to the co
until deep groove ball thrust bearing is free at top.
1- Torque wrench - V.A.G 1332-
rrectness of i
2- Hexagon bit, long reach - T10001/8-
l purpos
3- Spring compressor - V.A.G 1752/1-
nform
ercia
4- Strut support clamp - V.A.G 1752/20-

m
5- Spring retainer - V.A.G 1752/4-
at
om
ion
c
6- Hexagon bit, long reach - T10001/5-
in t
or
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ate
7- Ratchet wrench - T10001/11-
do
priv
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for
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WARNING
Co
Cop py
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First compress spring far enough to ensure that upper spring
p by
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plate is free. cted agen
Prote AG.
– Ensure that coil spring is correctly seated in spring retainer -

V.A.G 1752/4- -arrow-.
Installing spring
– Insert spring seat -1- into shock absorber -2-.
– Fit coil spring -3- with spring compressor - V.A.G 1752/1- onto
lower spring seat.
The end of the coil spring must lie against the stop -arrow-.
– Assemble all other parts and use new nut on piston rod.
Caution
Noise can ensue if the suspension strut mounting is not as‐

sembled correctly in relation to the deep groove ball thrust
bearing.
♦ Observe installation position of suspension strut mounting
in relation to deep groove ball thrust bearing when as‐
sembling.

– Align suspension strut mounting -1- with deep groove ball

thrust bearing -2-.
• Lug of suspension strut mounting -1- must be located in recess
-arrow A- of deep groove ball thrust bearing -2-.
• Edge of suspension strut mounting -1- must be folded over
collar of deep groove ball thrust bearing -2- -arrows 3-.
– Tighten nut on piston rod.
– Relieve tension on spring compressor .-VV.A.G 1752/1- and
AG olkswagen AG d
remove from coil spring. ksw
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– Remove suspension strut ed from suspension strut support
b ran
ris
clamp - V.A.G 1752/20-
ut
ho . tee
or
sa ac
– Install suspension
s strut ⇒ page 55 .
ce
le
un
pt
Specified torques
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d
itte
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pe
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
a
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tion in
r
te o
thi
s
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t.
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Cop py
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Prote AG.

4 Lower suspension link, swivel joint

⇒ “4.1 Assembly overview - lower suspension link, swivel joint”,
page 66
⇒ “4.2 Removing and installing lower suspension link”,
page 67
⇒ “4.3 Checking swivel joint”, page 73
⇒ “4.4 Removing and installing swivel joint”, page 74
⇒ “4.5 Renewing front bonded rubber bush for lower suspension
link”, page 78
⇒ “4.6 Renewing rear bonded rubber bush for lower suspension
link”, page 81
4.1 Assembly overview - lower suspensionswlink,

agen swivel joint
AG. Volkswagen AG d
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1 - Wheel bearing housing tho eo
au ra
❑ Different versions possi‐ ss c
ce
le
ble. Refer to ⇒ Electron‐

un
pt
ic parts catalogue “ET‐
an
d
itte
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KA”
erm
ab
ility
ot p
wit
⇒ page 86
is n
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ole,
2 - Nut
spec
t to the co
❑ 60 Nm
3 - Swivel joint
rrectne
⇒ page 74
ss o
4 - Nut
cial p
f inform
mer
atio
❑ 40 Nm +45°
om
n
c
i
or
n
5 - Lower suspension link thi
te
sd
a

iv
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pr
⇒ page 67
um
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fo
en
ng
t.
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6 - Front bonded rubber bush
Co
Cop py
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rig ht
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7 - Bolt
by lksw
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Prote AG.
❑ Tighten in unladen posi‐
tion ⇒ page 4 .
❑ 70 Nm +180°
8 - Bolt
❑ 70 Nm +180°
9 - Rear bonded rubber bush
10 - Nut
11 - Subframe

4.2 Removing and installing lower suspen‐

sion link
⇒ “4.2.1 Removing and installing lower suspension link, vehicle
with manual gearbox or dual clutch gearbox 0CW”, page 67
⇒ “4.2.2 Removing and installing lower suspension link, vehicles
with dual clutch gearbox 0D9”, page 69
4.2.1 Removing and installing lower suspen‐

sion link, vehicle with manual gearbox or
dual clutch gearbox 0CW
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Removing
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– Raise vehicle.
h re
hole
spec
– Remove wheel.
es, in part or in w
t to the co
– Remove noise insulation ⇒ General body repairs, exterior;
sulation .
rrectness of i
– Release rear section of wheel housing liner and fold it for‐
l purpos
wards.
nform
ercia

m
a
com
tio
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r

te o
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4. Lower suspension link, swivel joint 67

– Remove nuts -arrows-

– Pull suspension link out of swivel joint and turn wheel bearing
housing outwards to relieve suspension link.
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d ran
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– Unscrew bolts -arrows-. Counterhold at rear bolt on nut at top
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while doing so.
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ab
ility
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spec
es, in part or in w
t to the co
rrectness of i
l purpos
– Swivel suspension link -1- to rear and pull out of subframe in
nform
-direction of arrow-.
mercia
Installing
at
om
ion
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lowing:
ate
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Cop py
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Prote AG.
– Insert rear suspension link -1- into subframe in

-direction of arrow- and swivel forwards.

– Tighten bolts -arrows-. Counterhold nut on rear upper bolt

while doing so.
Note
Tighten nuts and bolts -arrows- in unladen state ⇒ page 4 .

Note
position.
– On vehicles with vehicle level sender, carry

agen
out
AG. Volksbasic
wagen setting
AG do
⇒ Vehicle diagnostic tester. Volksw es n
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by ua
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Specified torques oris tee
th or
au
♦ ⇒ “4.1 Assembly overview
ss - lower suspension link, swivel ac
joint”, page 66
ce
e
nl
pt
du
an
itte
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erm
220
ab
ility
ot p

wit
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h re
hole
♦ Bolts for noise insulation ⇒ General body repairs, exterior; spec

es, in part or in w

t to the co
sulation .
rrectness of i
4.2.2 Removing and installing lower suspen‐

sion link, vehicles with dual clutch gear‐
l purpos
box 0D9
nform
ercia

m
at
om
io

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or
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ate
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Cop py
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rig ht
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Prote AG.

♦ Engine support - T10533-
Removing
– Raise vehicle.
– Remove wheel.
wage es n
– Remove noise insulation ⇒ General bodyy Vrepairs,olks
exterior; ot g
ua
Rep. gr. 66 ; Noise insulation; Assemblyir se overview - noise in‐
d b ran
tee
sulation . utho
or
s a ac
– Release rear section of wheel housing liner and fold it for‐
s
ce
e
nl
wards.
pt
du
an
itte
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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

m
at
om
ion
– Pull suspension link out of swivel joint and turn wheel bearing
c
in t
or
housing outwards to relieve suspension link.

his
ate
do
riv
– Remove pendulum support ⇒ Rep. gr. 10 ; Assembly mount‐

p
cum
or
ings; Removing and installing pendulum support .

f
en
ng
t.
yi Co
op
– Loosen double clamp of exhaust system ⇒ Rep. gr. 26 ; Ex‐ C py
t. rig
haust pipes/silencers; Assembly overview - silencer .
gh ht
pyri by
Vo
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by
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Prote AG.


– Screw engine support - T10533- completely together to make
it as short as possible.
AG. Volkswagen AG d
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ss c
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un
pt
– Bolt engine support - T10533- -2- onto gearbox with the thicker
an
d
itte
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bracket -arrow-. Use the shorter pendulum support securing
erm
ab
bolt -1-.
ility
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– Press engine and gearbox far enough forward so that threa‐
h re
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ded rod - T10533/5- -3- can be inserted in pendulum support
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mer
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-direction of arrow-.
Installing
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Tighten nuts and bolts -arrows- in unladen state ⇒ page 4 .

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– Remove engine support - T10533- .
– Bolt on double clamp for exhaust system ⇒ Rep. gr. 26 ;
Exhaust pipes, silencers; Separating exhaust pipes and si‐
lencers .
– Install pendulum support ⇒ Rep. gr. 10 ; Assembly mountings;
Removing and installing pendulum support .

– Attach exhaust system bracket to subframe -arrows-.

Note
position. n AG. Volkswagen AG do
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Running gear, axles, steering - Edition 03.2018 AG. Volkswagen AG d
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Checking radial play e d by ara
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spec
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t to the co
“play” in upper suspension strut mounting.
♦ Check rubber boot for damage and renew swivel joint if nec‐
rrectne
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4.4 Removing and installing swivel joint
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o
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♦ Ball joint puller - 3287 A-

♦ Torque angle wrench - V.A.G 1756-
♦ Ring spanner insert - V.A.G 1332/10-


Removing
– Loosen drive shaft bolt at wheel hub ⇒ page 117 .
Caution

AG. Volkswagen
♦ Install an outer joint
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I - Tighten knurled nut -1- hand-tight.
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Installing
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s
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s o
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Note
Ensure that boot is not damaged or twisted.
Note
position.
– Install wheel and tighten.

– Tighten drive shaft bolt at wheel hub ⇒ page 117 .
Note
During this step, vehicle must not be standing on its wheels or

wheel bearing will be damaged.

Specified torques
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4.5 Renewing front bonded rubber bush for lower suspension link
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equipment required
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♦ Assembly tool - T10219- co Vo
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– Remove lower suspension link ⇒ page 67 .


– Press out bonded rubber bush as illustrated.
1- Press tool - VW 411-
2- Tube - T10219/1- (the cut-out must face the suspension link)
– Align bonded rubber bushes -1- to suspension link -2-.

The grooves -3- must face towards suspension link -2- as shown
in illustration.
– Moisten outer surface of bonded rubber bush with assembly
oil - G 294 421 A1- .
– Press in bonded rubber bush as illustrated.

1- Pin - T10219/2-
3- Tube - T10219/1- (the cut-out must face the suspension link)
AG. Volkswagen AG d
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– Press bush back slightly in the suspension link.

2- Tube - T10219/1- n AG. Volkswagen AG do
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The dimensions -a- and -b- must be the same. hole
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– Install lower suspension link ⇒ page 67 .
rrectness of i
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4.6 Renewing rear bonded rubber bush for lower suspension link
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– Remove suspension link.

♦ Vehicles with manual gearbox or dual clutch gearbox 0CW
nform
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⇒ page 67
m
♦ Vehicles with dual clutch gearbox 0D9 ⇒ page 69

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• The embossed arrow points between the two markings

m
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• The cam -arrow B- must always point to outside of vehicle.

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Open kidney faces to centre of vehicle.
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– Press in bonded rubber bush as illustrated.
2- Sleeve - VW 459/2- , inner shoulder of sleeve -arrow- faces
downwards
3- Suspension link
Note
Press in bonded rubber bush until wheel bearing tube - 3345-

makes contact with transverse link.

Greasing bonded rubber bush:

The kidney-shaped area -1- of the bonded rubber bush must be
greased.
– Grease must be applied to the kidney-shaped area -1- from
above.
– Use grease -G 052 150 A2-
– The total quantity of grease required for both sides is, as

shown, about 1 cm -dimension a-.
• Half of the quantity of grease (about 0.5 cm) must be applied
to each kidney-shaped area.
– The grease must be applied to the top using a commercially
available brush.
– No grease may be applied to the area contacting the suspen‐
sion link.
– Install suspension link ⇒ page 67 .
♦ Vehicles with manual gearbox or dual clutch gearbox 0CW AG. Volkswagen AG d
⇒ page 68 agen oes
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5 Wheel bearing
⇒ “5.1 Assembly overview - wheel bearing”, page 85
⇒ “5.2 Removing and installing wheel bearing housing”,
page 86
⇒ “5.3 Removing and installing wheel bearing unit”, page 90
5.1 Assembly overview - wheel bearing

Volkswa n AG. gen AG
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⇒ page 90
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tronic parts catalogue
atio
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“ETKA” .
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❑ Do not let drive shaft
hang down under its
own weight when per‐
forming repair work, as
otherwise excessive
bending could damage
inner CV joint
❑ Before fitting the outer
joint in the wheel hub,
apply a thin coat of assembly paste to the splines on the outer joint ⇒ Electronic Parts Catalogue “ETKA” .
5. Wheel bearing 85
5.2 Removing and installing wheel bearing housing

equipment required
AG. Volkswagen AG d
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♦ Ball joint puller - 3287A-

♦ Spreader - 3424-
♦ Torque angle wrench - V.A.G 1756-
Removing
– Remove bolt for drive shaft ⇒ page 117 .

Caution

AG. Volkswagen A
If wheel bearings are loaded with weight of
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– Remove wheel.
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– Detach brake caliper and tie to body with wire ⇒ Brake system;
Rep. gr. 46 ; Front brakes; Assembly overview - front brakes .
nf
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– Remove ABS speed sensor ⇒ Brake system; Rep. gr. 45 ;
m
atio
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Sensors; Removing and installing speed sensor on front axle

o
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Caution
– Push track rod off wheel bearing housing and remove nut.
5. Wheel bearing 87
lkswage es n
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ran
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Running
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– Remove threaded connection between wheel bearing housing

and suspension strut -arrow-.

– Insert spreader - 3424- in slot in wheel bearing housing.
Note
Make sure that the spreader - 3424- is only inserted into the wheel
bearing housing. Insert sufficiently to ensure that the metal tab of
the suspension strut is not damaged.
– Turn ratchet handle through 90° and detach from spreader -

3424- .
– Pull wheel bearing housing from suspension strut.
Note
If wheel bearing housing is renewed, swivel joint must be trans‐

ferred. Always use new nuts.
Installing
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5. Wheel bearing 89
5.3 Removing and installing wheel bearing

unit
AG. Volkswagen AG d
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Removing
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nevertheless be moved, comply with the following: Prote AG.


– Raise vehicle.
– Remove wheel.
– Detach brake caliper and tie to body with wire ⇒ Brake system;
Rep. gr. 46 ; Front brakes; Assembly overview - front brakes .
– Remove brake disc ⇒ Brake system; Rep. gr. 46 ; Front
brakes; Assembly overview - front brakes

– Unscrew hexagon nut -1- from coupling rod -3-.


– Bolt swivel joint to suspension link -arrows- again. agen
AG. Volkswagen AG d
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5. Wheel bearing 91
• When placing wheel bearing unit down, wheel bearing -1-

must always face upwards.
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Vol
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♦ ⇒ “6.2 Assembly overview - drive shaft”, page
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♦ ⇒ “4.1 Assembly overview - lower
ss asuspension link, swivel c
joint”, page 66
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5. Wheel bearing 93
6 Drive shaft
⇒ “6.1 Overview - drive shaft”, page 94
⇒ “6.2 Assembly overview - drive shaft”, page 95
⇒ “6.4 Loosening and tightening threaded connections of drive
shaft”, page 117
⇒ “6.5 Removing and installing drive shaft heat shield”,
page 119
⇒ “6.3 Removing and installing drive shaft”, page 100
⇒ “6.6 Dismantling and assembling drive shaft”, page 119
⇒ “6.7 Checking outer constant velocity joint”, page 134
⇒ “6.8 Checking inner constant velocity joint”, page 135
6.1 Overview - drive shaft
I-
⇒ “6.2.1 Assembly overview -
drive shaft, constant velocity
joint VL100”, page 95
II -
⇒ “6.2.2 Assembly overview - AG. Volkswagen AG d
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joint VL107”, page 97 d by V gu
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drive shaft, triple roller joint
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Distinguishing between drive shafts when installed

VL100 VL107 AAR3300i inser‐ AAR3300i bol‐
ted ted
Diameter of inner joint in mm 100 107 - -

VL100 VL107 AAR3300i inser‐ AAR3300i bol‐

ted ted
Cover between inner joint and - X - -
drive flange
Inner joint pushed into gearbox - - X -
(only automatic gearbox)
6.2 Assembly overview - drive shaft

⇒ “6.2.1 Assembly overview - drive shaft, constant velocity joint
VL100”, page 95
⇒ “6.2.2 Assembly overview - drive shaft, constant velocity joint
VL107”, page 97
⇒ “6.2.3 Assembly overview - drive shaft, triple roller joint
AAR3300i”, page 99
6.2.1 Assembly overview - drive shaft, constant velocity joint VL100
1 - Outer constant velocity joint

❑ Renew only as com‐
plete unit
❑ Removing ⇒ page 122
❑ Installing: drive onto
shaft to stop using plas‐
tic hammer
❑ Checking ⇒ page 134
2 - Bolt
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AG.
6. Drive shaft 95
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15 - Retaining ring
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16 - Seal
❑ Adhesive surface on constant velocity joint must be free of oil and grease!
17 - Inner constant velocity joint
❑ Renew only as complete unit
❑ Pressing off ⇒ page 123
❑ Pressing on ⇒ page 123
18 - Dished spring

6.2.2 Assembly overview - drive shaft, constant velocity joint VL107
1 - Bolt
ing ⇒ page 117
❑ Before securing, clean
the threads in the CV
joint using a thread tap.
❑ 200 Nm +180°
plete unit
shaft to stop using plas‐
tic hammer
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6 - Clip
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7 - Drive shaft
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10 - Clip
11 - Locking plate
12 - Cap
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6. Drive shaft 97
❑ Adhesive surface must be free of oil and grease!
13 - Inner constant velocity joint
❑ Renew only as complete unit
❑ Pressing on ⇒ page 127
14 - Retaining ring
❑ Remove and install with snap ring pliers - VW 161 VA- wage
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❑ 70 Nm
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6.2.3 Assembly overview - drive shaft, triple roller joint AAR3300i
1 - Bolt
ing ⇒ page 117
❑ Before securing, clean
the threads in the CV
joint using a thread tap.
❑ 200 Nm +180°
plete unit
shaft with plastic ham‐
mer until compressed
retaining ring seats
3 - Retaining ring
4 - Clip
5 - Boot for constant velocity
joint
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6. Drive shaft 99
13 - Adapter
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6.3 Removing and installing drive shaft
l purpos
⇒ “6.3.1 Removing and installing drive shaft, left drive shaft, con‐
stant velocity joints VL100 and VL107”, page 100
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ercia
⇒ “6.3.2 Removing and installing drive shaft, right drive shaft,

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constant velocity joints VL100 and VL107”, page 104
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6. Drive shaft 101


– Remove nuts -arrows- on suspension link.

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Note
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• Before fitting the outer joint in the wheel hub, apply a thin coat
pt
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6. Drive shaft 103

Note
G. Volkswage
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♦ ⇒ “6.4 Loosening and tightening threaded connections of drive
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spec
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6.3.2 Removing and installing drive shaft,

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6. Drive shaft 105


– If fitted, remove bolts -1- and detach heat shield -2-.

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ing:
• Before fitting the outer joint in the wheel hub, apply a thin coat
of assembly paste to the splines on the outer joint ⇒ Electronic
Parts Catalogue .
6. Drive shaft 107

Note
position.

Specified torques
shaft”, page 117
220
joint”, page 66
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6.3.3 Removing and installing drive shaft, triple roller joint AAR3300i inserted ed ran
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equipment required
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6. Drive shaft 109

Caution


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Note
6. Drive shaft 111

– Insert wedge - T10161- -1- between gearbox housing and tri‐

ple roller joint.
– Press inner joint out of gearbox with a blow to wedge - T10161-
using a rubber hammer.
– Remove drive shaft.
Installing
lowing:
– Fit new retaining ring into groove of joint pin.
– Mesh outer and inner splines of joint body and gearbox.
– Slide drive shaft into joint body to stop by hand.
– Now »suddenly« push joint body into gearbox.
The joint travel can be used for the »sudden push«. Do not, how‐
ever, pull the drive shaft too far out of the joint body.
Caution
Never use a hammer or other driving tools.
– Check that the drive shaft is securely seated in the gearbox by

pulling the joint body against the resistance of retaining ring.
Caution
For this check, pull only on joint body and not on drive shaft.
– Guide outer joint into wheel hub splines as far as possible. lkswage es n
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– Install lower noise insulation ⇒ General body repairs, exterior;
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Rep. gr. 66 ; Noise insulation; Assembly overview - noise au in‐
th or
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Note
Note
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Specified torques
shaft”, page 117
♦ ⇒ “2.1 Assembly overview - front vehicle level senders”,Vopage
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♦ ⇒ “2.1 Assembly overview - subframe”,
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Rep. gr. 66 ; Noise insulation; Assembly overview - noise in‐ wit
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6.3.4 Removing and installing drive shafts, tri‐

ple roller joint AAR3300i bolted
rrectness of i

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6. Drive shaft 113

Caution

Removing
Caution

fitted as this would damage the wheel bearing. If a vehicle must AG. Volkswagen AG d
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nevertheless be moved, comply with the following: b y Vol not
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♦ Install an outer joint instead of the drive shaft. oris tee
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♦ Tighten outer joint to 120 Nm. ss
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– Remove wheel.
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noise insulation .
rrectness of i
sides).
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114
Prote AG.

– Unbolt drive shaft from gearbox flange shaft.
– Unscrew nuts -arrows-.

– Pull wheel bearing housing with swivel joint out of suspension
link.
– Pull drive shaft out of wheel hub.
inserted.
AG. Volkswagen AG d
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6. Drive shaft 115

AG. Volk-sw
Edition
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n G do
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– It is essential to efollow
d by specified sequence. ua
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I- Tighten knurled
auth nut -1- hand-tight. or
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Note
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Installing
rrectness of i
Remove any paint residues and/or corrosion on thread and
l purpos
splines of outer joint.

– Insert drive shaft.
nf
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or
– Guide outer joint into wheel hub splines as far as possible.
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Note
– Fit inner joint of drive shaft in position and pre-tighten bolts in

diagonal sequence to 10 Nm.
– Tighten multi-point socket-head bolts diagonally to the speci‐
fied torque.
Note
engage in innerlkshole
wage in order to guarantee es n correct installation
position. d by Vo ot g
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– Ons vehicles
au with vehicle level sender, carry out basicr asetting
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nl
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ility
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– Tighten drive shaft bolt at wheel hub ⇒ page 117 .

h re
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spec
Specified torques
es, in part or in w
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shaft”, page 117
rrectness of i

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220
nf
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joint”, page 66
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6.4 Loosening and tightening threaded con‐
cted agen
Prote AG.
nections of drive shaft

6. Drive shaft 117

♦ Socket, 24 mm - T10361A-
♦ Torque angle wrench - V.A.G 1756 A-
Caution
Wheel bearings must not be subjected to loadagafter

en AG.bolt
Volkssecur‐
wagen AG
does
ing drive shaft to wheel hub has been yloosened.
Volksw not
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If wheel bearings are loaded withhoweight
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of vehicle, bearing will tee
be damaged. This reduces thes aservice
ut life of the wheel bearing. or
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Loosening twelve-point head bolt

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– To avoid damage to wheel bearing, do not loosen twelve-point

bolt using 24 mm socket - T10361A- further than 90° with ve‐
hicle still standing on its wheels.
nf
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– Raise vehicle so that wheels are off the ground.

m
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– Have second mechanic apply brakes.

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Prote AG.

– Remove twelve-point head bolt -arrow-.

Fitting twelve-point head bolt
– Renew twelve-point bolt.
Note
It must be ensured that the wheels do not yet touch the floor when
the drive shaft is being tightened. Otherwise the wheel bearing
may be damaged.
– Have second mechanic apply brakes.

– Tighten twelve-point bolt to 200 Nm.
– Lower vehicle onto its wheels.
– Turn twelve-point head bolt 180° further.
6.5 Removing and installing drive shaft heat

shield
Front-wheel drive:
Component Specified torque
Bolts -1- 25 Nm
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6.6 Dismantling and assembling drive shaft
a ac
ss
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pt
⇒ “6.6.1 Dismantling and assembling drive shaft, constant veloc‐

an
d
itte
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ity joint VL100”, page 119

rm
ab
pe
ility
⇒ “6.6.2 Dismantling and assembling drive shaft, constant veloc‐

ot
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ity joint VL107”, page 124

, is n
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hole
⇒ “6.6.3 Dismantling and assembling drive shaft, triple roller joint

spec
AAR3300i”, page 129

es, in part or in w
t to the co
6.6.1 Dismantling and assembling drive shaft, constant velocity joint VL100
rrectness of i
l purpos
nform
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te o
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6. Drive shaft 119


equipment required
AG. Volkswagen AG d
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♦ Press tool - VW 408 A- C py
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Prote
♦ Tube - VW 416 B-
AG.
♦ Thrust plate - VW 447 H-

AG. Volkswagen AG d
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♦ Snap ring pliers - VW 161 A-

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♦ Clamp tensioner - V.A.G 1682- cop Vo
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♦ Assembly tool - T10065-
♦ Multipurpose tool - VW 771-
6. Drive shaft 121

lkswage es n
o ot g
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Golf Sportsvan 2015 ➤ , Golf Sportsvanhor 2018 ➤
is tee
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Running gear, axles, steering - Edition
au 03.2018 ac
ss
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un
♦ Puller - T10382-
pt
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Removing outer constant velocity joint
mer
atio
– Clamp drive shaft in vice using jaw protectors.
om
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– Fold back boot.
thi
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– Set puller - T10382- up so that smooth side of puller plate -

i
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T10382/1- points to spindles - T10382/2- .

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– Assemble puller - T10382- complete with multi-purpose tool - Cop py
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– Pull constant velocity joint from drive shaft with puller -
by lksw
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T10382- and multi-purpose tool - VW 771- .
AG.
1- Puller plate - T10382/1-

2- Spindles - T10382/2-
Driving on outer constant velocity joint
Installation position of dished spring and thrust washer on outer

joint
1- Dished spring
2- Thrust washer
– Install new retaining ring.
– If necessary, push new joint boot onto drive shaft.
– Knock onto shaft with plastic hammer until retaining ring en‐
gages.

Pressing off inner constant velocity joint

Installing
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Installation position of dished spring at inner joint
nf
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Pressing on inner constant velocity joint
Note
Chamfer on internal circumference of ball hub (splines) must face

contact shoulder on drive shaft.
6. Drive shaft 123

Tighten clip on outer joint

– Position clamp tensioner - V.A.G 1682- as shown in diagram.
Ensure jaws of tensioner lie in corners -arrows B- of ear on O-
type clip.
– Tighten clamp by turning spindle with a torque wrench (do not
cant pliers).
Note
♦ Due to the hard material of the protective bellows (compared

to rubber) and the necessity of using a stainless steel clip, it is
only possible to tension the clip with clamp tensioner - V.A.G
1682- .
♦ Specified torque: 25 Nm.
♦ Use torque wrench -C- with setting range 5 … 50 Nm (e.g.
torque wrench - V.A.G 1331- ).
♦ Ensure that the spindle thread -A- moves smoothly. Lubricate
with MOS2 grease if necessary.
♦ If the spindle is tight owing to the thread being dirty, for exam‐
ple, the force required to tighten the clip will not be attained in
spite of correct specified torque specification.
Tightening clip on small diameter
AG. Volkswagen AG d
agen oes
olksw not
V gu
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6.6.2 Dismantling and assembling drive shaft, constant velocity joint VL107
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
nform
mercia
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com
tion in
r
te o
thi
s
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Prote
124
AG.

equipment required
AG. Volkswagen AG d
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cial p
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♦ Thrust plate - VW 402- by c lksw
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♦ Press tool - VW 408 A-
♦ Support sleeve - VW 522-
♦ Joint tensioner - 40 - 204 A-
♦ Clamp tensioner - V.A.G 1682-
6. Drive shaft 125

AG. Volkswagen AG d
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♦ Multipurpose tool - VW 771- spec

t to the co
♦ Puller - T10382-
rrectne

ss o
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– Fold back boot.

inform
mer

atio

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thi
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2- Spindles - T10382/2-
– Knock onto shaft with plastic hammer until retaining ring en‐
gages.
Driving off cover for inner joint

– Remove retaining ring.
– Remove both clips and slide boot towards outer joint.
– Drive off joint boot with a drift.
AG. Volkswagen AG d
agen oes
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Pressing off inner constant velocity joint s
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Installing
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Pressing on inner constant velocity joint

nform
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– Press joint on to stop.

m
– Install retaining ring.

com
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6. Drive shaft 127

agen
AG. V-olEdition 03.2018
kswagen AG do
w es n
olks ot g
yV ua
– Coat sealing surface
ris
ed of cover with -D 454 300 A2- .
b ran
tee
tho
o
– Apply an unbroken
au bead of sealant of 2 … 3 mm in diameter r ac
ss
onto clean surface of cover in area of inner holes -arrow-.
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– Using bolts -arrows-, align new cover in relation to bolt holes.
l purpos
The alignment must be very accurate, because no further align‐

ment is possible once the part has been hammered on.
nform
ercia
– Drive on cover with a plastic hammer.

m
at
– Wipe off surplus sealant.
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Prote AG.
– Apply special pliers -V.A.G 1682- as shown in diagram. En‐
sure jaws of tensioner lie in corners -arrows B- of ear on O-
type clip.
– Tighten clamp by turning spindle with a torque wrench (do not
cant pliers).
Note

1682- .
♦ Use torque wrench -C- with setting range 5 … 50 Nm (e.g.
torque wrench - V.A.G 1331- ).

Tightening clip on small diameter

Checking outer constant velocity joint ⇒ page 134
Checking inner constant velocity joint ⇒ page 135
Checking function of constant velocity joint ⇒ page 136
6.6.3 Dismantling and assembling drive shaft, triple roller joint AAR3300i

equipment required
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mer
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♦ Press tool - VW 408 A-

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♦ Tube - VW 416 B-
C py
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129
Prote AG.
6. Drive shaft
olkswagen AG
en AG. V
Golf Sportsvan 2015 ➤ , GolfolkSportsvan
swa
g 2018 ➤ does
not
V
ed by - Edition 03.2018 gu
ara
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utho eo
♦ Thrust plate - VW 447 H-
ss
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♦ Hose clip pliers - V.A.G 1275-

♦ Clamp tensioner - V.A.G 1682-
♦ Multipurpose tool - VW 771-

♦ Puller - T10382-

– Fold back boot.
– Assemble puller - T10382- complete with multi-purpose tool -
VW 771- .
2- Spindles - T10382/2-
– Knock onto shaft with plastic hammer until retaining ring gen‐
en AG. V
olkswagen AG
does
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gages. yV
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Dismantling triple roller joint thoris nte
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au ac
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– Open both clip on inner joint and push back boot.

du
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– Pull joint body off drive shaft.

ab
ility
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hole
– Remove retaining ring.

spec
es, in part or in w
1 - Pliers (commercially available)

t to the co
- or -VW 161 A-
rrectness of i
– Set drive shaft into press.

l purpos
nform
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Prote AG.
6. Drive shaft 131

– Press triple roller star off drive shaft.

– Pull boot off shaft.
– Clean shaft, joint body and groove for seal.
Assembling triple roller joint
– Push small hose clip for boot onto shaft.
– Push joint boot onto shaft.
Fit triple roller star
Chamfer on triple roller star -arrow- points towards shaft and
serves as an assembly aid.
– Fit triple roller star onto shaft and press on to stop.

– Ensure that pressure does not exceed 3.0 t.
– If necessary, coat splines of drive shafts and triple roller star
with lubricating paste - G 052 142 A2- .
– Insert retaining ring, ensuring that it is seated correctly.
– Press half of total amount of grease from repair kit into triple
roller joint.
– Place boot adapter onto joint.
– Slide joint body over rollers and hold.
– Press remaining amount of grease from repair kit into rear of
triple roller joint. G. Volkswage A n AG d
agen oes
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– Slide boot onto boot adapter and ensure that boot engages
y li
rm
ab
correctly in groove -arrow- of adapter.

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es, in part or in w
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Prote
132
AG.
– Install clip.
Note
Clamping lug of clip -arrow A- must be located between securing

flanges of joint body -arrows B-. This is the only way of assuring
that the multi-point socket head bolts can be guided correctly
when installing the drive shaft.
Tightening clip on large diameter of inner joint

– Position clamp tensioner - V.A.G 1682- as shown in illustra‐
tion. Ensure jaws of tensioner lie inAcorners
agen
G. Volksw-arrows
agen AG B- of ear
does
on O-type clip. Volksw not
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– Tighten clamp by turning
ris
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spindle with a torque wrench (do notantee
cant pliers). utho or
a a c
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an
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Note
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1682- .
es, in part or in w
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♦ Use torque wrench -C- with adjustment range 5 … 50 Nm, (e.g.
torque wrench - V.A.G 1331- ). rrectness of i

l purpos

nform
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a
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tion in
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te o
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– Position clamp tensioner - V.A.G 1682- as shown in diagram.

fo
en
ng
Ensure jaws of tensioner lie in corners -arrows B- of ear on O-

t.
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– Tighten clamp by turning spindle with a torque wrench (do not cop Vo
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6. Drive shaft 133

Tightening clip on small diameter of inner/outer joint
AG. Volkswagen AG d
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6.7 Checking outer constant velocity joint
wit
is n
h re
ole,
The joint is to be dismantled to renew the grease if it is heavily
spec
soiled, or to check the running surfaces of the balls for wear and
damage.
t to the co
Removing
rrectne
– Before dismantling, mark position of ball hub in relation to ball
cage and joint body with an electric scriber or oil stone.
ss
– Swing ball hub and ball cage.
o
cial p
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– Remove balls one at a time.
form
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– Turn cage until the two rectangular windows -arrow- lie on joint
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body.
AG.
– Take out cage with hub.

– Swing segment of hub into square cage window.

– Tip hub out of cage.
The 6 balls for each joint belong to a tolerance group. Check stub
axle, hub, cage and balls for small indentations (pitting) and
traces of seizing. Excessive circumferential backlash in the joint
is noticeable during load change jolts. In this case the joint must
be replaced. Smoothing and traces of wear of the balls are no
reason to change the joint.
Installing
– Pack half of total grease quantity (40 g) into joint body.
– Fit cage with hub into joint body.
– Press in opposing balls one after the other; the original position
of the hub relative to the cage and joint body must be restored.
– Fit new retaining ring into hub.
AG. Volkswagen AG d
– Distribute remaining grease in boot. agen oes
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Removing
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The joint is to be dismantled when following work is done:
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♦ Check of running surfaces for wear
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♦ Check of balls for wear
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– Swing ball hub and ball cage.
– Press out joint body in direction of arrow.
rrectness of i
– Press balls out of cage.
l purpos
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The ball hub and joint body are paired. Do not interchange them.
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– Tip ball hub out of ball cage via ball track -arrows-.
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– Check joint body, ball hub, ball cage and balls for pitting and
ht
pyri by
traces of seizing.
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Excessive circumferential backlash in the joint is noticeable dur‐
ing load change jolts. In this case the joint must be replaced.
Smoothing and traces of wear of the balls are no reason to renew
the joint.
Installing
6. Drive shaft 135

– Insert hub into cage via the two chamfers. The hub can be
installed in any position. Press balls into cage.
The ball hub has two different distances between the ball tracks:
a smaller one and a larger one.
– Insert hub with cage and balls at a right angle to joint body.
When inserting, ensure that the wide spacing -a- on the joint body
is aligned with the narrow spacing -b- on the hub after it is swung
in.
Chamfer on internal diameter of ball hub (splines) must face large
diameter of joint body.
– Also take note of chamfer on interior diameter of ball hub. It
must be visible after swivelling in.
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– Swivel the hub into the joint body; at the same time the hub
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must be swivelled out of the cage -arrows- far enough to allow
erm
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the balls to fit into the ball tracks.
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– Swivel in hub with balls by applying firm pressure to cage
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Checking function of constant velocity joint by c lksw
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The constant velocity joint is correctly assembled if the ball hub
can be moved by hand backwards and forwards over its entire
range of axial movement.

42 – Rear suspension agen

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⇒ “1.1 Overview - rear axle”, page 137 ss c
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⇒ “1.2 Lowering rear axle”, page 140
pt
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⇒ “1.3 Removing and installing rear axle”, page 142
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⇒ “1.4 Removing and installing shield for rear axle”, page 149
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1.1 Overview - rear axle
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⇒ “1.1.1 Overview - rear axle, torsion beam axle”, page 137
t to the co
⇒ “1.1.2 Overview - rear axle, multi-link suspension”, page 138
rrectness of i
1.1.1 Overview - rear axle, torsion beam axle
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I - ⇒ “2 Axle beam”, page 150
nform
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II -
m
⇒ “6 Suspension strut, shock
at
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io
absorber, spring”, page 175
n
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III -
at
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⇒ “7 Wheel bearing assembly,

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trailing arm”, page 191

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1. Rear axle 137

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1.1.2 Overview - rear axle, multi-link suspension
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I - ⇒ “3 Subframe”, page 158 au ra
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II -
un
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⇒ “4 Anti-roll bar”, page 164
itte
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III -
pe
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⇒ “5 Suspension link, track
ot
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rod”, page 169
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138 Rep. gr.42 - Rear suspension

IV -
⇒ “6 Suspension strut, shock
absorber, spring”, page 175
V-
⇒ “7 Wheel bearing assembly,
trailing arm”, page 191
AG. Volkswagen AG d
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nl
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1. Rear axle 139

1.2 Lowering rear axle

equipment required
AG. Volkswagen AG d
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es, in part or in w
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rrectness of i
Lowering subframe with attachments

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– Raise vehicle.
nform
ercia
– Remove wheels.
m
at
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ion
– Unbolt brake calipers on both sides of vehicle and suspend

c
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or
from body.
his
ate
do
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– Remove springs ⇒ page 184 .

p
cum
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en
g
– Remove rear silencer of exhaust system ⇒ Rep. gr. 26 ; Ex‐

n
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op
haust pipes/silencers; Assembly overview - silencer . C py
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2015 ➤ , Golf Sportsvan 2018 ➤
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ss Running c gear, axles, steering - Edition 03.2018
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Vehicles with vehicle level sender. du
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– Disconnect connector -1-.
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es, in part or in w
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– Unplug electrical connector -1- from ABS speed sensor on

both sides and move clear.
m
at
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ion
– Unplug electrical connector -2- from electromechanical park‐
c
in t
or
ing brake motor on brake caliper on both sides.
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ate
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– Detach wiring harness from retainers -arrows- and move clear.

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– Pull out retaining clip -1- on both sides of vehicle.

– Free brake lines from holder.
Note
Do not open brake line.
– Secure vehicle to support arms of lifting platform on both sides

using tensioning straps - T10038- .
1- Tensioning strap - T10038-
WARNING
If the vehicle is not strapped down, it may slip off the lifting
platform.
– Fix subframe at both forward bolts ⇒ page 159 .
1. Rear axle 141

– Unscrew rear right bolt of subframe -arrow-.
– Screw spindle - 3346/2- into thread of longitudinal member

using thrust piece of assembly tool - 3301- and nut - 3346/3- .
1- Spindle -3346/2-
2- Subframe
3- Thrust piece from assembly tool - 3301-
4- Nut -3346/3-
– Unscrew rear left bolt of subframe.
– Turn nut -3346/3- on spindle -3346/2- until subframe is low‐
ered by -a- = 40 mm.
Installing subframe with attachments AG. Volkswagen AG d
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Install in reverse order. During this procedure, observe the fol‐by Vol
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– On vehicles with vehicle level sender, carry out basic
ss a setting
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Specified torques
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♦ ⇒ “3 Subframe”, page 158
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– When does wheel alignment have to be checked
⇒ page 234 ?
rrectness of i
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1.3 Removing and installing rear axle

nform
ercia
⇒ “1.3.1 Removing and installing rear axle, torsion beam axle”,

page 142
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a
com
tio
⇒ “1.3.2 Removing and installing rear axle, multi-link suspension,

n in
r
front-wheel drive”, page 145

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1.3.1 Removing and installing rear axle, tor‐

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♦ Engine and gearbox jack - VAS 6931-
r
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rig ht
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by lksw
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Prote AG.
Removing
– Raise vehicle.
– Remove wheel.
– Release connector on rear left and right speed sensors and
pull off.
– Remove left and right brake calipers and tie to body with wire
⇒ Brake system; Rep. gr. 46 ; Rear brake; Assembly overview
- rear brake .
1. Rear axle 143

– Unclip electric cable -1- from both sides -arrows- of retainer

-2- on axle beam.
AG. Volkswagen AG d
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es, in part or in w
t to the co
– Release connector -1- on rear left vehicle level sender - G76-
and disconnect.
– Unclip line -2- from clip -arrow-.
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
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– Unclip brake line -1- from clip -arrow- on right mounting brack‐
rp
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Note
p by
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The clip will be destroyed and must be renewed.

WARNING
platform.
– Position engine and gearbox jack - V.A.G 1383 A- or engine

and gearbox jack - VAS 6931- underneath.

– Unclip electrical wiring -2- at mounting bracket -1- and axle

beam and move clear.
– Mark positions of bolts -arrows- on mounting bracket -1- on left
and right sides of vehicle and remove them.
– Unbolt rear axle from shock absorbers -arrows-.

– Lower rear axle using engine and gearbox jack -
V.A.G 1383 A- or engine and gearbox jack - VAS 6931- -1-.
1- Engine and gearbox jack - V.A.G 1383 A- or engine and
gearbox jack - VAS 6931-
2- Universal gearbox support - V.A.G 1359/2- (for engine and
gearbox jack - V.A.G 1383 A- only)
Installing
lowing:
• Tighten bolted connection securing shock absorber to axle
beam with suspension in unladen position ⇒ page 6 .
Specified torques
♦ ⇒ “2.1 Assembly overview - axle beam”, page 150
♦ ⇒ “6.1.1 Assembly overview - suspension strut, shock absorb‐ agen AG. Volkswagen AG do
er, spring, torsion beam axle”, page 175 Vol
ksw es n
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♦ Wheel bolts ⇒ Wheels and Tyres Guide; Rep. gr. 44
ho
ris; Wheels,
e
tee
tyres; Specified torque for wheel bolts au
t or
ac
ss
♦ Bolts for brake caliper and brake disc ⇒ Brake system; Rep.
ce
e
nl
pt
du
gr. 46 ; Rear brakes; Assembly overview - rear brakes

an
itte
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erm
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ility
1.3.2 Removing and installing rear axle, multi-

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link suspension, front-wheel drive

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spec

es, in part or in w
t to the co

rrectness of i
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orm
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Vo
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by c lksw
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Prote
145
AG.
1. Rear axle
Removing subframe with attachments

– Raise vehicle.
– Remove wheels.
AG. Volkswagen AG d
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– Unplug electrical connector -1- from ABS speed sensor on olksw not
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both sides and move clear. ise
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– Unplug electrical connector -2- from electromechanical park‐
s aut ra
c
ing brake motor on brake caliper on both sides. s
ce
e
nl
pt
du
– Detach wiring harness from retainers -arrows- and move clear.
an
itte
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ility
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es, in part or in w
t to the co
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orm
m
atio
m

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or c
thi
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sd
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– Remove rear left vehicle level sender - G76- -3- from trans‐ op
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verse link.
C py
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Continued for all vehicles cop Vo
by lksw
cted agen
Prote AG.

– Pull out retaining clip -1- on both sides of vehicle.

– Free brake lines from holder.
Note
AG. Volkswagen AG d
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Do not open brake line. ed byV gu
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ut
– Remove brake calipers on both sides and tie
ss a to body with ra
c
brake lines connected ⇒ Brake system; Rep. gr. 46 ; Rear
ce
e
nl
pt
brakes; Assembly overview - rear brakes .
du
an
itte
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– Remove rear silencer of exhaust system ⇒ Rep. gr. 26 ; Ex‐
erm
ab
ility
haust pipes/silencers; Assembly overview - silencer .
ot p
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hole
spec
es, in part or in w
t to the co
WARNING
rrectness of i
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platform.
nf
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orm
m
atio
– Fix position of subframe ⇒ page 159 .
om
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or c
thi
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– Unclip electrical wire -2- on mounting bracket -1- and move

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clear.
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– Mark installation position of mounting bracket -1- on body.
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– Remove bolts -arrows- rig ht
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by lksw
– Carefully lower subframe with attachments by maximum of cted agen
Prote AG.
30 mm.
1. Rear axle 147

– Unclip brake line from clips -arrows-.
Note
♦ The clips will be destroyed and must be renewed.

♦ For reasons of clarity, the illustration shows the subframe from
above in removed state.
♦ The number of clips may vary.
– Lower subframe with attachments.
Note
When lowering, ensure sufficient clearance to brake lines and

electrical wiring.
Installing subframe with attachments

lowing:
Specified torques
♦ ⇒ “3 Subframe”, page 158
♦ ⇒ “7.2 Assembly overview - trailing arm”, page 193
♦ ⇒ “6.1.2 Assembly overview - suspension strut, shock absorb‐
er, spring, multi-link suspension”, page 176
♦ ⇒ “2.2.2 Assembly overview - rearAvehicle
G. Volkswlevel senders, multi-
agen A
link suspension, front-wheel
lkswdrive”,
agen page 222 G do
es n
Vo ot g
by u
♦ Wheel bolts ⇒ Wheelsris
ed and Tyres Guide; Rep. gr. 44 ; Wheels,
ara
nte
tyres; Specifiedutorque
tho for wheel bolts eo
r
sa ac
♦ Bolts for brake
s
caliper and brake disc ⇒ Brake system; Rep.
ce
e
nl
gr. 46 ; Rear brakes; Assembly overview - rear brakes

pt
du
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erm
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– When does wheel alignment have to be checked

h re
⇒ page 234 ?
hole
spec
es, in part or in w
t to the co
rrectness of i
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nf
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Prote AG.

1.4 Removing and installing shield for rear

axle
Removing
– Unscrew nuts -1-.
– Pull off shield -2- downwards from subframe and, at the same
time, detach at top -arrow-.
Installing
– Hook in shield -1- in direction of -arrow- and swivel in so that

it engages into top part of subframe.
en AG. V
olkswagen AG
ag does
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– Tighten nuts -2-. by Vo gu
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After installing shield, check again whether shield lug -2- has en‐
itte
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gaged properly in subframe -arrow-.

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Specified torques
h re
hole
♦ ⇒ “3.2 Assembly overview - add-on parts for subframe”, page

spec
es, in part or in w
159
t to the co
rrectness of i
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nform
mercia
at
om
ion
c
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or
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ate
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Cop py
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Prote AG.
1. Rear axle 149

2 Axle beam
⇒ “2.1 Assembly overview - axle beam”, page 150
⇒ “2.2 Renewing bonded rubber bush for axle beam”, page 151
2.1 Assembly overview - axle beam
1 - Cover
2 - Bolt
❑ 50 Nm +45°
3 - Bolt
❑ Tighten in unladen state
⇒ page 6 .
❑ 70 Nm +360°
4 - Axle beam
⇒ page 142 wage
es n
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5 - Bonded rubber bush byV ua
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ir se tee
❑ Observe installation po‐ utho
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6 - Mounting bracket
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nf
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AG. Volkswagen AG d
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Golf Sportsvan
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2015 ➤ , Golf Sportsvan 2018ra➤ nte
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Running
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gear, axles, steering - Edition 03.2018 or a
ss c
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2.2 Renewing bonded rubber bush for axle beam
nl
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Cop py
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rig ht
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Prote AG.

♦ Engine and gearbox jack - V.A.G 1383 A- -2- with gearbox
support - V.A.G 1359/2-
♦ Hydraulic press - VAS 6178- and press button - 10205/13-
2. Axle beam 151

♦ Foot pump - VAS 6179-
AG. Volkswagen AG d
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olksw not
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Modifying tube - T10495/2- ss a c
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Tube - T10495/2A- does not have to be modified.
hole
spec
es, in part or in w
t to the co
– Clamp tube - T10495/2- in vice using protective jaw covers.
– Red areas -a- must be cut away.
rrectness of i
a = 18 mm
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– After cutting away material, deburr edges with a file.

– An -A- must be added to the tool designation. The new tool
nf
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number is now called -T10495/2A- .
rm
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– Apply corrosion protection.

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Removing
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– Raise vehicle.
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Cop py
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– Remove wheels. opyri
gh by
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c by lksw
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Prote AG.

– Release connector -1- on rear left vehicle level sender - G76-
and disconnect.
– Unclip line -2- from clip -arrow-.


– Pull rear left - G76- lever -2- off axle beam -3-.
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– Unclip brake
rised line -1- from clip -arrow- on right mountingnte brack‐
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The clip will be destroyed and must be renewed.
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– Unclip electric cable -1- from both sides -arrows- of retainer
-2- on axle beam.
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WARNING
platform.
2. Axle beam 153

Golf Sportsvan 2015 ➤ , Golf Sportsvan
gen AG 2018 ➤n AG doe
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olk s no
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– Remove bolt -1- on left and
au
th right.
o e or
ac
ss
– Position engine and gearbox jack - V.A.G 1383 A- with uni‐
ce
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nl
versal gearbox support - V.A.G 1359/2- and suitable support
pt
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– Unclip line -2- from mounting bracket -1-.
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– Mark positions of bolts -arrows- on mounting bracket -1- on
nform
ercia
both sides of vehicle.

m
– Unscrew bolts -1- for right and left axle beams.
at
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– Carefully lower rear axle with engine and gearbox jack -
V.A.G 1383 A- until bolt -1- can be removed.
– Fit special tools as shown in illustration.

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1 - Spindle - T10254/5-
t to the co
2 - Nut - T10254/4-
3 - Hydraulic press - VAS 6178- with thrust piece - T10205/13- rrectne
4 - Thrust plate - T10495/3-

s
5 - Tube - T10495/2-
s o
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♦ Make sure that the tube is lying against the axle beam
nform
-arrow-.
mer
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6 - Thrust piece - T10495/1-

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7 - Nut - T10254/4-
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– Pull out bonded rubber bush by operating the pump.

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2. Axle beam 155

Installing
– Ensure correct installation position of bonded rubber bush
-1- on axle beam -2-.
Lug -arrow A- of bonded rubber bush -1- must point towards lug
-arrow B- of axle beam -2-.
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– Fit special tools as shown in illustration.
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1 - Spindle - T10254/5-
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2 - Nut - T10254/4-
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4 - Thrust piece - T10495/1-
t to the co
5 - Bonded rubber bush
rrectness of i
6 - Thrust plate - T10495/3-
7 - Nut - T10254/4-
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– Before pressing in bonded rubber bush, make sure that mark‐

ot
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ing on bonded rubber bush aligns with mark on axle beam.

h re
hole
spec
– Press bonded rubber bush in to stop.

es, in part or in w
t to the co
– After mounting, check installed position of bonded rubber

bush.
Continue installation in reverse order of removal.
rrectness of i

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Specified torques
nform
ercia
♦ ⇒ “2.1 Assembly overview - axle beam”, page 150

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tion in
♦ ⇒ “2.2.1 Assembly overview - vehicle rear level sender, torsion

r
te o
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beam axle”, page 221

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2. Axle beam 157

3 Subframe
⇒ “3.1 Assembly overview - subframe”, page 158
⇒ “3.2 Assembly overview - add-on parts for subframe”,
page 159
⇒ “3.3 Fixing position of subframe”, page 159
3.1 Assembly overview - subframe
1 - Subframe
subframe with attach‐
ments ⇒ page 145 AG. Volkswagen AG d
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❑ 50 Nm +45°
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❑ 70 Nm +180°
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3.2 Assembly overview - add-on parts for subframe
1 - Shield n AG. Volkswagen AG do

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⇒ page 149 ir se
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❑ When installing, the aut or
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shield must be attached ss
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to the subframe
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an
⇒ Item 3 (page 159)
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2 - Nut
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3 - Subframe
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3.3 Fixing position of subframe

♦ Locating pins - T10096-
3. Subframe 159
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Running gear, axles, steerings - Edition 03.2018
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♦ Rear axle support - T10552-

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Preparing rear axle support - T10552-
n in
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– Loosen bolts -arrows- and set dimension -a-.
s
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um
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Tighten bolts -arrows-.
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– Loosen bolt -arrow- for support - T10552/2- -2-.
– Turn support - T10552/2- -2- in such a way that moulding is

perpendicular to direction of travel.
– Set dimension -b-.
b - 330 mm
Tighten bolt -arrow- to 30 Nm.

– Loosen mounting pins - T10552/1- -3- at bottom on both sides.

– Set dimension -c-.
c - 47 mm
– Turn threaded sleeve of mounting pins - T10552/1- -3- on both

sides to set dimension -d-.
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– Place rear axle support - T10552- -1- on engine and gearbox
jack - V.A.G 1383 A- or engine and gearbox jack - VAS 6931- . rrectness of i
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– Tighten bolt -arrow- to 30 Nm.
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Vehicles with trim for rear axle
rig ht
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– Remove rear axle cladding ⇒ page 149
agen
Prote AG.
– Position rear axle support - T10552- -1- with engine and gear‐
box jack - V.A.G 1383 A- or engine and gearbox jack - VAS
6931- -5- under rear axle and jack up.
3. Subframe 161
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t to the co
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– Insert mounting pins - T10552/1- -2- in holes of rear axle

-arrows A-.
– Secure support - T10552/2- -3- on rear axle using tensioning
strap -4-.
Installing locating pins - T10096-
– Remove bolt -1- on both sides.
• To fix position of subframe, locating pins - T10096- must be
screwed in successively at positions -2- and -3- on both sides
of vehicle.

– Remove one of the front bolts of the subframe -arrow-
– Screw in locating pins - T10096- -1-.
Note
The locating pins - T10096- may be tightened only to a maximum

of 20 Nm; otherwise the threads of the locating pins may be dam‐
aged.
– This procedure must now be carried out for the second front
bolt and the rear bolts of the subframe.
The position of the subframe is now fixed.
AG. Volkswagen AG d
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3. Subframe 163
AG. Volkswagen AG d
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Golf Sportsvan 2015 ➤ed, bGolf Sportsvan 2018 ➤
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Running gear, axles,thorsteering - Edition 03.2018 eo
au ra
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4 Anti-roll bar
un
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⇒ “4.1 Assembly overview - anti-roll bar”, page 164
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⇒ “4.2 Removing and installing anti-roll bar”, page 164
is n
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⇒ “4.3 Removing and installing coupling rod”, page 166
spec
4.1 Assembly overview - anti-roll bar
t to the co
rrectne
1 - Lower transverse link
2 - Nut
ss
o
cial p
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❑ 20 Nm +180°
form
mer
3 - Coupling rod
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⇒ page 166
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❑ Tighten evenly.
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5 - Bolt
Prote AG.

6 - Nut
❑ When tightening, coun‐
terhold at multi-point
socket of coupling rod
❑ 55 Nm
7 - Anti-roll bar
❑ With rubber bushes
⇒ page 164
8 - Subframe
4.2 Removing and installing anti-roll bar


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Removing
, is n
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Vehicles with trim for rear axle
spec
es, in part or in w
– Remove rear axle cladding ⇒ page 149
t to the co
rrectness of i
Note
l purpos
The following procedure is for the left side of the vehicle. The
nform
ercia
procedure for the right side of the vehicle is identical.

m
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– Unscrew nut -1- from coupling rod -2-.

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– Remove bolts -arrows- for anti-roll bar -1-.

– Remove anti-roll bar -1- from subframe -2-.
Installing
ing:
4. Anti-roll bar 165

– Tighten bolts -arrows- for anti-roll bar -1- evenly on subframe

-2-.
Specified torques
♦ ⇒ “4.1 Assembly overview - anti-roll bar”, page 164
4.3 Removing and installing coupling rod

equipment required
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♦ Engine and gearbox jack - VAS 6931- or engine and gearbox
jack - V.A.G 1383 A-

Removing
WARNING
platform.
Vehicles with stone deflector

– Remove spreader rivet -1-.
– Remove bolts -2- for stone guard -3-.
AG. Volkswagen AG d
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– Undo nuts -1- and -3- and pull out bolt -4-.
t to the co
– Pull coupling rod -2- out of anti-roll bar and trailing arm.
rrectness of i
Installing
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ing:
nform
mercia
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4. Anti-roll bar 167

– Insert coupling rod -2-, fit nuts -1- and -3- and tighten in unla‐
den position ⇒ page 6 .
– When tightening nut -1-, counterhold at multi-point socket of
bolt.
Specified torques lkswage es n
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♦ ⇒ “4.1 Assembly overview - anti-roll bar”, page 164 ir se
d ran
tee
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5 Suspension link, track rod

⇒ “5.1 Assembly overview - transverse link”, page 169
⇒ “5.2 Assembly overview - track rod”, page 170
⇒ “5.3 Removing and installing upper transverse link”,
page 170
⇒ “5.4 Removing and installing lower transverse link”, page 171
⇒ “5.5 Removing and installing track rod”, page 173
5.1 Assembly overview - transverse link
1 - Nut
❑ Renew after removal wage
es n
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2 - Washer byV ua
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3 - Upper transverse link auth or
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⇒ page 170
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4 - Bolt
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❑ Always tighten threaded
h re
ole,
connections in unladen
spec
position ⇒ page 6
t to the co
❑ 130 Nm +180°
rrectne
6 - Bolt
ss o
cial p
f in
form
mer
position ⇒ page 6
atio
m
❑ 70 Nm +180°
o
n
c
i
or
n
7 - Nut
thi
te
sd
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8 - Spreader rivet yi
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10 - Bolt
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❑ 8 Nm
AG.

⇒ page 171
12 - Eccentric bolt
❑ A wheel alignment check must be performed if loosened ⇒ page 227
❑ Do not turn more than 90° in either direction (i.e. from minimum to maximum adjustment position).
13 - Eccentric washer
❑ Inner hole with lug
14 - Nut
❑ Always tighten threaded connections in unladen position ⇒ page 6
❑ 95 Nm
5. Suspension link, track rod 169

15 - Subframe
16 - Eccentric bolt
❑ A wheel alignment check must be performed if loosened ⇒ page 227
❑ Do not turn more than 90° in either direction (i.e. from minimum to maximum adjustment position).
17 - Eccentric washer
❑ Inner hole with lug
18 - Nut
❑ Always tighten threaded connections in unladen position ⇒ page 6
❑ 95 Nm
AG. Volkswagen AG d
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5.2 Assembly overview - track rod d by Vol not
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2 - Bolt
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❑ 70 Nm +180°
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spec
4 - Track rod
es, in part or in w
t to the co
⇒ page 173
5 - Bolt
rrectness of i
l purpos

nform
ercia
position ⇒ page 6
m
❑ 70 Nm +180° at
om
ion
c
6 - Nut
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5.3 Removing and installing upper trans‐

verse link

AG. Volkswagen AG d
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s no axles, steering- Edition 03.2018
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Removing
l purpos
nform
ercia
– Raise vehicle.
m
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com
t
– Remove wheels.
ion in
r
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– Remove spring ⇒ page 184 .
thi
s
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– Unhook line -1- from retainer -2- -arrows-.
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rp
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– Unscrew nut -3- and remove washer -4-.

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– Use felt-tip pen or similar to mark position of eccentric bolt

-3- in relation to subframe.
– Unscrew nut -2- and pull out eccentric bolt -3-.
– Take out upper transverse link -1-.
Installing
ing:
• The threaded connections of the suspension link may only be
loosened and tightened in the unladen weight position
⇒ page 6 .
Specified torques
♦ ⇒ “5.1 Assembly overview - transverse link”, page 169
– Perform wheel alignment ⇒ page 234 .
5.4 Removing and installing lower trans‐

verse link

AG. Volkswagen AG d
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Removing
ole,
spec
t to the co
– Raise vehicle.
– Remove wheel.
rrectne
s
s o
cial p
f in
– Remove bracket for rear left vehicle level sender -2-.
form
mer
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c
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Vehicles with stone deflector Prote AG.

– Disengage and lower exhaust system at rear ⇒ Rep. gr. 26 ;
Exhaust pipes/silencers; Assembly overview - silencers .

– Mark position of eccentric bolt -2- in relation to subframe, for

example using a felt-tip pen.
– Undo nut -1- and pull out bolt -2-.
– Remove lower transverse link.
Installing
ing:
• Observe mark made for position of eccentric bolt -2- relative
to subframe.
• The threaded connections of the transverse link may only be
loosened and tightened in the unladen weight position
⇒ page 6 .
Specified torques
♦ ⇒ “2.2.2 Assembly overview - rear vehicle level senders, multi-
link suspension, front-wheel drive”, page 222
♦ Rear exhaust system ⇒ Rep. gr. 26 ; Exhaust pipes/silencers;
Assembly overview - silencer
AG. Volkswagen AG d
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5.5 d by
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Removing and installing track rod
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Special toolsutand workshop equipment required
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♦ Torque wrench - V.A.G 1331- s
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pt
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itte
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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
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at
om
ion
c
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or
his
ate
do
priv
cum
for
en
ng
t.
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Cop py
t. rig
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pyri by
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Prote AG.

Removing
– Raise vehicle.
– Remove wheel.
– Unscrew nut -1- from coupling rod -2-.
– Remove bolts -arrows- for anti-roll bar -1-.

– Remove anti-roll bar -1- from subframe -2-.
– Unscrew nut -1- and bolt -3- by a few turns. n AG. Volkswagen AG do
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– Unscrew bolt -3- and remove. d byV ua
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– Unscrew nut -1- and remove bolt -4- towards rear. auth or
ac
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– Remove track rod -2-. ce
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Installing
itte
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ility
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ing:
wit
, is n
h re
Specified torques
hole
spec
es, in part or in w
♦ ⇒ “5.2 Assembly overview - track rod”, page 170

t to the co

rrectness of i

l purpos
• The threaded connection of the track rod may be tightened

only when the dimension measured between the centre of
nf
wheel hub and lower edge of wheel housing before starting

ercia
the work has been attained ⇒ page 6 .

rm
m
atio
m

o
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or c
thi
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Cop py
t. rig
gh ht
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co lksw
by
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Prote AG.

6 Suspension strut, shock absorber,

spring
⇒ “6.1 Assembly overview - suspension strut, shock absorber,
spring”, page 175
⇒ “6.2 Removing and installing shock absorbers”, page 177
⇒ “6.3 Repairing shock absorber”, page 182
⇒ “6.4 Removing and installing spring”, page 184
6.1 Assembly overview - suspension strut,

shock absorber, spring
⇒ “6.1.1 Assembly overview - suspension strut, shock absorber,
spring, torsion beam axle”, page 175
⇒ “6.1.2 Assembly overview - suspension strut, shock absorber,
spring, multi-link suspension”, page 176
6.1.1 Assembly overview - suspension strut, shock absorber, spring, torsion

beam axle
1 - Bolt
❑ 50 Nm +45°
2 - Shock absorbers
❑ Removing and installing n AG. Volkswagen AG do
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⇒ page 177 olks es n
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❑ Defective shock absorb‐ ir se
d ran
tee
ers must always be de‐ autho
or
ac
gassed and drained be‐ ss
fore disposal ⇒ page 13
ce
e
nl
pt
du
an
itte
3 - Upper spring seat

y li
erm
ab
❑ Fit on “lug” on body.

ility
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wit
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4 - Spring
h re
hole

spec
⇒ page 184
es, in part or in w
t to the co
5 - Retaining ring
❑ After installing stone de‐
rrectness of i
flector, press clamp ring

on so it is flush
l purpos
6 - Lower spring seat

❑ Turn end of spring
nf
ercia
against stop
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❑ When installing, fit pin in

om
n in
aperture in spring
or c
mounting on axle beam.

thi
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7 - Axle beam
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8 - Stone deflector
t.
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9 - Spreader rivet
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gh ht
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10 - Bolt
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❑ Always tighten bolted
connection with suspension in unladen position ⇒ page 6
6. Suspension strut, shock absorber, spring 175

AG. Volkswagen AG d
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Running gear, axles, steering - Edition 03.2018 d by gu
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❑ 70 Nm +180° au
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6.1.2 Assembly overview - suspension strut, shock absorber, spring, multi-link
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suspension
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spec
1 - Bolt
es, in part or in w
t to the co
❑ 50 Nm +45°
2 - Shock absorbers
rrectness of i
l purpos
⇒ page 177
❑ Note correct installation
nform
ercia
position of cable tie fas‐

tener.
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❑ Defective shock absorb‐
n in
r
ers must always be de‐

te o
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3 - Upper spring seat

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❑ Fit on “lug” on body. t. C rig
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4 - Spring
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AG.
⇒ page 184
5 - Clip
❑ Assists with installation
6 - Lower spring seat
❑ Turn end of spring
against stop
❑ When installing, fit pin
into aperture in spring
mounting on lower
transverse link -arrow-.
8 - Nut
❑ Always tighten bolted
connection with suspen‐
sion in unladen position ⇒ page 6
❑ 70 Nm +180°
9 - Bolt

6.2 Removing and installing shock absorb‐

ers
⇒ “6.2.1 Removing and installing shock absorber, torsion beam
axle”, page 177
⇒ “6.2.2 Removing and installing shock absorbers, multi-link sus‐
pension”, page 179
6.2.1 Removing and installing shock absorber, torsion beam axle

equipment required
AG. Volkswagen AG d
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hole
spec
es, in part or in w
t to the co
rrectness of i
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nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
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t.
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♦ Torque wrench - V.A.G 1332- t. Cop py
rig
gh ht
♦ Torque wrench - V.A.G 1410- pyri by
Vo
co lksw
by
cted agen
♦ Spring compressor - V.A.G 1752/1- Prote AG.
♦ Spring retainer - V.A.G 1752/3A-

Removing
– Raise vehicle.
– Remove wheel.

– Remove rear wheel housing liner ⇒ General body repairs,

exterior; Rep. gr. 66 ; Wheel housing liner; Removing and
installing rear wheel housing liner .
– Pull rear left - G76- lever -2- off axle beam -3-.
Vehicles with adaptive chassis control

agen
AGDCC
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do w es n
olks ot g
– Disconnect connectord b-1-
y V on shock absorber -2-. ua
ran
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– Pull line -3- off shock
ut
ho absorber -2- -arrow-. or
ac
a
ss
ce
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un
pt
Note
an
d
itte
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ility
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air on the contacts on the shock absorber and the connector. wit
, is n
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hole
spec
es, in part or in w
t to the co
– Insert spring compressor -1-.

rrectness of i
2- Spring retainer - V.A.G 1752/3A-

l purpos
nform
WARNING
mercia
Ensure that coil spring is correctly seated in spring retainers -

com
tion in
V.A.G 1752/3A- -2-.

r
te o
thi
s
iva
do
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rp
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– Compress coil springs until load on shock absorber is relieved.

fo
en
ng
t.
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op py
– Remove bolts -1- for shock absorber -2-.
t. C rig
gh ht
pyri by
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by
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Prote AG.


– Remove shock absorber.
Installing
lowing:
Specified torques
♦ ⇒ “6.1.1 Assembly overview - suspension strut, shock
olksw absorb‐
agen AG
en AG. V
er, spring, torsion beam axle”, page
olks
wag175 does
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♦ Wheel bolts ⇒ Wheels and ise Tyres Guide; Rep. gr. 44 ; Wheels,
d
nte
tyres; Specified torquet or wheel bolts
hfor eo
u a ra
ss c
♦ Wheel housing liner ⇒ General body repairs, exterior; Rep.
ce
le
un
gr. 66 ; Wheel housing liner; Removing and installing rear
pt
an
d
wheel housing liner .

itte
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erm
ab
ility
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6.2.2 Removing and installing shock absorb‐
wit
is n
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ers, multi-link suspension
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
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

♦ Torque wrench - V.A.G 1410- AG. Volkswagen AG d

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pt
an
d
itte
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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
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pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
Removing gh ht
pyri by
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– Loosen wheel bolts. Prote
cted AG.
agen
– Raise vehicle.
– Remove wheel.
– Use tensioning straps - T10038- to strap vehicle at rear to
support beams of lifting platform on both sides.
WARNING
platform.


Vehicles with adaptive chassis control DCC

– Disconnect connector -1- on shock absorber -2-.
– Pull line -3- off shock absorber -2- -arrow-.
Note

air on the contacts on the shock absorber and the connector.

– Position engine and gearbox jack - VAS 6931- under trans‐
verse link, and push it upwards slightly.
– Remove bolts -1- for shock absorber -2-.
AG. Volkswagen AG d
agen oes
olksw not
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ara
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itte
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ab
ility
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wit
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h re
hole
spec
es, in part or in w
t to the co
– Remove stone guard -3- from lower transverse link -4-.
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
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

– Unscrew nut -1- and remove bolt -2-.

– Remove shock absorber.
Installing
lowing:
• The threaded connections of the shock absorber to the lower
transverse link may only be loosened and tightened in the un‐
laden weight position ⇒ page 6 .
Specified torques
♦ ⇒ “6.1 Assembly overview - suspension strut, shock absorber,
spring”, page 175
6.3 Repairing shock absorber
1 - Shock absorbers
❑ Removing and installing agen
AG. Volkswagen AG d
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⇒ page 177 Volksw not
gu
by ara
❑ Defective shock absorb‐ rised
nte
ers must always be de‐ aut
ho eo
ra
gassed and drained be‐ ss c
ce
le
un
pt
an
d
❑ Checking shock absorb‐

itte
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erm
ab
⇒ page 2
ility
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2 - Protective tube h re
ole,
spec
3 - Buffer stop
t to the co
4 - Shock absorber mounting

5 - Nut
rrectne

s
ing ⇒ page 183

s o
cial p
❑ 25 Nm
inform
mer
6 - Cover
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
o
by c lksw
cted agen
Prote AG.

Special tools and work‐

shop equipment re‐
quired
♦ Torque wrench -
V.A.G 1331-
♦ Shock absorber tool

set - T10001-
AG. Volkswagen AG d
agen oes
olksw not
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ara
ed
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ce
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pt
an
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itte
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wit
is n
h re
♦ Ring spanner insert
ole,
(commercial type,
spec
e.g. »Hazet
t to the co
6630c-21«)
Loosening and tighten‐
ing threaded connection
rrectne
for shock absorber
mounting ss o
1- Ring spanner in‐

cial p
f in
sert (commercial
form
mer
type, e.g. »Hazet

atio
6630c-21«)
om
n
c
i
or
2- Insert - T10001/9-
thi
te
sd
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3- Commercially
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o
pr
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available ratchet
fo
en
ng
handle
t.
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4- Torque wrench -
ht ht
rig by
py
V.A.G 1331- co Vo
by lksw
cted agen
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5- Insert - T10001/1-
AG.
6- Shock absorber
mounting
Install in reverse order.
During this procedure,
observe the following:

– Slide protective tube -1- onto shock absorber mounting -2-.

– Fit cable tie -3- and tighten.
Note
The fastener -arrow- of the cable tie -3- must be located within
area -a-.
Specified torques
♦ ⇒ “6.3 Repairing shock absorber”, page 182
6.4 Removing and installing spring

⇒ “6.4.1 Removing and installing spring, torsion beam axle”, page
184
⇒ “6.4.2 Removing and installing spring, multi-link suspension”,
page 186
6.4.1 Removing and installing spring, torsion

AG. Volkswagen AG d
beam axle Volksw
agen oes
not
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db ran
Special tools and workshop equipment orequired
ris
e
tee
h
ut or
♦ Spring compressor - V.A.G 1752/1-
ss
a ac
ce
le
un
pt
an
d
itte
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erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
rrectness
♦ Spring retainer - V.A.G 1752/3A-

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.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
♦ Adapter - V.A.G 1752/9- , not illustrated

Removing
– Raise vehicle.
– Remove wheel.
– Pull out clip -1- in -direction of arrow- onto stop.

WARNING
Ensure that coil spring is correctly seated in spring
olks
wagretainers
e
- es n
ot g
V.A.G 1752/3A- -2-. d byV ua
ran
e
ris tee
utho or
sa ac
– Compress coil springs until they scan be removed.
ce
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nl
pt
du
an
itte
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erm
Note
ab
ility
ot p
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Use a spanner or a reversible ratchet handle to compress spring h re

compressor.
hole
spec
es, in part or in w
t to the co
Installing
lowing:
rrectness of i
– Check that the lower spring plate is not damaged.

l purpos
– If necessary, renew lower spring plate.

nf
ercia
or
– Place lower plate onto bottom of coil spring.

m
m
atio
m
End of spring -arrow- must contact stop in lower spring seat.

o
n in
or c
thi
e
– Mount spring together with spring plate.

t
sd
iva
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r
rp
cu
– The spring seat has a lug.

o
m
f
en
ng
t.
yi
– Insert this pin into hole in torsion beam axle.
Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

– Insert upper spring seat into upper end of spring.

– Bead of spring seat -arrow- must lie against coil spring cor‐
rectly.
– Release tension on coil spring while locating upper spring seat
on lug on body.
– Remove spring compressor .
– Push in clip -1- in opposite -direction of arrow- onto stop.

Specified torques
6.4.2 Removing and installing spring, multi-

link suspension
wage
equipment
n AG. Volkswarequired
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♦ Tensioning strap
ed - T10038-
by ara
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ra
a c
ss
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
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.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

♦ Torque wrench - V.A.G 1410- 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
y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
♦ Suspension strut clamp - V.A.G 1752-
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
yri by
♦ Engine and gearbox jack - VAS 6931- or engine and gearbox cop Vo
by lksw
jack - V.A.G 1383 A-
cted agen
Prote AG.
Removing
– Raise vehicle.
– Remove wheel.
WARNING
platform.

AG. Volkswagen AG d
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olksw not
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Golf Sportsvan 2015 ➤ , GolfisSportsvan
e d b 2018 ➤ ara
nte
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ut
ho - Edition 03.2018 eo
ra
s a c
s
ce
le
un
pt
an
d
itte
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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
– Press lugs -arrows- of assembly aid -1- inwards.
nform
ercia
– Remove assembly aid -1- upwards.

m
a
com
tio
– Position engine and gearbox jack - VAS 6931- or engine and
n in
r
gearbox jack - V.A.G 1383 A- under transverse link, and press

te o
thi
upwards slightly.
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
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by c lksw
cted agen
Prote AG.

2- Adapter - V.A.G 1752/9-
4- Spring
WARNING
Ensure that coil spring is correctly seated in spring retainer -

V.A.G 1752/3A- -arrow- (risk of accident).
Note
Use a spanner or a reversible ratchet handle to compress spring

compressor.
– Compress coil spring.
– Undo nut -1- and pull out bolt -2- for coupling rod -3-.

AG. Volkswagen AG d
agen oes
lksw n t
– Unscrew nut -1- and y V out bolt -2- securing shock oabsorber.
o
pull gu
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rise nte
– Unscrew nut u-3-
t and pull out bolt -4- securing wheel bearing
ho eo
ra
housing. ss a c
ce
le
un
pt
an
d
WARNING
itte
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rm
ab
pe
ility
Hold spring compressor - V.A.G 1752/1- with the compressed
ot
wit
, is n
spring (risk of accident).
h re
hole
spec
es, in part or in w
– Slowly lower engine and gearbox jack - VAS 6931- or engine
t to the co
and gearbox jack - V.A.G 1383 A- below transverse link far
enough that spring compressor - V.A.G 1752/1- can be re‐
moved together with compressed spring.
rrectness of i
Installing
l purpos

lowing:
nform
mercia
a
– Check that the lower spring plate is not damaged.
com
tion in
r
– If necessary, renew lower spring plate.

te o
thi
s
iva
do
– Place lower plate onto bottom of coil spring.
r
rp
cum
fo
en
g
End of spring -arrow- must contact stop in lower spring seat.

n
t.
yi Co
op py
– Mount spring together with spring plate.
t. C rig
gh ht
pyri by
Vo
o
– The spring seat has a lug.
c by lksw
cted agen
Prote AG.
– Insert this pin in holes in lower transverse link -arrow-.
– Insert upper spring seat into upper end of spring.

– Bead of spring seat -arrow- must lie against coil spring cor‐
rectly.
WARNING
Hold spring compressor - V.A.G 1752/1- with the compressed

spring (risk of accident).
– Position engine and gearbox jack - VAS 6931- or engine and

gearbox jack - V.A.G 1383 A- beneath lower transverse link
and press upwards.

– Insert bolt -4- for wheel bearing housing, and screw on nut
-3-.
– Insert bolt -2- for shock absorber, and screw on nut -1-.
– Insert bolt -2- for coupling rod -3-, and screw on nut -1-.
AG. Volkswagen AG d
agen oes
olksw not
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d b ara
rise nte
tho eo
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– Releasesstension on spring -4- while locating upper spring seat c
on lug on body.
ce
e
nl
pt
du
an
itte
– Remove spring compressor -3-.

y li
erm
ab
ility

ot p
wit
, is n
2- Adapter - V.A.G 1752/9-

h re
hole
spec

es, in part or in w
t to the co
4- Spring
rrectness of i

Specified torques
l purpos

nf
ercia

rm
m
atio
m
♦ ⇒ “6.1 Assembly overview - suspension strut, shock absorber,

o
n in
c
spring”, page 175

or
thi
te
sd
a

iv
o
r
rp
cu

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

7 Wheel bearing assembly, trailing arm

⇒ “7.1 Assembly overview - wheel bearing”, page 191
⇒ “7.2 Assembly overview - trailing arm”, page 193
⇒ “7.3 Removing and installing wheel bearing housing”,
page 193
⇒ “7.4 Removing and installing wheel bearing unit”, page 197 AG. Volkswagen AG d
agen oes
olksw not
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⇒ “7.5 Renewing bonded rubber bush for wheel bearingshousing”,
d b ara
i e nte
page 204 thor eo
au ra
c
⇒ “7.6 Removing and installing trailing arm with mounting
ss
brack‐
ce
le
et”, page 207
un
pt
an
d
itte
y li
⇒ “7.7 Repairing trailing arm”, page 209
erm
ab
ility
ot p
7.1 Assembly overview - wheel bearing
wit
is n
h re
ole,
⇒ “7.1.1 Assembly overview - wheel bearing assembly, torsion
spec
t to the co
⇒ “7.1.2 Assembly overview - suspension, multi-link suspension,
front-wheel drive”, page 192
rrectne
7.1.1 Assembly overview - wheel bearing assembly, torsion beam axle
ss o
1 - Dust cap
cial p
f inform
mer
❑ Pressing off and driving
atio
m
in ⇒ page 197
o
n
c
i
or
n thi
❑ A proper seal can be
te
sd
a
achieved only by instal‐

iv
o
pr
c
ling a new grease cap.
um
r
fo
en
ng
t.
yi
2 - Bolt
Co
Cop py
t. rig
❑ Renew after removal opyri
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Vo
ht
❑ Before fitting, clean

c by lksw
cted agen
threads in stub axle us‐ Prote AG.
ing a thread tap.
❑ 200 Nm +90°
⇒ page 197
❑ The wheel bearing and
wheel hub are assem‐
bled in one housing.
❑ This wheel bearing unit
is maintenance-free and
does not require adjust‐
ment. Adjustments and
repairs are not possible!
4 - Bolt
❑ 30 Nm +90°
5 - Heat shield
6 - Stub axle
7 - Axle beam
7. Wheel bearing assembly, trailing arm 191

7.1.2 Assembly overview - suspension, multi-link suspension, front-wheel drive

⇒ page 193
3 - Bolt
❑ Specified torque ⇒
Brake system; Rep. gr. gen AG
. Volkswagen AG
does
46 ; Rear brakes; As‐ Volkswa not
sembly overview - rear d by gu
ara
brakes rise nte
ho e t or
au ac
4 - Brake disc ss
ce
e
nl
❑ Removing and instal‐
pt
du
an
ling: ⇒ Brake system;
itte
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Rep. gr. 46 ; Rear
erm
ab
ility
brakes; Assembly over‐
ot p
wit
view - rear brakes
, is n
h re
hole
5 - Dust cap
spec
es, in part or in w
t to the co
❑ Pressing off and driving
in ⇒ page 197
rrectness of i
❑ A proper seal can be
achieved only by instal‐
l purpos
ling a new grease cap.

6 - Bolt
nform
ercia

m
at
❑ Before fitting, clean

om
ion
threads in stub axle us‐

c
in t
or
ing a thread tap.

his
ate
do
riv
❑ 200 Nm +90°
p
cum
for
en
g

n
t.
yi Co
op
C py
t. rig
gh
⇒ page 197
ht
pyri by
Vo
co lksw
by
❑ The wheel bearing and wheel hub are assembled in one housing. Prote
cted AG.
agen
❑ This wheel bearing unit is maintenance-free and does not require adjustment. Adjustments and repairs
are not possible!
8 - Bolt
❑ Specified torque ⇒ Brake system; Rep. gr. 46 ; Rear brakes; Assembly overview - rear brakes
9 - Heat shield
❑ Removing and installing: ⇒ Brake system; Rep. gr. 46 ; Rear brakes; Assembly overview - rear brakes

7.2 Assembly overview - trailing arm
1 - Cover
2 - Bolt
❑ 50 Nm +45°
4 - Bolt
AG. Volkswagen AG d
❑ 90 Nm +90° agen oes
olksw not
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d by ara
5 - Wheel bearing housing orise nte
h eo
❑ Different versions possi‐ aut ra
s c
ble. Refer to ⇒ Electron‐ s
ce
le
un
pt
an
d
KA”
itte
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rm
ab
6 - Trailing arm
pe
ility
ot
wit
, is n
h re
⇒ page 207
hole
spec
es, in part or in w
t to the co
❑ Observe installation po‐
sition
rrectness of i
8 - Bolt
l purpos
❑ M12 x 1.5
nform
ercia
❑ 70 Nm +90°
m
a
com
tio
9 - Bolt
n in
r
te o
thi
❑ M14 x 1.5
s
iva
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rp
cum
fo
en
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❑ 70 Nm +90°
n
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
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by c lksw
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Prote AG.
housing

Removing
– Raise vehicle.
– Remove wheel.
– Remove wheel bearing unit ⇒ page 197 .
– Remove heat shield ⇒ Brake system; Rep. gr. 46 ; Rear
brakes; Assembly overview - rear brakes .
AG. Volkswagen AG d
agen oes
olksw not
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ara
ed
ris nte
ho eo
aut ra
ss c
ce
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nl
pt
du

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
– Disconnect electrical connector from ABS speed sensor and

t to the co
electromechanical parking brake motor.

rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
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thi
te
sd
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cu
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f
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t.
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Cop py
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rig ht
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co Vo
by lksw
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Prote AG.


AG. Volkswagen AG d
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1- Tensioning strap - T10038- olksw not
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d b ara
rise nte
ho eo
WARNING s aut ra
c
s
ce
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nl
pt
du
an
platform.
itte
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erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
track rod and press upwards slightly.
– Remove bolts -2- and -3- one after the other.
rrectness of i
– Remove engine and gearbox jack - V.A.G 1383 A- -1- from
l purpos
under track rod.
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
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cu
o
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f
en
ng
– Unscrew nut -1- and remove washer -2-.

t.
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op py
t. C rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

– Take out wheel bearing housing -2-.
Installing
ing:
It is essential to follow specified sequence of work steps below!

– Insert wheel bearing housing -2-.

– Insert bolt -1- and tighten only hand-tight.
– Insert bolt -3-.

– Install washer -2-.
– Tighten nut -1- hand-tight.
lkswage es n
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d ran
ir se tee
tho
u or
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– Position engine and gearbox
ss jack - V.A.G 1383 A- -1- under
ce
le
un
pt
an
d
itte
– Screw in bolts -2- and -3- by hand.

y li
erm
ab
– Remove engine and gearbox jack - V.A.G 1383 A- -1- from ility
ot p
under track rod. wit

is n
h re
ole,
– Install heat shield ⇒ Brake system; Rep. gr. 46 ; Rear brakes;

spec
Assembly overview - rear brakes .

t to the co
– Install wheel bearing unit ⇒ page 197 .

The threaded connections of the wheel bearing housing may only
rrectne
be loosened and tightened in the unladen weight position

⇒ page 6 .
ss o
– Tighten bolt -1-.

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.

– Tighten nut -1-.

– Detach engine and gearbox jack - V.A.G 1383 A- with support
- T10149- from wheel hub.
AG. Volkswagen AG d
agen oes
olksw not
y V gu
Do not tighten bolts rise securing trailing arm to wheel bearing housing
d b ara
nte
until all other ususpension
tho components (especially spring and eo
ra
shock absorber)
ss a on that side are fitted. To tighten, wheel suspen‐ c
sion must be in extended position. Only then do trailing arm and
ce
e
nl
pt
wheel bearing housing move to the necessary position -arrows-.
du
an
itte
y li
– Installing spring ⇒ page 184 .
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
– Tighten bolts -2- and -3-.
l purpos

nf
ercia
Specified torques
orm
m
atio
♦ ⇒ “7.1.2 Assembly overview - suspension, multi-link suspen‐

om
n in
sion, front-wheel drive”, page 192

or c
thi
te

sd
iva
o
r

rp
cu
o
m
f
en
ng

t.
yi Co
Cop py
t. rig
♦ ⇒ “5.2 Assembly overview - track rod”, page 170 opyri
gh by
Vo
ht
c
by lksw
cted agen
Prote
AG.

♦ Bolts for heat shield, brake caliper and brake disc ⇒ Brake
system; Rep. gr. 46 ; Rear brakes; Assembly overview - rear
brakes

unit
⇒ “7.4.1 Removing and installing wheel bearing unit, torsion beam
axle”, page 197
⇒ “7.4.2 Removing and installing wheel bearing unit, multi-link
suspension, front-wheel drive”, page 200
7.4.1 Removing and installing wheel bearing unit, torsion beam axle


equipment required
AG. Volkswagen AG d
agen oes
olksw not
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d by ara
ise nte
or eo
h
aut ra
ss c
ce
e
♦ Fitting sleeve - 3241/4-

nl
pt
du
an
itte
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♦ Hub grease cap puller - VW 637/2-

erm
ab
ility
ot p

wit
, is n
h re
♦ Insert tool - T10162 A-

hole
spec

es, in part or in w
t to the co
Removing
rrectness of i
– Raise vehicle.
l purpos
– Remove wheel.
nf
ercia
– Detach brake carrier with brake caliper and tie to body with
or
wire ⇒ Brake system; Rep. gr. 46 ; Rear brakes; Assembly

m
m
atio
overview - rear brakes .

om
n in
or c
thi
te
sd
a
Note
iv
o
r
rp
cu
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m
f
en
ng
Hang brake caliper from body.

t.
yi Co
Cop py
t. rig
gh ht
– Remove bolt for brake disc and remove brake disc. pyri by
Vo
o
by c lksw
cted agen
Prote AG.

– Loosen grease cap from seat by tapping lightly on claw of hub

grease cap puller - VW 637/2- -1-.
– Pry off grease cap.

1- Hub grease cap puller - VW 637/2-
lkswage es n
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ss
ce
le
un
pt
an
d
itte
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erm
ab
ility
ot p
wit
is n
– Unscrew bolt -1- using socket - T10162 A- -2-.
h re
ole,
spec
Caution
t to the co
Do not use an impact driver when removing bolt -1- with socket
- T10162 A- -2-!
rrectness
– Pull wheel bearing unit off stub axle.
o
cial p
f inform
mer
Caution
atio
om
n
c
i
• Avoid soiling and damage to seal when placing on a sur‐
or
n thi
e
face or storing.
t
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.

Wheel bearing -1- must always face upwards.

– Always set wheel bearing unit on hub -2- when placing on a
surface.
Installing
ing:
– Carefully push wheel hub/wheel bearing unit onto stub axle.
Caution
Ensure that the wheel hubs/wheel bearing unit does not cant!
– Screw in new bolt and tighten to specified torque.
Note lkswage es n
o ot g
byV ua
d ran
ir se
♦ First tighten bolt to specified torqueuthsetting using torque
o tee
or
wrench. ss
a ac
ce
le
♦ Use a rigid spanner for turning further by angle.

un
pt
an
d
itte
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rm
ab
pe
ility
Caution
ot
wit
, is n
h re
hole
Do not use an impact driver when tightening bolt -1- with socket
spec
- T10162 A- -2-!
es, in part or in w
t to the co
rrectness of i
l purpos
nform
ercia
– Drive in grease cap.

m
a
com
tio
1- Fitting sleeve - 3241/4-

n in
r
te o
thi
Always renew removed grease caps.

s
iva
do
r
rp
Damaged grease caps may allow moisture to enter the bearing.

um
fo
en
Therefore, always use the tool shown in the illustration.

ng
t.
yi Co
op py
Specified torques t. C rig
gh ht
pyri by
♦ ⇒ “7.1.1 Assembly overview - wheel bearing assembly, torsion
co Vo
by lksw
cted agen
beam axle”, page 191 Prote AG.

brakes
7.4.2 Removing and installing wheel bearing unit, multi-link suspension, front-
wheel drive

AG. Volkswagen AG d
agen oes
olksw not
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GolfrisSportsvan
ed b
2015 ➤ , Golf Sportsvan 2018 ara ➤
nte
utRunning gear, axles, steering - Edition 03.2018
ho eo
ra
s a c
s
ce
e
nl
pt
du
equipment required
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
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
♦ Fitting sleeve - 3241/4-

♦ Hub grease cap puller - VW 637/2-
♦ Insert tool - T10162 A-
Removing
– Raise vehicle.
– Remove wheel.

– Loosen grease cap from seat by tapping lightly on claw of hub

grease cap puller - VW 637/2- -1-.
– Pry off grease cap.

1- Hub grease cap puller - VW 637/2-
G. Volkswagen AG d
– Detach brake carrier with brake caliper and tie to body with lkswagen A oes
not
wire ⇒ Brake system; Rep. gr. 46 ; Rear brakes; Assembly yV
o gu
db ara
overview - rear brakes . o
ir se nte
th eo
au ra
c
ss
ce
le
Note
un
pt
an
d
itte
y li
Hang brake caliper from body.
rm
ab
pe
ility
ot
wit
, is n
– Remove bolt for brake disc and remove brake disc.
h re
hole
spec
– Unscrew bolt -1- using socket - T10162 A- -2-.
es, in part or in w
t to the co
Caution
rrectness of i
Do not use an impact driver when removing bolt -1- with socket
l purpos
- T10162 A- -2-!
nform
ercia
– Pull wheel bearing unit off stub axle.

m
a
com
tion in
Caution
r
te o
thi
s
iva
do
• Avoid soiling and damage to seal when placing on a sur‐
r
rp
cum
fo
face or storing.
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

Wheel bearing -1- must always face upwards.

– Always set wheel bearing unit on hub -2- when placing on a
surface.
Installing
ing:
– Carefully push wheel hub/wheel bearing unit -2- onto stub

axle.
Caution
Ensure that the wheel hubs/wheel bearing unit does not cant!
– Screw in new bolt -1- and tighten to specified torque.
Note agen
AG. Volkswagen AG d
oes
olksw not
yV gu
♦ First tighten bolt to specified torque d setting using torque
b ara
ise nte
r
wrench. ut
ho eo
ra
s a c
♦ Use a rigid spanner for turning further by angle. s
ce
e
nl
pt
du
an
itte
y li
erm
ab
Caution
ility
ot p
wit
, is n
Do not use an impact driver when tightening bolt -1- with socket
h re
hole
- T10162 A- -2-!
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
thi
te
sd
iva
o
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rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
203
by lksw
cted agen
Prote AG.
7. Wheel bearing assembly, trailing arm
– Drive in grease cap.

1- Fitting sleeve - 3241/4-
Always renew removed grease caps.
Damaged grease caps may allow moisture to enter the bearing.
Therefore, always use the tool shown in the illustration.
Specified torques
♦ ⇒ “7.1.2 Assembly overview - suspension, multi-link suspen‐
sion, front-wheel drive”, page 192
brakes
7.5 Renewing bonded rubber bush for wheel bearing housing

equipment required
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
ss c
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
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
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rp
cu
o
m
f
en
ng
t.
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op py
. C rig
ht ht
rig by
opy Vo
♦ Assembly tool - 3350- by c lksw
cted agen
Prote AG.

♦ Press tool - 3367-

♦ Follower - 3390-
Removing
– Raise vehicle.
– Remove wheel.

AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
ss c
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
1- Nut - 3346/3-
l purpos
2- Thrust disc from assembly tool - 3301-

3- Follower - 3390-
nf
ercia
or
4- Sleeve from assembly tool - 3350-

m
m
atio
m
5- Nut
o
n in
or c
thi
e
6- Spindle - 3346/2-
t
sd
iva
o
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rp
cu
– Pull out bonded rubber bush by turning nut - 3346/3- -1-. When
o
m
f
en
doing this, counterhold spindle - 3346/2- -6-.

ng
t.
yi Co
op py
Pulling in bonded rubber bush
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ht ht
rig by
copy Vo
by lksw
cted agen
Prote AG.

Note
♦ When pulling in, make sure that the tip of the spindle - 3301/1-agen AG. Volkswagen AG d
does not rest against the wheel bearing housing. olks
w oes
not
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ara
ed
♦ Do not use lubricant. ris nte
tho eo
au ra
♦ Insert bearing carefully so it does not cant. ss c
ce
le
un
pt
an
1- Nut from assembly tool - 3301-
d
itte
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rm
ab
pe
ility
ot
wit
3- Thrust piece from assembly tool - 3346- , with open side
, is n
h re
facing towards wheel bearing housing
hole
spec
4- Wheel bearing housing
es, in part or in w
t to the co
6- Press tool - 3367/2-
rrectness of i
7- Spindle - 3301/1-
l purpos
– Pull in bonded rubber bush by turning nut - 3301- -1- just far
enough so that it is positioned right in front of wheel bearing
nform
ercia
housing. When doing this, counterhold spindle - 3301/1- -7-.

m
a
com
tio
– Remove tools, and fit them again as shown in illustration.
n in
r
te o
thi
1- Nut from assembly tool - 3301-
s
iva
do
r
rp
cum
fo
en
ng
t.
yi
3- Thrust piece from assembly tool - 3346- , with open side
Co
Cop py
facing towards wheel bearing housing ht. rig
rig ht
py by
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4- Wheel bearing housing by c lksw
cted agen
Prote AG.
5- Press tool - 3367/2-
6- Press tool - 3301/2-
7- Spindle - 3301/1-
– Pull in bonded rubber bush to stop by turning nut - 3301- -1-.
When doing this, counterhold spindle - 3301/1- -7-.
Installing
Perform further installation in reverse order, paying attention to
the following:
• The threaded connections to the lower transverse link may
only be loosened and tightened in the unladen weight position
⇒ page 6 .
Specified torques

7.6 Removing and installing trailing arm with

mounting bracket
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c
ce
le
un
pt
an
d
itte
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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
t.
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Removing
Co
Cop py
t. rig
gh
ht
pyri by
Vo
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by c lksw
– Raise vehicle.
cted agen
Prote AG.
– Remove wheel.
– Detach line -1- from trailing arm -2-. To do this push out inner
pin of retainer -arrows-.


WARNING
platform.

– Remove bolts -2- and -3- one after the other.
under track rod.
– Detach wire -2- from mounting bracket -1-.

– Mark installation position of mounting bracket
agen
-1-
AG.on
Volkbody.
swagen AG
do
ksw es n
– Remove bolts -arrows- Vol ot g
d by ua
ran
e
ris tee
– Remove trailing arm with mounting
tho bracket. or
au ac
ss
Installing
ce
e
nl
pt
du
an

itte
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ing:
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
– Tighten bolts -arrows- onto old impression marks or previously

t to the co
applied marks.
– Secure line -2- on mounting bracket -1-.
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
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rp
cu
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m
f
en
ng
t.
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Cop py
t. rig
gh ht
pyri by
Vo
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by c lksw
cted agen
Prote AG.

Golf Sportsvan AG.2015
Volksw➤ , nGolf
age AG doSportsvan 2018 ➤
agen
Running
V olksw gear, axles, steeringe-s n Edition
ot g 03.2018
y ua
db ran
rise tee
– Position engine and gearbox jack - V.A.G 1383tho A- -1- under or
track rod and press upwards slightly. s au ac
s
ce
e
nl
– Screw in bolts -2- and -3- by hand.
pt
du
an
itte
y li
erm
ab
under track rod.
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
Do not tighten bolts securing trailing arm to wheel bearing housing
l purpos
until all other suspension components (especially spring and

shock absorber) on that side are fitted. To tighten, wheel suspen‐
nform
ercia
sion must be in extended position. Only then do trailing arm and

wheel bearing housing move to the necessary position -arrows-.
m
at
om
io
– Installing spring ⇒ page 184 .
n
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.
– Tighten bolts -2- and -3-.
– Install retainers -arrows- on trailing arm -2- for line -1-. To do

this push in inner pin of rivets.
Specified torques
After installation, wheel alignment must be checked on wheel
alignment unit ⇒ page 234 .
7.7 Repairing trailing arm


equipment required
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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rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
♦ Tube for wheel bearing - 3345-

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♦ Thrust piece - T10496-

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– Remove trailing arm with mounting bracket ⇒ page 207 .

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– Clamp trailing arm -1- in vice using protective jaw covers.

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– Fit tools as shown in illustration.
2- Tube -3346/1- from assembly tool - 3346- (the deep recess
must face the bonded rubber bush)
3- Trailing arm
– Press out bonded rubber bush.
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– Mark position of bonded rubber bush on trailing arm using a
wit
set square.
is n
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– Position outer edge of set square on upper radius of hole -1-
spec
and on lower radius of hole -2-.
t to the co
– Make a mark above and below the trailing arm bush respec‐
tively -arrows-.
rrectne
a - 90°
ss o
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mer
Position bonded rubber bush on trailing arm so that marked line

atio
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-arrows- lies between the ribs -1-.

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Take great care to ensure that the installation position of the bon‐
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ded rubber bush is correct relative to the bush in the trailing arm.
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Running gear, axles, steeringuth- Edition 03.2018
o eo
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– Fit tools as shown in illustration.
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2- Press tool - T10496-
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4- Trailing arm
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– Pressing in bonded rubber bush.
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– Clamp trailing arm -2- in vice using protective jaw covers.
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– Position mounting bracket -1- on trailing arm -2-. C py
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– Screw in bolt -3-. co Vo
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– Set dimension -a- to 37 mm and tighten bolt -3-.
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– Install trailing arm with mounting bracket ⇒ page 207 .

43 – Self-levelling suspension
1 Electronically controlled damping
system
⇒ “1.1 Assembly overview - electronically controlled damping
system”, page 213
⇒ “1.2 Removing and installing electronically controlled damping
control unit J250 ”, page 216
⇒ “1.3 Removing and installing front body acceleration senders
G341 / G342 ”, page 217
⇒ “1.4 Removing and installing rear left body acceleration sender
G699 ”, page 218
1.1 Assembly overview - electronically con‐

trolled damping system n AG. Volkswagen A ge G do
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⇒ “1.1.1 Assembly overview - electronically
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⇒ “1.1.2 Assembly overview -sselectronically
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1.1.1 Assembly overview - electronically controlled damping system, torsion
itte
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beam axle
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1. Electronically controlled damping system 213

1 - Front right vehicle level

sender - G289-
⇒ page 222
2 - Front right body accelera‐
tion sender - G342-
⇒ page 217
3 - Electronically controlled
damping control unit - J250-
⇒ page 216
❑ Location: the electroni‐
cally controlled damping
control unit - J250- is in‐
stalled under the front gen AG
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❑ Function Replace con- orise nte
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s
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❑ If the reference position
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hole
spec
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es, in part or in w
er assist systems must

t to the co
be recalibrated on vehi‐
cles with lane departure
warning function
rrectness of i
⇒ “3.1 Calibrating front

camera for driver assist
l purpos
systems”, page 257 .

4 - Rear left body acceleration
nform
ercia
sender - G699-
m
at
om
❑ Location: on left suspension strut dome behind left luggage compartment side trim.
ion
c
in t
❑ Removing and installing ⇒ page 218

or
his
ate
do
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5 - Rear left vehicle level sender - G76-

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6 - Front left body acceleration sender - G341- C py
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❑ Removing and installing ⇒ page 217 py by
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7 - Front left vehicle level sender - G78-
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8 - Shock absorber with front right shock absorber damper adjustment valve - N337-
❑ Removing and installing suspension strut ⇒ page 55 .
❑ Repairing suspension strut ⇒ page 62 .
9 - Shock absorber with rear right shock absorber damper adjustment valve - N339- .
❑ Removing and installing shock absorber ⇒ page 177 .
❑ Repairing shock absorber ⇒ page 182 .
10 - Shock absorber with rear left shock absorber damper adjustment valve - N338- .
11 - Shock absorber with front left shock absorber damper adjustment valve - N336-
214 Rep. gr.43 - Self-levelling suspension

1.1.2 Assembly overview - electronically controlled damping system, multi-link

suspension
1 - Front right vehicle level

sender - G289-
⇒ page 222
2 - Front right body accelera‐ AG. Volkswagen AG d
tion sender - G342- agen oes
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❑ Removing and installing ise
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⇒ page 217 uthor eo
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3 - Electronically controlled s
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damping control unit - J250-
nl
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⇒ page 216
ility
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❑ Location: the electroni‐
wit
, is n
cally controlled damping
h re
hole
control unit - J250- is in‐
spec
stalled under the front
es, in part or in w
t to the co
right seat.
❑ Function Replace con-
trol unit must be per‐
rrectness of i
formed with ⇒ Vehicle
diagnostic tester if elec‐
l purpos
tronically controlled
damping control unit -
nf
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J250- is renewed.
orm
❑ If the reference position
m
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has been re-adapted,

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the front camera for driv‐

or
thi
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er assist systems must

t
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be recalibrated on vehi‐
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cles with lane departure
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warning function
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4 - Rear left body acceleration
sender - G699-
❑ Location: on left suspension strut dome behind left luggage compartment side trim.
5 - Rear left vehicle level sender - G76-
❑ Removing and installing, front-wheel drive ⇒ page 225
6 - Front left body acceleration sender - G341-
7 - Front left vehicle level sender - G78-
8 - Shock absorber with front right shock absorber damper adjustment valve - N337-
9 - Shock absorber with rear right shock absorber damper adjustment valve - N339- .

10 - Shock absorber with rear left shock absorber damper adjustment valve - N338- .
11 - Shock absorber with front left shock absorber damper adjustment valve - N336-
1.2 Removing and installing electronically

controlled damping control unit - J250-
♦ Vehicle diagnostic tester
Removing
Location: the electronically controlled damping control unit - J250-
is installed under the front right seat.
– Withdraw ignition key.
lock engages.
– Move front seat (right-side)
wage
as far
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– Pull out spreaderedrivets
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– Pull cover -2-
au in -direction of arrow- out of
th retainer. eo
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– Press lugs -arrows- outwards.

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– Remove electronically controlled damping control unit - J250-

-1- from retainer.
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– Release connector -1- and pull off electronically controlled

damping control unit - J250- -2-.
– Remove electronically controlled damping control unit - J250-
-2-
Installing
ing:
– Function Replace control unit must be performed with
⇒ Vehicle diagnostic tester if electronically controlled damping
control unit - J250- has been renewed.
– If the reference position has been re-adapted, the front camera
for driver assist systems must be recalibrated on vehicles with
lane departure warning function
⇒ “3.1 Calibrating front camera for driver assist systems”, page
257 .
1.3 Removing and installing front body ac‐

celeration senders -G341- / -G342-
lkswage es n
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Removing autho
or
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ss
– Pull seal off entire length of plenum chamber cover.
ce
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– Detach clips.
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– Remove plenum chamber cover ⇒ General body repairs, ex‐

pe
ility
terior; Rep. gr. 50 ; Bulkhead; Removing and installing plenum

ot
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chamber cover .
h re
hole
spec
– Release connectors -1- and pull off.

es, in part or in w
t to the co
– Remove screw -2-.

– Remove front body acceleration sender .
rrectness of i
Installing
l purpos

lowing:
nform
mercia
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tion in
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– Insert front body acceleration sender -1- so that connector

-arrow- points to rear (opposite to normal direction of travel).
– Tighten bolt -2- for front body acceleration sender -1-.
Installation position: angle tolerance -a- is ±10°. Installation po‐
sition of front body acceleration sender may deviate by this angle
along the longitudinal axis of the vehicle.
– Install plenum chamber cover ⇒ General body repairs, exte‐
rior; Rep. gr. 50 ; Bulkhead; Removing and installing plenum
chamber cover .
– Perform basic setting of wheel damper electronics ⇒ Vehicle
diagnostic tester. agen
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Component tho torque
Specified
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Front body acceleration sender 8 Nm
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1.4 Removing and installing rear left body
ot
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acceleration sender - G699-
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
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tion in
r
te o
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Removing
C py
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– Remove left luggage compartment side trim ⇒ General body cop Vo
by lksw
repairs, interior; Rep. gr. 70 ; Luggage compartment trims;
cted agen
Prote AG.
Removing and installing luggage compartment side trim .
– Release connectors -1- and pull off.
– Unscrew bolt -2- and remove rear body acceleration sender -
G343- -3-.
Installing
lowing:

– Insert rear body acceleration sender - G343- -1- so that lug

-arrow A- engages into hole -arrow B-.
– Perform basic setting of wheel damper electronics ⇒ Vehicle
diagnostic tester.
Specified torques
Component Specified torque
Rear body acceleration sender 8 Nm
- G343- to body
AG. Volkswagen AG d
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2 Vehicle level sender

⇒ “2.1 Assembly overview - front vehicle level senders”,
page 220
⇒ “2.2 Assembly overview - rear vehicle level senders”,
page 221
⇒ “2.3 Removing and installing front vehicle level senders G78 /
G289 ”, page 222
⇒ “2.4 Removing and installing rear vehicle level senders G76 /
G77 ”, page 224
2.1 Assembly overview - front vehicle level senders
Note
wage
The front left/right vehicle level sender - G78/G289- is only availabley Vas o a replacement part complete
lks es n
ot gwith
coupling rod and upper and lower retaining plates. ir se
d b ua
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th or
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1 - Suspension link
un
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2 - Subframe
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ility
3 - Electrical connector
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wit
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4 - Front left vehicle level send‐
h re
hole
er - G78- and front right vehicle
spec
level sender - G289-
es, in part or in w
t to the co
❑ Complete with attach‐
ments
❑ Lever must face out‐
rrectness of i
wards
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⇒ page 222
nform
ercia
❑ Carry out basic setting

of headlights ⇒ Electri‐
m
a
com
cal system; Rep. gr. 94 ;
tion in
Headlights; Adjusting
r
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thi
headlights
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5 - Bolt
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❑ 8 Nm
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❑ 8 Nm
Prote AG.

2.2 Assembly overview - rear vehicle level

senders
⇒ “2.2.1 Assembly overview - vehicle rear level sender, torsion
⇒ “2.2.2 Assembly overview - rear vehicle level senders, multi-
2.2.1 Assembly overview - vehicle rear level sender, torsion beam axle
Note
The rear left vehicle level sender - G76- is only available as a replacement part complete with coupling rod and
upper and lower retaining plates.
2 - Bolt
❑ 5 Nm
3 - Rear left vehicle level send‐
er - G76-
⇒ page 224
– Perform basic setting of
wheel damper electron‐
ics ⇒ Vehicle diagnostic
tester.
G. Volkswagen AG d
❑ Carry out basic setting lkswagen A oes
not
of headlights ⇒ Electri‐
yV
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Headlights; aAdjusting eo
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headlightsss c
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nl
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4 - Bolt
du
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itte
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❑ 8 Nm
erm
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5 - Axle beam
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es, in part or in w
t to the co
rrectness of i
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ion
c
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2. Vehicle level sender 221

2.2.2 Assembly overview - rear vehicle level senders, multi-link suspension, front-
wheel drive
Note
The vehicle level sender is available as a replacement part only complete with coupling rod and upper and
lower retaining plates.
1 - Bolt
❑ 5 Nm
2 - Vehicle level sender at rear
❑ Complete with attach‐
ments
❑ Lever must face out‐
wards
⇒ page 224
❑ Perform basic setting of
wheel damper electron‐
ics ⇒ Vehicle diagnostic
tester.
❑ Carry out basic setting AG. Volkswagen AG d
of headlights ⇒ Electri‐ agen oes
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cal system; Rep. gr. 94 ; d by
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Headlights; Adjusting orise nte
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3 - Pop rivet nut
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5 - Pop rivet nut
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6 - Bolt
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❑ 5 Nm
spec
es, in part or in w
t to the co
rrectness of i
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2.3 Removing and installing front vehicle

iv
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level senders -G78- / -G289-

f
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Special tools and workshop equipment required t. C rig
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Removing
applicable.
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– Unscrew nut -1-. d by V o gu
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– Pull bracket -2- ut for front left vehicle level sender - G78- or frontor a
ho e
right vehicless level sender - G289- out of suspension link -3-. c
a
ce
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un
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t to the co
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mer
atio
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n
c
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te
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fo
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t.
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rig ht
py by
co Vo
by lksw
cted agen
Prote AG.


– Remove front left vehicle level sender - G78- and/or front right
vehicle level sender - G289- , as applicable.
Installing
lowing:
Note
position.
• Perform basic setting of wheel damper electronics ⇒ Vehicle

diagnostic tester.
• If the reference position has been re-adapted, the front camera
for driver assist systems must be recalibrated on vehicles with
lane departure warning function AG. Volkswagen AG d
agen
⇒ “3.1 Calibrating frontVocamera
lksw for driver assist systems”,
oes
not page
257 . ed by gu
ara
is nte
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• Carry out basic
au setting of headlights ⇒ Electrical system; Rep.r ac
th
gr. 94 ; Headlights;
ss Adjusting headlights .
ce
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nl
pt
Specified torques
du
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itte
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erm
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ility
220
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wit
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2.4 Removing and installing rear vehicle

hole
spec
level senders -G76- / -G77-

es, in part or in w
t to the co
⇒ “2.4.1 Removing and installing rear left vehicle level sender

G76 , torsion beam axle”, page 224
rrectness of i
⇒ “2.4.2 Removing and installing rear left vehicle level sender

l purpos
G76 , multi-link suspension, front-wheel drive”, page 225
2.4.1 Removing and installing rear left vehicle

nform
ercia
level sender - G76- , torsion beam axle

m
at
om
io

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c
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at
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Removing
– Remove bolts -2- and -4-.
– Remove rear left vehicle level sender - G76- -3-.
Installing
lowing: gen AG
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d a oes
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Note oris eo
th
au ra
c
ss
The lever of the rear left vehicle level sender - G76- must face
ce
le
un
pt
towards rear of vehicle.
an
d
itte
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erm
ab
ility
ot p
diagnostic tester.
wit
is n
h re
ole,
• Carry out basic setting of headlights ⇒ Electrical system; Rep.
spec
gr. 94 ; Headlights; Adjusting headlights .
t to the co
Specified torques
♦ ⇒ “2.2.1 Assembly overview - vehicle rear level sender, torsion
rrectne
s
2.4.2 Removing and installing rear left vehicle
s o
cial p
f
level sender - G76- , multi-link suspen‐
inform
mer
sion, front-wheel drive
atio
om
n
c
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or
n thi
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t.
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Removing
– Unscrew bolts -2- and -3-.
– Take out rear left vehicle level sender - G76- -4-.
Installing
lowing:
The lever of the vehicle level sender must point towards the out‐
side of the vehicle.
diagnostic tester.
• Carry out basic setting of headlights ⇒ Electrical system; Rep.
gr. 94 ; Headlights; Adjusting headlights .
Specified torques
AG. Volkswagen AG d
agen oes
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t to the co
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cial p
f inform
mer
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c
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44 – Wheels, tyres, vehicle geometry

1 Wheel alignment
⇒ “1.1 Notes for wheel alignment”, page 227
⇒ “1.2 Conditions for testing”, page 228
⇒ “1.3 Test preparations”, page 228
⇒ “1.4 Specifications for wheel alignment”, page 230
⇒ “1.5 Wheel alignment procedure”, page 233
⇒ “1.6 Necessity of wheel alignment”, page 234
⇒ “1.7 Vehicle data sticker”, page 236
⇒ “1.8 Adjusting camber at front wheels”, page 237
⇒ “1.9 Adjusting camber on rear axle”, page 238
⇒ “1.10 Adjusting toe at rear axle”, page 239
⇒ “1.11 Adjusting front axle toe”, page 240
⇒ “1.12 Wheel runout compensation”, page 241
⇒ “1.13 Checking maximum wheel lock”, page 241
1.1 Notes for wheel alignment

Wheel alignment must be performed only using a VW/AUDI-ap‐
proved wheel alignment unit!
Whenever wheels are aligned, both the front and rear axles must
be measured.
– Carry alignment out with the wheel alignment computer.
All the information on wheel alignment can be found in the wheel
alignment computer. wage
e ks s no
Vol t gu
Current data »updates« are located in VW ServiceNet.
ed
by ara
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⇒ VW ServiceNet; Systems; Wheel alignment
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ware; Wheel alignment; Beissbarth ss c
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⇒ VW ServiceNet; Systems; Wheel alignment computer soft‐

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Note
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♦ Wheel alignment should not be checked before the vehicle has

completed 1000 to 2000 km after the coil springs have settled.
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♦ When making adjustments, adhere to the relevant specifica‐

inform
tions as closely as possible.

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♦ Whenever adjustments are made to the running gear, always

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check whether any driver assist systems must be recalibrated

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following the adjustments.

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Prote AG.
1. Wheel alignment
Crabbing and accident damaged vehicles

This may be due to the rack in the steering rack not being exactly
centred when vehicle is driven in a straight line.
Power steering assistance is thereby slightly one sided, rather
than central. The vehicle will pull to one side as a consequence.
When checking the alignment of a “vehicle which pulls to one
side”, always ensure that the steering rack is centred.
Observe
⇒ “1.2 Safety precautions when working on subframe”, page 1 .
1.2 Conditions for testing

• Check wheel suspension, wheel bearing assembly and steer‐
ing for excessive play and damage.
• Tread depth difference of no more than 2 mm on one axle.
• Tyres inflated to correct pressures.
• Vehicle unladen.
• Fuel tank must be full.
• Spare wheel and vehicle tools are stowed in correct locations.
• Windscreen washer fluid reservoir must be full.
• When checking wheel alignment, ensure that sliding plates
and turn tables are not touching end stop.
Please note the following:
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• The test equipment must be properly adjusted and Vol
kattached
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to the vehicle; observe device manufacturer'sed operating in‐
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structions. ho
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If necessary, ask the manufacturer to show
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wheel alignment machine.
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Wheel alignment platforms and wheel alignment computers can

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lose their original calibration over a period of time.
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Wheel alignment platforms and computers should be checked

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and adjusted as necessary during inspection and maintenance at

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least once per year!

spec
es, in part or in w
t to the co
– Handle these highly sensitive devices carefully and conscien‐

tiously.
1.3 Test preparations

rrectness of i
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⇒ “1.3.1 Test preparations, wheel alignment with no driver assist

systems”, page 228
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⇒ “1.3.2 Test preparations, wheel alignment with driver assist

or
systems”, page 230

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1.3.1 Test preparations, wheel alignment with no driver assist systems

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228 Rep. gr.44 - Wheels, tyres, vehicle geometry

AG. Volkswagen AG d Golf Sportsvan 2015 ➤ , Golf Sportsvan 2018 ➤
agen oes
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Running
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gear, axles, steering - Edition 03.2018
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Special tools and tho eo
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equipment required
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♦ Wheel alignment computer - V.A.G 1813F- or VW/Audi-ap‐

proved wheel alignment units
♦ Brake pedal depressor - V.A.G 1869/2-
♦ Insert tool, 18 mm - T10179-
♦ Shock absorber tool set - T10001-
The existing lateral runout of the wheel must be compensated for.
Otherwise, the result of the measurement will be incorrect.
If runout compensation is not performed, it is not possible to adjust
toe-in correctly!
Please follow the instructions of the manufacturer of the wheel
alignment equipment.
– Carry out wheel runout compensation.
– Apply brake pedal depressor - V.A.G 1869/2- .
– Use brake pedal depressor to depress brake pedal.
1. Wheel alignment 229

Preparations required before calibration of driver assist systems
1.3.2 Test preparations, wheel alignment with

driver assist systems
The following steps are required if one or more driver assist sys‐
tems on the vehicle are to be calibrated via the “Quick-start”
procedure (i.e. without first checking and adjusting the wheel
alignment):
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• Before driving the vehicle onto the alignment platform, make Volkswa not
sure there is sufficient space between the vehicle and the cal‐ed
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ibration unit. The distance between the calibrating devicehoand
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the vehicle must be 120 cm ± 2.5 cm. sa
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• If the available space is not adequate, move the vehicle back‐
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wards on the alignment platform as required. This allows the
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• Before starting calibration, read out event memory and rectify
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any faults.
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• Vehicle accurately aligned, suspension bounced and rocked
spec
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several times.
t to the co
• When checking wheel alignment, ensure that sliding plates
and turn tables are not touching end stop.
rrectness of i
• Connect battery charger ⇒ Electrical system; General infor‐
mation; Rep. gr. 27 ; Charging battery .
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• Move front wheels to straight-ahead position.
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• Connect ⇒ Vehicle diagnostic tester to vehicle, route diagnos‐

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• Vehicle exterior lighting switched off.
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• All doors of vehicle are closed.
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• Press button to select required calibration on wheel alignment

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1.4 Specifications for wheel alignment
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⇒ “1.4.1 Specified values for wheel alignment, torsion beam axle”, Prote AG.
page 230
⇒ “1.4.2 Specified values for wheel alignment, multi-link suspen‐
sion”, page 231
1.4.1 Specified values for wheel alignment, torsion beam axle

These specifications apply to all engines.
Explanations regarding PR numbers
⇒ “1.7 Vehicle data sticker”, page 236 .
Front axle Standard running Sports running Raised running BlueMotion
gear/ gear gear
running gear with
DCC
PR numbers G01/ G02/ G05/ G01/G02 +GM1/ G01+2UF G01+2UC+GM1
G07+2UA G06 G03/G07 G01+2UP
G16/G18/G22 G07/ G21+2UC/ G02+2UF G02+2UC+GM1
G01 G24/G25/G27/ G07+2UC
G14+ 2UP/G17 G35 G21/G26
G21/G26
Total toe (without load) 10’ ± 10’ 10’ ± 10’ 10’ ± 10’ 10’ ± 10’
Camber (in straight-ahead posi‐ -30’ ± 30’ -41’ ± 30’ -16’ ± 30’ -41’ ± 30’
tion) 1)

AG. VoRunning gear,
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does axles, steering - Edition
03.2018
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PR numbers G01/ G02/ G05/ G01/G02 +GM1/ G01+2UF G01+2UC+GM1
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G07+2UA G06 G03/G07 G01+2UP
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G14+ 2UP/G17 G35 G21/G26
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G21/G26
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Maximum permissible differ‐ max. 30' max. 30' max. 30' max. 30'
ence between sides
Toe-out on turns with 20° steer‐ 1° 19′ ± 20′ 1° 30′ ± 20′ 1° 09′ ± 20′ 1° 30′ ± 20′
rrectness of i
ing angle 2)
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Caster 7° 23′ ± 30′ 7° 38′ ± 30′ 7° 09′ ± 30′ 7° 38′ ± 30′

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ence between sides
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Ride height ⇒ page 231 383 ± 10 mm 368 ± 10 mm 398 ± 10 mm 368 ± 10 mm
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1) Camber cannot be adjusted. Corrections are possible by moving the subframe
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2) The toe-out on turns can be displayed as a negative value on the wheel align‐
Co
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Rear axle Standard running Sports running Raised running BlueMotion
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Camber -1° ± 10′ -1° ± 10′ -1° ± 10′ -1° ± 10′

ence between sides
Total track (at prescribed cam‐ 20’ ± 12’ 24’ ± 12’ 26’ ± 12’ 24’ ± 12’
ber)
Max. permissible deviation from max. 20' max. 20' max. 20' max. 20'
direction of travel
Ride height ⇒ page 231 385 ± 10 mm 370 ± 10 mm 400 ± 10 mm 370 ± 10 mm
Measuring ride height

– The dimension -a- between the centre of the wheel hub and
the lower edge of the wheel housing defines the ride height.
1.4.2 Specified values for wheel alignment, multi-link suspension

These specifications apply to all engines.

Explanations regarding PR numbers

⇒ “1.7 Vehicle data sticker”, page 236 .
Front axle Standard running Sports running gear Raised running gear
gear/
running gear with
DCC
PR numbers G01/ G02/ G05 G01/G02 +GM1 G01+2UF
G07+2UA G06/G07/ G21+2UC G02+2UF
G16/G18/G22 G01/ G14+ 2UP G07/G24/G25/G27
G17,G21,G26
Total toe (without load) 10’ ± 10’ 10’ ± 10’ 10’ ± 10’
Camber (in straight-ahead position) 3) -30’ ± 30’ -41’ ± 30’ -16’ ± 30’
Maximum permissible difference be‐ max. 30' max. 30' max. 30'
tween sides
Toe-out on turns with 20° steering angle 1° 19′ ± 20′ 1° 30′ ± 20′ 1° 09′ ± 20′
4)
Caster 7° 23′ ± 30′ 7° 38′ ± 30′ 7° 09′ ± 30′

tween sides
Ride height ⇒ page 232 383 ± 10 mm 368 ± 10 mm 398 ± 10 mm
AG. Volkswagen AG d
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3) Camber cannot be adjusted. Corrections are possible by moving by V the subframe gu
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4) The toe-out on turns can be displayed as a negative
s s a value on the wheel align‐ c
ment computer, depending on the manufacturer.
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Rear axle Standard running Sports running gear Raised running gear
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Camber -1° 20′ ± 30′ -1° 20′ ± 30′ -1° 20′ ± 30′
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tween sides
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Total track (at prescribed camber) 10’ ± 10’ 10’ ± 10’ 10’ ± 10’
Max. permissible deviation from direc‐ max. 20' max. 20' max. 20' t to the co
tion of travel rrectness of i
Ride height ⇒ page 232 385 ± 10 mm 370 ± 10 mm 400 ± 10 mm

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Measuring ride height

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– The dimension -a- between the centre of the wheel hub and
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the lower edge of the wheel housing defines the ride height.
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1.5 Wheel alignment procedure ol ot g
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Always adhere to the followingauprocedure!
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The vehicle must always be in unladen condition when measuring ot p
wheel alignment ⇒ page 4 .
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– Take note of the information in the wheel alignment unit.
es, in part or in w
t to the co
rrectness of i
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Alignment procedure
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Start → Carry out wheel runout com‐ → Bounce springs.
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pensation.
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↓
Turn steering wheel to ← Measure vehicle height. ← Fit brake pedal depressor - V.A.G
straight-ahead position 1869/2-
and fix in place 5).
↓
Check front axle camber → Is actual value within toler‐ → no
ance?
↓ ↓
↓ ← ← yes Adjusting ⇒ page 237
↓ ↓
↓ ← ← ← ← ←
↓
Check rear axle camber → Is actual value within toler‐ → no
ance?
↓ ↓
↓ ← ← yes Checking (torsion beam axle)
⇒ page 238
Adjusting (multi-link suspension)
⇒ page 238
↓ ↓
↓ ← ← ← ← ←
↓
Check rear axle toe → Is actual value within toler‐ → no
ance?
↓ ↓
↓ ← ← yes Checking (torsion beam axle)
⇒ page 239
Adjusting (multi-link suspension)
⇒ page 239
↓ ↓

↓ ← ← ← ← ←
↓
Check front axle caster → Is actual value within toler‐ → no
ance?
↓ ↓
↓ ← ← yes Inspect axle components and
body
↓ ↓
↓ ← ← ← ← ←
↓
Check front axle toe → Is actual value within toler‐ → no
ance?
↓ ↓
End ← yes Adjusting ⇒ page 240
AG. Volkswagen AG d
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5) If steering wheel is notaucentred, it must be straightened after wheel alignment is finished.
ra Then carry out basic setting for steering angle
sender - G85- using ⇒ sVehicle
s diagnostic tester. c
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♦ If adjustments have been made to the suspension after a spec

wheel alignment check on vehicles with ESP or ABS, the

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steering angle sender - G85- must be calibrated using the

♦ If any changes are made to the rear wheel alignment settings,
rrectne
the following driver assist systems must be recalibrated:

s
♦ Lane departure warning (Audi lane assist)

s o
⇒ “3.1 Calibrating front camera for driver assist systems”, page

cial p
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257 ,
form
mer
♦ ACC ⇒ “2.1 Calibrating adaptive cruise control”, page 243 .

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1.6 Necessity of wheel alignment

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⇒ “1.6.1 Necessity of wheel alignment, torsion beam axle”,

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page 234
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⇒ “1.6.2 Necessity of wheel alignment, multi-link suspension”,
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page 235
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1.6.1 Necessity of wheel alignment, torsion
Prote AG.
beam axle
Wheel alignment is necessary if:
♦ The vehicle does not handle properly.
♦ Vehicle has been involved in an accident and components
have been renewed.
♦ Axle components are removed or renewed.
♦ Tyres wear on one side.

Components have been renewed

Front axle component was Alignment necessary Rear axle component re‐ Alignment necessary
renewed. newed
yes no yes no
Lower suspension link X Shock absorbers X
Bonded rubber bush X Coil spring X
for suspension link
Wheel bearing housing X Axle beam X
Track rod/track rod ball joint X
Steering rack X
Subframe X
Suspension strut X
AG. Volkswagen AG d
Anti-roll bar X 6) lkswagen oes
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ri before removing ⇒ page 17 .
6) Prerequisite: The subframe and brackets were fixed se nte
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Components removed and installed
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Front axle component re‐ Alignment necessary Rear axle component re‐ Alignment necessary
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moved and reinstalled moved and reinstalled
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yes no yes no
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spec
Lower suspension link X 7)
Shock absorbers X
es, in part or in w
t to the co
Wheel bearing housing X Coil spring X
Track rod/track rod ball X Axle beam X
joint
rrectness of i
Steering rack X
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Subframe X 7)
Suspension strut X
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Anti-roll bar X 7)
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7) Prerequisite: The subframe and brackets were fixed before removing ⇒ page 17 . n in
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1.6.2 Necessity of wheel alignment, multi-link

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Wheel alignment is necessary if: cop Vo
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♦ The vehicle does not handle properly.
AG.
♦ Vehicle has been involved in an accident and components

have been renewed.
♦ Axle components are removed or renewed.
♦ Tyres wear on one side.
Components have been renewed
renewed. newed
yes no yes no
Lower suspension link X Lower transverse link X
Bonded rubber bush X Upper transverse link X
for suspension link
Wheel bearing housing X Track rod X
Track rod/track rod ball joint X Wheel bearing housing X

renewed. newed
yes no yes no
Steering rack X Subframe X
Subframe X Coil spring X
Suspension strut X Shock absorbers X
Anti-roll bar X 8) Anti-roll bar X
Trailing arm X
8) Prerequisite: The subframe and brackets were fixed before removing ⇒ page 17 .
Components removed and installed

Front axle component re‐ Alignment necessary Rear axle component re‐ Alignment necessary
moved and reinstalled moved and reinstalled
yes no yes no
Lower suspension link X Lower transverse link 9)
X
Wheel bearing housing X Upper transverse link X
Track rod/track rod ball X Track rod X
joint
Steering rack X Wheel bearing housing X
Subframe wage
n AG. VolkswX
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X
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Suspension strut d by V X Coil spring
ua
ran
X
ir se
Anti-roll bar tho X 9)
Shock absorbers
tee
or X
au a
ss Anti-roll bar c X
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Trailing arm X
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9) Prerequisite: The subframe and brackets were fixed before removing ⇒ page 17 .
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1.7 Vehicle data sticker

spec
es, in part or in w
t to the co
Explanation regarding “PR numbers” on vehicle data sticker

Various types of running gear are installed depending on engine
and equipment level. These are identified by the PR numbers.
rrectness of i
The PR numbers are critical in determining the wheel alignment

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specifications.
The running gear version fitted in the vehicle is indicated on the
nform
ercia
vehicle data sticker by the PR number for the front axle.

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om
The vehicle data sticker can be found in the spare wheel well and
on
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in the service schedule.

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ate
Example of a vehicle data sticker

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In this example, the vehicle is equipped with sports running gear

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G03 -arrow-.
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1.8 Adjusting camber at front wheels

Note
♦ Camber correction is necessary only after body repairs. Cam‐ agen

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ber cannot be adjusted. However, it can be mediated by y Volksw not
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shifting the subframe! se
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♦ Move subframe only to left or right, but never in or opposite
au
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direction of normal travel! ss c
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– Undo bolt -1- and screw a new one in loosely.
ole,
spec
t to the co
rrectne
The camber adjustment range is limited by the tolerances of the
holes in the subframe. If the specified value is not reached by
ss
shifting the subframe, this and the body must be inspected
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cial p
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⇒ page 9 .
inform
mer
– Now camber may be adjusted to specification by moving sub‐
atio
frame.
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– Move subframe -5- sideways until camber is the same on both
thi
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sd
sides ⇒ page 230 .

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– Tighten subframe bolts -1-, -2-, -3- and -4-.

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After shifting subframe, check clearance between steering col‐
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umn universal joint and cut-out in bulkhead. p by
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– Unscrew bolt -1- and fold footwell covering -2- in direction of Prote AG.

There must be a clearance of 5 mm all around between universal

joint -1- and aperture in plenum chamber bulkhead -2-.
Specified torques
sulation .
1.9 Adjusting camber on rear axle

⇒ “1.9.1 Adjusting camber at rear axle, torsion beam axle”, page
238
⇒ “1.9.2 Adjusting camber at rear axle, multi-link suspension”,
page 238
1.9.1 Adjusting camber at rear axle, torsion

beam axle
Camber cannot be adjusted.
If the measurements are outside the permitted tolerances, check
the axle beam for damage and renew if necessary.
1.9.2 Adjusting camber at rear axle, multi-link

suspension
AG. Volkswagen AG d
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♦ Insert tool, 18 mm - T10179-

rrectness o
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– Loosen upper transverse link nut -A- on subframe.

– Adjust camber by turning hexagon head of eccentric bolt
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The maximum adjustment range is 90° to the left or right of centre.
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– Tighten nut -A-.
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– To do so, use insert tool 18 mm - T10179- .

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On use of insert tool 18 mm - T10179- , tighten nuts to 80 Nm.

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– Check camber value again after nut -A- has been tightened.
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– Check camber value again after tightening nut -A-
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⇒ “1.4 Specifications for wheel alignment”, page 230 .
AG.
Specified torques
1.10 Adjusting toe at rear axle

⇒ “1.10.1 Adjusting toe at rear axle, torsion beam axle”,
page 239
⇒ “1.10.2 Adjusting toe on rear axle, multi-link suspension”, page
239
1.10.1 Adjusting toe at rear axle, torsion beam

axle
Toe cannot be adjusted.
If the measurements are outside the permitted tolerances, check
the axle beam for damage and renew if necessary.
1.10.2 Adjusting toe on rear axle, multi-link sus‐

pension

– Loosen nut -1-.

– Turn eccentric bolt -2- until specification is attained.
Note
The maximum adjustment range is 90° to the left or right of centre.
– Tighten nut -1-.

– Check toe value again after tightening nut -A-
Specified torques
1.11 Adjusting front axle toe AG. Volkswagen AG d

agen oes
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Special tools and workshop equipment required d by
Vo gu
ara
ise nte
r
♦ Torque wrench - V.A.G 1332- ut
ho eo
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nl
pt
du
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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
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nf
ercia
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m
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om
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240
cted agen
Prote
Rep. gr.44 - Wheels, tyres, vehicle geometry
AG.
♦ Insert tool - V.A.G 1332/9-
– Counterhold track rod ball joint -1- with a suitable tool when
loosening and tightening lock nut -2-.
– Loosen lock nut -2-.
– Adjust toe setting at both wheels by turning hexagon flats
-arrow-.
Note
n AG. Volkswagen AG
♦ Ensure that bellows on steering orack
lksw are not damaged or twis‐
age does
no
ted. Twisted boots wear out
ed
quickly.
by
V t gu
ara
ris nte
♦ Tighten lock nuts on threaded
utho portion only when vehicle is eo
ra
standing on its wheels
ss - track rod ball head must be parallel
a c
with steering lever of suspension strut. ce
e
nl
pt
du
an
itte
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– Tighten lock nut -2- and check toe setting again.
erm
ab
ility
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The setting may change slightly after lock nut -2- is tightened .
wit
, is n
h re
However, if the measured toe value lies within the tolerance, the
hole
spec
adjustment is correct
es, in part or in w

t to the co
Specified torques
♦ ⇒ “3.6 Repairing steering rack”, page 306
rrectness of i
l purpos
1.12 Wheel runout compensation

nform
ercia
If runout compensation is not performed, it is not possible to adjust

toe-in correctly!
m
at
om
io
The existing lateral runout of the wheel must be compensated for.

n
c
in t
r
Otherwise, the result of the measurement will be incorrect.

o
his
ate
do
riv
The specified toe-in tolerance may already be exceeded by the

p
cum
or
permitted amount of axial runout at the wheel rims. In such cases

f
en
g
it is not possible to set the toe-in correctly without first compen‐

n
t.
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op
sating for the wheel runout. C py
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yri by
Please follow the instructions of the manufacturer of the wheel cop Vo
by lksw
alignment equipment. cted agen
Prote AG.
1.13 Checking maximum wheel lock

The maximum wheel lock is determined with the aid of the wheel
alignment computer.
– When the values for the maximum wheel lock lie outside the
tolerances, then check following:
♦ Are steering or suspension components damaged or de‐
formed?

lkswage es n
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byV ua
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ir se
Golf Sportsvan 2015 ➤ , Golf Sportsvan 2018 th ➤
o tee
or
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ss
a ac
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le
un
pt
♦ Are track rods visually OK.?
an
d
itte
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erm
ab
♦ Is the symmetry of the track rods OK.?
ility
ot p
wit
Damaged components must be renewed.
is n
h re
ole,
– If the steering wheel is found to be off centre, check the fol‐
spec
lowing:
t to the co
♦ Check steering components for damage and deformation. If
necessary, renew damaged components.
rrectne
♦ Check suspension components for damage and deformation.
If necessary, renew damaged components.
ss
♦ Check symmetry of track rods also.
o
cial p
f in
– Measure dimension -a- of “shorter” track rod. Shorten “longer”
form
mer
track rod to same dimension. Screw track rod ball joint -1-
atio
m
deeper onto track rod -2-.

o
n
c
i
or
n
Dimension -a- must be the same on left side and right side track
thi
te
sd
a
rod ball joints.

iv
o
pr
cum
r
fo
Maximum permissible difference between left and right < 2.5 mm.
en
ng
t.
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op
– When returning steering to central position, “swivel” steering C py
t. rig
wheel with even movements.
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pyri by
Vo
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cted agen
Prote AG.

2 Adaptive cruise control

⇒ “2.1 Calibrating adaptive cruise control”, page 243
2.1 Calibrating adaptive cruise control

⇒ “2.1.1 Calibrating adaptive cruise control, Golf SV 2015 to
WEEK 22/16”, page 243
⇒ “2.1.2 Calibrating adaptive cruise control, Golf SV 2015 from
WEEK 22/16”, page 248
⇒ “2.1.3 Calibrating adaptive cruise control, Golf SV 2018”, page
253
2.1.1 Calibrating adaptive cruise control, Golf

SV 2015 to WEEK 22/16
Before calibrating the adaptive cruise control (ACC) system,
check the sensor, its bracket and its securing elements for dam‐
age, external influence and secure seating. Repair any damaged
parts if necessary.
Before calibrating the adaptive cruise control (ACC) system, read
out the event memory and rectify any faults found.
The “measured misalignment angle” of the ACC control unit indi‐
cates whether or not the sensor is out of adjustment.
Use only a wheel alignment machine and adjusting devices ap‐
proved by VW/AUDI to calibrate
agen
the
AG . Voadaptive
lkswagen Acruise
G do control (ACC)
system. Volksw es n
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Correct calibration
ris is an essential prerequisite for the perfect
nte
functioning of tho eo
au the adaptive cruise control (ACC) system. ra
c
ss
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le
un
pt
an
d
Note
itte
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erm
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ility
♦ Re-adjustment is required when:

ot p
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is n
♦ The rear axle toe setting has been adjusted.

h re
ole,
spec
♦ The adaptive cruise control unit - J428- has been removed and
reinstalled.
t to the co
♦ The front bumper support has been removed and installed.

rrectne
♦ The front bumper support has been loosened or moved.

♦ The misalignment angle is outside the tolerance. Determine
ss
the tolerance with the vehicle diagnostic tester.

o
cial p
f in
♦ The lock carrier has been moved to the service position.

form
mer
atio
♦ Conversions/adjustments have been carried out on the run‐

om
ning gear that affect the suspension height.

n
c
i
or
n thi
te
sd
va

i
o
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Cop py
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Prote AG.
2. Adaptive cruise control 243

♦ ACC setting device - VAS 6430- or setting device, basic set -

VAS 6430/1-
♦ ACC reflector mirror - VAS 6430/3-

♦ Wheel alignment computer
Note
♦ Before driving vehicle onto wheel alignment platform, make

sure there is sufficient space between vehicle and setting de‐
vice - VAS 6430- . The distance between ACC reflecting mirror
- VAS 6430/3- and the sensor must be 120 cm ± 2.5 cm.
♦ If available space is not adequate, move vehicle backwards
onto alignment platform as required to achieve space re‐
quired.
♦ If the position of the ACC reflecting mirror - VAS 6430/3- on
alignment beam is changed during the adjustment work,agthe en AG. V
olkswagen AG
does
setting of setting device - VAS 6430- must always be Volchecked
ksw not
(e.g. spirit levels, individual toe values on adjusting
ed b beam,
y gu
ara
etc.). thoris nte
eo
au ra
c
ss
• Before starting calibration, read out event memory and rectify ce
le
un
pt
any faults. 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
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o
pr
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fo
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t.
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Cop py
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Prote AG.

Only for replacement of adaptive cruise control unit - J428-

– Adjust adjuster screws ⇒ Electrical system; Rep. gr. 27 ;
Adaptive cruise control; Removing and installing control unit
for adaptive cruise control
Continued for calibration procedure
The procedure is described here using the setting device - VAS
6430- .
The following sequence is to be adhered to:
1- Establish a distance of 120 cm ± 2.5 cm between the ACC
reflecting mirror - VAS 6430/3- fitted in the middle and the
sensor in the radiator grille.
2- Install ACC reflector mirror - VAS 6430/3- centred on align‐
ment beam.
swage es n
3 - Calibrating adaptive cruise control unit - J428- yV
o lk ot g
ua
b
ed ran
If wheel alignment has just been carried out, the stepsthor described
is tee
or
under “Procedure without preceding wheel alignment” au do not ac
ss
have to be carried out.
ce
e
nl
pt
du
Procedure without preceding wheel alignment
an
itte
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ab
– Press button to select ACC calibration in wheel alignment
ility
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computer.
wit
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h re
– Note testing preconditions for wheel alignment ⇒ page 228 .
hole
spec
– Drive car onto wheel alignment platform.
es, in part or in w
t to the co
– Connect battery charger ⇒ Electrical system; General infor‐
rrectness of i
– Connect ⇒ Vehicle diagnostic tester. (Route diagnostic cable
through open window.)
l purpos
nform
ercia
Note
m
at
om
During the procedure, make sure that all of the car doors remain
ion
c
closed and that the car's exterior lighting is switched off.
in t
or
his
ate
do
riv
– Move front wheels to straight-ahead position.

p
cum
for
en
ng
– Mount quick-release clamps on rear wheels.

t.
yi Co
Cop py
.
– Mount measurement transducers on rear wheels.
t rig
gh ht
pyri by
Vo
co
– Carry out wheel run-out compensation at rear wheels.
by lksw
cted agen
Prote AG.
Procedure with or without preceding wheel alignment.
– Remove trim -1-.

– Remove trim -1-.
– Remove dirt, if there is any, from the sensor lens.

– Position ACC setting device - VAS 6430/3- centrally and par‐

allel at a distance -a- from centrally fitted ACC reflector mirror
- VAS 6430/3- to adaptive cruise control unit - J428- .
a - 120 cm ± 2.5 cm
Note
ACC setting device - VAS 6430- is not allowed to be moved on

the beam.
– Mount measurement transducers of front wheels -1- on align‐

ment beam.
AG. Volkswagen AG d
– In the area -A-, move position -2- on rotary knob so that itlkco‐
wage
n oes
o s not
incides with marking on mirror (the number 2 on the drotary
by
V gu
ara
knob must point towards the vehicle). or
ise nte
eo
th
au ra
c
ss
ce
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nl
pt
du
an
itte
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erm
ab
ility
ot p
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, 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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nf
ercia
orm
m
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om
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or c
thi
te
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Prote AG.

– Use adjusting screws -1-, -2- and -3- to bring spirit levels -A-
and -B- to - VAS 6430/3- horizontal.
– Adjust mirror -4- by means of crank handle -arrow- in such a
way that the laser beam contacts the centre of the sensor lens.
lkswage es n
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byV ua
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ir se tee
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a ac
ss
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nl
pt
du
an
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ab
ility
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, is n
– Position mirror on side of alignment beam so that laser beam
h re
hole
contacts centre of sensor lens.
spec
es, in part or in w
t to the co
rrectness of i
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nf
ercia
orm
m
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om
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or c
thi
e
– Level spirit levels -2- of the measurement transducer -1-.

t
sd
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f
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t.
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Cop py
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pyri by
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co lksw
by
cted agen
Prote AG.

– Turn fine adjuster screw -5- until display on wheel alignment

computer is within tolerance.
AG. Volkswagen AG d
agen oes
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pt
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– Level spirit levels -2- of the measurement transducer -1-.
ility
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– Now, use laser beam -3- of -VAS 6430/3- to check again
h re
whether spirit levels are horizontal and laser beam hits centre
hole
spec
of sensor lens.
es, in part or in w
t to the co
Note
rrectness of i
The alignment of - VAS 6430/3- must be repeated if the laser
l purpos
beam does not coincide with the sensor lens.
nform
ercia
– Select “Own test schedule” on ⇒ Vehicle diagnostic tester.

m
– On the screen, click the following buttons one after the other:
at
om
ion
c
♦ Diagnosis-capable systems
in t
or
his
ate
♦ 0013 – Adaptive cruise control

do
priv
cum
or
♦ 0013 - Adaptive cruise control, functions

f
en
ng
t.
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op
♦ 0013 - Calibration C py
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Follow instructions on screen. cop Vo
by lksw
cted agen
Prote AG.
Designation of adjusting screws of adaptive cruise control unit -
J428-
1- Adjuster screw 1
2- Adjuster screw 2
WARNING
♦ The ACC setting is not accepted until “Final control diag‐

nosis is completed” is displayed in the ⇒ Vehicle diagnos‐
tic tester.

SV 2015 from WEEK 22/16


parts if necessary.
proved by VW/AUDI to calibrate the adaptive cruise control (ACC)
system.
Correct calibration is an essential prerequisite for the perfect
functioning of the adaptive cruise control (ACC) system.
Note
♦ Re-adjustment is required when:

♦ The rear axle toe setting has been adjusted.
♦ The adaptive cruise control unit - J428- has been removed and
reinstalled.
♦ The front bumper support has been removed and installed.
♦ The front bumper support has been loosened or moved.
♦ The lock carrier has been moved to the service position.
Volkswagen AG
swa
gen AG
.
does
k not
Vol gu
♦ ACC setting device - VAS 6430- ior d by
setting device, basic set - ara
e nte
VAS 6430/1- rs
utho eo
ra
a c
ss
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

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
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

Note

sure there is sufficient space between
n AG. Volkvehicle
swagen Aand
G do
setting de‐
vice - VAS 6430- . The distance
olksw
agebetween ACC reflecting
es n mirror
ot g
- VAS 6430/10- andedtheby sensor must be 120 cm ± 2.5 cm.
V ua
ra
ris nte
♦ If available space
au
tho is not adequate, move vehicle backwards eo
ra
onto alignment
ss platform as required to achieve space re‐ c
quired.
ce
e
nl
pt
du
an
itte
y li
erm
alignment beam is changed during the adjustment work, the
ab
ility
setting of setting device - VAS 6430- must always be checked
ot p
wit
(e.g. spirit levels, individual toe values on adjusting beam,
, is n
h re
etc.).
hole
spec
es, in part or in w
t to the co
any faults.
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
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

Only for replacement of adaptive cruise control unit - J428-

– Adjust adjuster screws ⇒ Electrical system; Rep. gr. 27 ;
Adaptive cruise control; Removing and installing control unit
for adaptive cruise control
Continued for calibration procedure
The calibration procedure is described here using the setting de‐
vice - VAS 6430- .
n AG. Volkswagen A
The following calibration sequence
olks
wage is to be adhered
G do
eto:
s no
V t gu
by a
1- Establish a distance
ris
ed of 120 cm ± 2.5 cm between the ACCran
tee
reflecting mirror
ut
ho - VAS 6430/10- fitted in the middle and the or
sensor inssthe radiator grille.
a ac
ce
le
un
pt
an
d
ment beam.
itte
y li
erm
ab
3- Calibrating adaptive cruise control unit - J428-
ility
ot p
wit
is n
If wheel alignment has just been carried out, the steps described
h re
ole,
under “Procedure without preceding wheel alignment” do not
spec
t to the co
Calibration without preceding wheel alignment
rrectne
computer.
ss o
cial p
f inform
– Connect battery charger ⇒ Vehicle electrics; Rep. gr. 27 ;
mer
Battery; Charging battery .

atio
om
n
c

i
or
n thi
e

t
sd
iva
o
pr
cum
r
fo
en
ng
t.
Note Cop
yi Co
py
t. rig
gh ht
During the procedure, make sure that all of the car doors remain pyri by
Vo
co
closed and that the car's exterior lighting is switched off.
by lksw
cted agen
Prote AG.

Procedure with or without preceding wheel alignment.
– Remove dirt, if there is any, from the sensor lens.
– Position ACC setting device - VAS 6430- centrally and parallel

at a distance -a- from centrally fitted ACC reflector mirror - VAS
6430/10- to adaptive cruise control unit - J428- .
a - 120 cm ± 2.5 cm
Note

the beam.

Sequence of steps for all

ment beam.
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
ss c
ce
e
nl
pt
du
an
itte
y li
– Position mirror on side of alignment beam so that laser beam
erm
ab
ility
contacts centre of sensor lens.
ot p
wit
, is n
h re
hole
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
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
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Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.


– Now, use laser beam -3- of -VAS 6430/10- to check again
whether spirit levels are horizontal and laser beam hits centre
of sensor lens.
Note
The alignment of - VAS 6430/10- must be repeated if the laser

beam does not coincide with the sensor lens.

♦ 0013 - Adaptive cruise control, functions lkswage es n
o ot g
byV ua
d
♦ 0013 - Calibration o
ir se
ran
tee
th or
u
Follow instructions on screen. ss
a ac
ce
e
nl
pt
du
an
itte
y li
erm
ab
SV 2018
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
parts if necessary.
t to the co
rrectness of i
l purpos

nf
ercia
proved by VW/AUDI to calibrate the adaptive cruise control (ACC)
orm
system.
m
atio
om
Correct calibration is an essential prerequisite for the perfect

n in
or c
functioning of the adaptive cruise control (ACC) system.

thi
te
sd
iva
– The adaptive cruise control unit - J428- must be calibrated if

r
rp
cu
o
any of the following conditions apply:

f
en
ng
t.
yi Co
op
♦ Adaptive cruise control unit - J428- has been renewed C py
t. rig
gh ht
yri
♦ Lock carrier has been moved to service position
p by
co Vo
by lksw
cted agen
♦ Lock carrier has been removed and installed
Prote AG.
♦ Lock carrier has been renewed

♦ Toe on rear axle has been adjusted

♦ ACC setting device - VAS 6430- or setting device, basic set -

VAS 6430/1-
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,
Note
spec
t to the co
sure there is sufficient space between vehicle and setting de‐
vice - VAS 6430- . The distance between ACC reflecting mirror
rrectne
- VAS 6430- and the sensor must be 120 cm ± 2.5 cm.
ss
o
cial p
f
quired.
inform
mer
atio
m
alignment beam is changed during the adjustment work, the

o
n
c
setting of setting device - VAS 6430- must always be checked
i
or
n thi
e
(e.g. spirit levels, individual toe values on adjusting beam,

t
sd
va
etc.).
i
o
pr
cum
r
fo
en
ng
t.
yi
Co
op py
any faults. t. C rig
gh ht
pyri by
Vo
The calibration procedure is described here using the setting de‐
co lksw
by
cted agen
vice - VAS 6430- . Prote AG.
The following calibration sequence is to be adhered to:

1- Establish a distance of 120 cm ± 2.5 cm between the ACC
reflecting mirror - VAS 6430/10- fitted in the middle and the
sensor in the radiator grille.
ment beam.
3- Calibrating adaptive cruise control unit - J428-
If wheel alignment has just been carried out, the steps described
under “Calibration without preceding wheel alignment” do not
Calibration without preceding wheel alignment
computer.

Note
During the calibration procedure, make sure that all the car doors
remain closed and that the car's exterior lighting is switched off.

Calibration with or without preceding wheel alignment.
– Position ACC setting device - VAS 6430- in the middle and
parallel at a distance -a- from the ACC reflector mirror - VAS
6430/10- fitted in the middle to the VW emblem in the radiator
grille.
a - 120 cm ± 2.5 cm
– Remove any dirt from Volkswagen badge as necessary.
Note

the beam.

ment beam.
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
ss c
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
nf
ercia
orm
m
atio
om
n in
or c
thi
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.

– Position mirror on side of alignment beam so that the laser

beam contacts the centre of the Volkswagen badge -1-.
– Level spirit levels of measurement transducer.

– Level spirit levels of measurement transducer.
– Now, use laser beam of -VAS 6430/10- to check again whether
spirit levels are horizontal and laser beam hits centre of sensor
lens.
AG. Volkswagen AG d
agen oes
lksw not
Note d byV
o gu
ara
ise nte
or eo
th
The alignment of - VAS 6430/10-s aumust be repeated if the laser ra
c
beam does not coincide with the
s sensor lens.
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
♦ 0013 - Adaptive cruise control, functions
♦ 0013 - Calibration
rrectness of i
Follow instructions on screen to perform calibration.

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
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

3 Front camera for assist systems

⇒ “3.1 Calibrating front camera for driver assist systems”,
page 257
3.1 Calibrating front camera for driver assist

systems
Note
The following situations can cause the camera function to be im‐

paired by sustained poor visibility of the lane marker lines:
AG. Volkswagen
♦ The field of view of the camera lksis
wasoiled
gen or iced over. Inesthis
AG do
not
case, clean the affected darea.
by
Vo gu
a
e ran
ris tee
♦ The field of view of uthe
tho camera is fogged over. or
sa ac
The camera’s viewing s
window must be cleaned manually if there
ce
e
nl
is heavy soiling on the inside of the windscreen in the field of view
pt
du
an
of the camera. To do this, the control unit and lens hood must be
itte
y li
removed and the windscreen cleaned using cleaning solution.
erm
ab
ility
Remove control unit and lens hood ⇒ Electrical system; Rep. gr.
ot p
wit
96 ; Front camera for driver assist systems .
, is n
h re
hole
Correct calibration is a basic precondition for the front camera for
spec
driver assist systems - R242- to function without faults.
es, in part or in w
t to the co
The front camera for driver assist systems - R242- must be reca‐
librated if:
rrectness of i
♦ Entry “no or incorrect basic setting / adaptation” is stored in
event memory.
l purpos
♦ The front camera for driver assist systems - R242- was re‐
newed.
nform
ercia
♦ Windscreen has been renewed or removed.

m
at
om
io
♦ Rear axle toe has been adjusted.

n
c
in t
or
his
e
♦ Modifications having an effect on the body height have been

at
do
riv
made to the car's running gear.

p
cum
for
en
g
♦ The vehicle level senders have been reprogrammed on vehi‐

n
t.
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op
cles with damper control. C py
t. rig
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cted agen
Note Prote AG.
♦ Before calibrating the front camera for driver assist systems,

read out event memory and rectify faults as necessary.
♦ Calibration of the front camera for driver assist systems must
be performed using only VW/AUDI approved wheel alignment
equipment!
♦ Calibration of the driver assistant system's front camera is
permitted only with the setting device - VAS 6430- !
3. Front camera for assist systems 257

♦ Setting device - VAS 6430-

♦ ⇒ Vehicle diagnostic tester
Note
♦ The front camera for driver assist systems - R242- must be

correctly located in the holder.
♦ The field of view of the camera must be clean and clear.
♦ Before driving the vehicle onto the wheel alignment platform,
make sure there is sufficient space between the midpoint of
the hub of the front wheels and the setting device - VAS 6430- .
♦ The distance between the setting device - VAS 6430- and the
centre point of the hub of the front wheels must be 1500 mm
± 25 mm.
quired.
♦ The calibration board must be positioned centrally on the set‐ agen
AG. Volkswagen AG d
oes
ting device. Volksw not
gu
d by ara
♦ The event memory must be read before starting calibration.orise nte
eo
Any memory entries must be deleted. aut
h
ra
c
ss
ce
e
nl
– Note testing preconditions for wheel alignment ⇒ page 228 . pt

du
an
itte
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erm
ab
ility
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wit
, is n

h re
hole
spec

es, in part or in w

t to the co
Note
rrectness of i
l purpos
During the calibration procedure, make sure that all the car doors
remain closed and that the car's exterior lighting is switched off.
nform
ercia

m
at
om
– Select calibration run for front camera for driver assist systems
on
c
in t
-R242- on wheel alignment computer.

or
his
ate
do
– Mount quick-release clamps on all four wheels.

priv
cum
for
– Mount wheel alignment sensors on wheels.

en
ng
t.
yi Co
op
C py
t. rig
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pyri by
Vo
o
by c lksw
cted agen
Prote
258
AG.
Rep. gr.44 - Wheels, tyres, vehicle geometry
– Bounce springs.
– Measure standing height at all four wheels and note it.
AG. Volkswagen AG d
agen oes
olksw not
Note byV gu
ara
ed
ris nte
ho eo
ut
♦ Setting device - VAS
ss a 6430- is not allowed to be moved on the ra
c
beam.
ce
e
nl
pt
du
an
♦ Wheel alignment platform must be in the lowermost levelled
itte
y li
position for next work step.
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
– Turn setting device - VAS 6430- upwards so that alignment
beam is parallel to middle of measurement transducers on
front wheels, in order to perform a correct measurement with
rrectness of i
distance measuring unit -1-.
1- Distance measuring unit with tape measure and socket pin
l purpos
– Position setting device - VAS 6430- at distance -a- of 1500 mm
nform
ercia
± 25 mm from centre point of hub of front wheels to beam of

setting device - VAS 6430- .
m
at
om
ion
c
in t
Caution
or
his
ate
do
riv
♦ Distance -a- of 1500 mm ± 25 mm must be measured on

p
cum
or
both sides of vehicle and adjustment device - VAS 6430-

f
en
ng
t.
yi
must then be aligned.
Co
Cop py
ht. rig
♦ Distance -a- must be same on both sides of car. rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
– Mount measurement transducer -1- of front wheels on setting

device - VAS 6430- .
– Measure height value -a- between standing surface of setting

device - VAS 6430- and wheel support surface on wheel align‐
ment platform. Enter value in wheel alignment computer.

– Unscrew clamping bolt -arrow-, place measuring bar -1- on

floor.
– Use crank -1- to set calibration panel - VAS 6430/4- to nominal

height -2- indicated by wheel alignment computer and make a
note.
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
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aut ra
ss c
ce
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nl
pt
du
an
itte
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When nominal height has been reached, measuring bar -1- must
erm
ab
be moved upwards slightly and secured with clamping screw

ility
ot p
-arrow-.
wit
, is n
h re
hole
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
thi
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.

– Move setting device - VAS 6430- sideways -arrows B- until

display on wheel alignment computer is within tolerance.
– Screw down adjuster screws -2- and -3- slightly to secure set‐
ting device - VAS 6430- to preventlksitwfrom rolling away.
n AG. Vo agen AG
lkswage does
not
Vo gu
by ara
ed nte
oris eo
th
au ra
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ss
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nl
pt
du
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

t to the co

rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
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o
m
f
en
ng
t.
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Cop py
t. rig
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pyri by
Vo
co lksw
by
cted agen
Prote AG.

– Use adjuster screw -1- to level spirit level -A-.
lkswage es n
o ot g
byV ua
– Use adjuster screws -2-riseand
d -3- to level spirit level -B-. ran
tee
tho
u or
a ac
ss
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
nf
ercia
orm
m
atio
om
n in
or c
– Unscrew clamping bolt -arrow-, place measuring bar -1- on

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

– Check nominal height -2- again and correct if necessary.
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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erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
rrectne
When nominal height has been reached, measuring bar -1- must
ss
be moved upwards slightly and secured with clamping screw
o
cial p
f
-arrow-.
inform
mer
Concluding work is carried out via ⇒ Vehicle diagnostic tester.
atio
om
– Switch on ignition.
n
c
i
or
n thi
e
– On ⇒ Vehicle diagnostic tester, select “Guided Fault Finding”.

t
sd
iva
o
pr
cum
r
fo
Body (Rep. Gr. 01;27;50…97)

en
ng
t.
yi Co
op
Electrical system (Rep. Gr. (01, 27, 90…97) t. C py
rig
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pyri by
01_Self-diagnosis capable systems co
by
Vo
lksw
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Prote AG.
Front camera for driver assistance system -R242-
Camera for driver assistance systems, functions
A5 - Calibrating the control unit (Rep. Gr. 44)
Follow instructions on screen to perform calibration.
Note
The next step in Guided fault finding is to measure the body

height.
– Enter the noted standing height.

48 – Steering
1 Steering wheel
⇒ “1.1 Assembly overview - steering wheel”, page 264
⇒ “1.2 Removing and installing steering wheel”, page 264
1.1 Assembly overview - steering wheel
1 - Steering column
⇒ page 269
❑ The centre punch marks
-arrows- on the steering AG. Volkswagen AG d
agen oes
ksw
wheel and the steering by
Vol not
gu
ara
column must align when rised
nte
reinstalling. Some ut
ho eo
ra
steering columns leave ss a c
the factory with no cen‐
ce
e
nl
pt
tre punch mark. On
du
an
itte
these steering columns
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erm
ab
a respective centre
ility
ot p
punch mark must be
wit
, is n
made before removing
h re
the steering wheel
hole
spec
⇒ page 264 .
es, in part or in w
t to the co
2 - Steering wheel
⇒ page 264
rrectness of i
❑ Different versions possi‐
l purpos

ic parts catalogue
nform
ercia
❑ The centre punch marks

-arrows- on the steering
m
at
wheel and the steering

om
ion
column must align when

c
in t
or
reinstalling. Some
his
ate
steering columns leave

do
priv
the factory with no cen‐

um
for
tre punch mark. On

en
ng
t.
yi Co
these steering columns Cop py
a respective centre
t. rig
gh ht
yri
punch mark must be
p by
o Vo
by c lksw
made before removing Prote
cted AG.
agen
the steering wheel
⇒ page 264 .
3 - Bolt
❑ 30 Nm +90°
1.2 Removing and installing steering wheel

264 Rep. gr.48 - Steering

Removing
WARNING
The following conditions must be met before starting work on

the electrical system and removing the steering wheel:
♦ Disconnect battery ⇒ Electrical system; Rep. gr. 27 ;
Battery; Disconnecting and reconnecting battery .
♦ The wheels must be in straight-ahead position.
Failure to comply with these precautions may lead to subse‐
quent failure of the airbag system!
– Move steering column to middle height position.

– Remove airbag unit ⇒ General body repairs, interior; Rep. gr.
69 ; Driver side airbag; Assembly overview - driver side airbag .
– Turn wheels to straight-ahead position.
AG. Volkswagen AG d
agen oes
olksw not
y V gu
Note ise
d b ara
nte
or eo
th
u ra
The ssteering
sa wheel must be removed/installed in the middle c po‐
sition (wheels facing straight ahead).
ce
le
un
pt
an
d
itte
y li
– If fitted, disconnect connector for steering wheel heating.

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
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
1. Steering wheel 265

– Remove bolt -1-.

– Check that steering column has a centre punch mark that
aligns with mark on steering wheel. AG. Volkswagen AG d
agen oes
olksw not
– If this is not the case, the position of the steering wheel tod by V gu
ara
steering column must be marked on the steering column orisewith nte
eo
a centre punch mark. auth
ra
ss c
– Pull steering wheel -2- off steering column.
ce
le
un
pt
an
d
Installing
itte
y li
rm
ab
pe
ility
ot
lowing:
wit
, is n
h re
Make sure that the wheels are pointing straight ahead before fit‐ hole
spec
ting the steering wheel.
es, in part or in w
t to the co
– When installing a steering wheel that has been removed,
make sure that the markings on the steering column and steer‐
ing wheel are in line.
rrectness of i
– When installing a new steering wheel (without marking), the
l purpos
steering wheel must be mounted in middle position (steering

wheel spoke must be horizontal and wheels in straight posi‐
tion).
nform
ercia
– Install steering wheel.

m
a
com
tion in
– Install airbag unit ⇒ General body repairs, interior; Rep. gr.
r
te o
thi
s
iva
do
r
– Carry out road test.

rp
cum
fo
en
g
– If the steering wheel is skewed, the steering wheel must be

n
t.
yi Co
op
removed again and fitted onto the splines of the steering col‐ C py
t. rig
umn.
gh ht
pyri by
Vo
co lksw
by
Specified torques cted agen
Prote AG.
♦ ⇒ “1.1 Assembly overview - steering wheel”, page 264

2 Steering column
⇒ “2.1 Assembly overview - steering column”, page 267
⇒ “2.2 Checking steering column for damage”, page 268
⇒ “2.3 Handling and transporting steering column”, page 268
⇒ “2.4 Removing and installing steering column”, page 269
⇒ “2.5 Removing and installing control unit for electronic steering
column lock J764 ”, page 278
2.1 Assembly overview - steering column
Note
♦ Always renew self-locking nuts.

♦ Always renew corroded nuts and bolts.
♦ Always renew nuts and bolts that have been tightened further
by a set angle.
1 - Dash panel central tube

2 - Shear bolt
ing ⇒ page 278
3 - Right bracket
❑ For knee airbag AG. Volkswagen AG d
agen oes
olksw not
V gu
4 - Electronic steering column d by ara
ise nte
lock control unit - J764- hor eo
aut ra
❑ For vehicles with key‐ ss c
less entry and start sys‐ ce
le
un
tem “Keyless Access” pt

an
d
itte
y li
rm
ab
pe
ility
⇒ page 278
ot
wit
, is n
5 - Bolt
h re
hole
❑ Observe tightening se‐

spec
es, in part or in w
quence ⇒ page 276

t to the co

❑ 20 Nm
rrectness of i
6 - Left bracket
l purpos
❑ For knee airbag

7 - Bolt
nform
ercia

m
a
com
❑ 20 Nm
tion in
r
te o
8 - Bolt
thi
s
iva
do

r
rp
cum
fo
❑ 20 Nm +90°
en
ng
t.
yi Co
op
9 - Steering column C py
t. rig
gh ht
❑ Removing and installing yri
p by
o Vo
by c
⇒ page 269
lksw
cted agen
Prote AG.
❑ When installing, steer‐
ing column must be engaged at mounting bracket for central tube for dash panel (assists with installation).
2. Steering column 267

❑ Different versions possible. Refer to ⇒ Electronic parts catalogue “ETKA”
2.2 Checking steering column for damage

Visual check
– Check all steering column parts for damage.
Checking function
– Check that steering column turns smoothly and easily.
olkswagen AG
en AG. V
– Check whether steeringolkcolumn
swa
g
can be moved in
doethe
s no longitu‐
dinal direction andedvertically.
by V t gu
ara
ris nte
tho
2.3 Handling and transporting steering col‐
eo
au ra
ss c
umn
ce
le
un
pt
an
d
itte
y li
rm
ab
WARNING
pe
ility
ot
wit
, is n
♦ Adherence to proper steering column handling is essen‐
h re
tial.
hole
spec
es, in part or in w
♦ Improper handling of steering column may damage the
t to the co
steering column, leading to safety risks.
rrectness of i
Proper steering column handling and transport
l purpos
♦ Use both hands to transport steering column.

♦ Hold steering column upper jacket tube and in area of upper
nform
ercia
universal joint.
m
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
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
Improper handling of steering column

Transportation using the clamping lever leads to primary steering
column damage.

Improper handling of steering column with safety risks

Following methods of handling will damage universal joint bushes
and lower steering column bearing:
♦ Transporting steering column with one hand on jointed shaft.
♦ Bending joints more than 90°.
AG. Volkswagen AG d
agen oes
olksw not
V gu
2.4 Removing and installing steering col‐
by ara
d
rise nte
o
umn
th 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
t.
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Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
Removing
Only the complete steering column is supplied as a replacement
part. A repair is not possible.
Vehicles with mechanical ignition lock
Steering lock housing can be transferred ⇒ Electrical system;
Rep. gr. 94 ; Steering column switch module; Removing and in‐
stalling steering column switch module .

Vehicles with electronic ignition lock

Electronic steering column lock control unit - J764- can be trans‐
ferred ⇒ page 278 .
WARNING
The following are prerequisites before starting work on the

electrical system and removing the steering wheel:
♦ Mechanic must electrostatically discharge himself/herself.
This can be done by touching earthed metal such as a
water pipe, a heating pipe, metal girders or a lifting plat‐
form ⇒ page 4 .
Failure to comply with this precaution may lead to subsequent
failure of the electronic steering column lock control unit -
J764- ! wage
es n
olks ot g
♦ Disconnect battery ⇒ Electrical system; Rep. gr. 27e;d by V ua
ran
Battery; Disconnecting and reconnecting battery .hor is tee
ut or
a ac
♦ The wheels must be in straight-ahead position.ss
ce
le
un
Failure to comply with these precautions may lead to subse‐
pt
an
d
itte
quent failure of the airbag system!
y li
rm
ab
pe
ility
ot
wit
, is n
– Turn wheels to straight-ahead position.
h re
hole
spec
– Pull down lever on side of steering column.
es, in part or in w
t to the co
– Swing steering column down as far as possible and pull out.
– Press lever on side of steering column back up.
rrectness of i
– Remove airbag unit ⇒ General body repairs, interior; Rep. gr.
l purpos
– Remove steering wheel ⇒ page 264 .
nform
ercia
– Remove upper steering column trim ⇒ General body repairs,

interior; Rep. gr. 68 ; Compartments/covers; Removing and
m
a
com
ti
installing upper steering column trim .
on in
r
te o
thi
– Remove lower steering column trim ⇒ General body repairs,
s
iva
interior; Rep. gr. 68 ; Compartments/covers; Removing and

do
r
rp
installing lower steering column trim .

um
fo
en
ng
t.
yi
– Remove steering column switch module ⇒ Electrical system;
Co
op py
Rep. gr. 94 ; Steering column switch module; Removing and t. C rig
gh ht
installing steering column switch module . pyri by
Vo
co lksw
by
cted agen
– Remove knee airbag ⇒ General body repairs, interior; Rep. Prote AG.
gr. 69 ; Knee airbags; Assembly overview - knee airbag .
– Unplug connector -1- from immobiliser reader coil - D2- .
– Pull off connector -2- off ignition/starter switch -1-.


– Unclip cable from holder on electronic steering column lock
control unit - J764- -arrow-.
– Remove footwell vent below steering column ⇒ Heating, air
conditioning system; Rep. gr. 87 ; Air duct; Assembly overview
- air duct and air distribution in passenger compartment .
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
– Remove bolts -1- and -2-. aut ra
ss c
ce
e
– Remove left bracket -3- for knee airbag.
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
– Remove bolts -1- and -2-.

– Remove right bracket -3- for knee airbag.
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
– Release tab -arrow- using a small screwdriver.

– Pull cable guide -1- forwards off metal tab.

– Release bottom cable retainer -1- from lugs in direction of

-arrow-.
Note
The lugs are anchored directly in the steering column and are
located between the retainer -1- and the steering column.
– Pull off bottom cable retainer -1- downwards.
– Release tabs -arrows- of cable guide -1- using a small screw‐

driver.
– Pull cable guide -1- off steering column downwards.
– Disengage cable retainer under steering column -2- and pull
off downwards.
– Move electrical wire for steering column to side.
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
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erm
ab
LHD only
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
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ut
ho Golf Sportsvan
eo
ra
2015 ➤ , Golf Sportsvan 2018 ➤
a
ss Running gear, c axles, steering - Edition 03.2018
ce
e
nl
pt
du
RHD only
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
Continuation for both sides
t to the co
rrectness of i
l purpos
nform
ercia
m
at
om
ion
c
in t
or
Caution
his
ate
do
priv
cum
for
en
g

n
t.
yi Co
Cop py
♦ Connect battery ht. rig
rig ht
py by
o Vo
by c lksw
cted agen
Prote AG.
– Remove bolt -1- while holding steering column -2- securely.

LHD only AG. Volkswagen AG d

agen oes
ksw
– Unhook steering column -1- upwards out of lugs -2- and by V-3- on
ol not
gu
ara
mounting bracket and remove. rise
d
nte
tho eo
au ra
ss c
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
nform
ercia
RHD only
m
at
om
io
– Unhook steering column -1- upwards out of lugs -2- and -3- on
n
c
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or
mounting bracket and remove.
his
ate
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Caution Cop py
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Ensure the steering column is handled and transported cor‐
co Vo
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cted
rectly ⇒ page 268 .
agen
Prote AG.
Installing
ing:
LHD only
– Hook steering column -1- into lugs on mounting bracket at
bottom -2- and top -3-.

RHD only
– Hook steering column -1- into lugs on mounting bracket at
bottom -2- and top -3-.
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– Align steering column -2- with mounting bracket. Screw in bolt
-1- hand-tight.
rrectness of i
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– Install right bracket -3- for knee airbag.
t. rig
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– Screw in bolts -1- and -2- hand-tight.
c by lksw
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Prote AG.
– Install left bracket -3- for knee airbag.

– Screw in bolts -1- and -2- hand-tight.

– Tighten bolts -1-, -2-, -3- and -4- one after the other to the
specified torque.
– The flat surface of the steering column -1- must lie against the
flat surface of the steering rack -2-. The cut-out in the steering
rack must align exactly with the hole for the securing bolt
-arrows-.
AG. Volkswagen AG d
agen oes
lksw not
– Fit universal joint -2- onto steering by pinion in opposite
Vo gu
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-direction of arrow-. orised
nte
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– Insert new hexagon bolt s-1-s and tighten.
a c
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nl
pt
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LHD only
rrectness of i
– Fold footwell trim -2- forwards and secure with bolt -1-.
l purpos
nform
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c
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RHD only
– Fold floor covering forwards.
– Install foot support -2- in opposite -direction of arrow-.
– Tighten bolt -1-.

– Connect connector -arrow- to immobilizer reader coil - D2- .
– Connect connector -2-.
AG. Volkswagen AG d
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spec
– Connect connector -1-.

t to the co
– Clip cable into holder on electronic steering column lock con‐

trol unit - J764- -arrow-.
rrectne
– Install steering column switch module ⇒ Electrical system;

s
Rep. gr. 94 ; Steering column switch module; Removing and

s o
installing steering column switch module .

cial p
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mer
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by
cted agen
Prote AG.

– Fit cable retainer under steering column -2- so that lugs in

guide engage in steering column.
– Fit cable guide -1-. Lugs -arrows- must engage in steering
column.
– Install footwell vent below steering column ⇒ Heating, air con‐
ditioning system; Rep. gr. 87 ; Air duct; Assembly overview -
air duct and air distribution in passenger compartment .
– Install knee airbag ⇒ General body repairs, interior; Rep. gr.
69 ; Knee airbags; Assembly overview - knee airbag .
– Install lower steering column trim ⇒ General body repairs, in‐
terior; Rep. gr. 68 ; Compartments/covers; Removing and
installing lower steering column trim .
– Install upper steering column trim ⇒ General body repairs,
olks
wage es n
ot g
interior; Rep. gr. 68 ; Compartments/covers; Removing
db
y V and ua
ran
installing upper steering column trim . or
ise tee
th or
au
– Install steering wheel ⇒ page 264 . ss ac
ce
le
un
– Install driver side airbag unit ⇒ General body repairs, interior;
pt
an
d
Rep. gr. 69 ; Driver side airbag; Assembly overview - driver

itte
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side airbag .
ab
pe
ility
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– Carry out basic setting for steering angle sender - G85- using
wit
, is n
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hole
spec
Specified torques
es, in part or in w
t to the co
♦ Footwell vent below steering column ⇒ Heating, air condi‐
rrectness of i
tioning system; Rep. gr. 87 ; Air duct; Assembly overview - air
duct and air distribution in passenger compartment .
l purpos
♦ Steering column switch module ⇒ Electrical system; Rep. gr.

94 ; Steering column switch module; Removing and installing
nform
ercia
steering column switch module .

m
a
♦ Knee airbag ⇒ General body repairs, interior; Rep. gr. 69 ;
com
tion in
Knee airbags; Assembly overview - knee airbag .
r
te o
thi
♦ Driver side airbag unit ⇒ General body repairs, interior; Rep. s
iva
do
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gr. 69 ; Driver side airbag; Assembly overview - driver side

rp
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fo
airbag .
en
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op
♦ Lower steering column trim ⇒ General body repairs, interior; C py
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Rep. gr. 68 ; Compartments/covers; Removing and installing
gh ht
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lower steering column trim .
o Vo
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cted agen
Prote AG.
♦ Upper steering column trim ⇒ General body repairs, interior;
Rep. gr. 68 ; Compartments/covers; Removing and installing
upper steering column trim .
2.5 Removing and installing control unit for

electronic steering column lock - J764-

♦ Socket - T10424-
AG. Volkswagen AG d
agen oes
olksw not
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wit
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hole
spec
Removing
es, in part or in w
t to the co
– Remove steering column switch module ⇒ Electrical system;
Rep. gr. 94 ; Steering column switch module; Removing and
installing steering column switch module .
rrectness of i
– Separate electrical connector -2-. To do this, slide catch -1- to
l purpos
rear and push release downwards.

– Unscrew shear bolt -3- using socket - T10424- .
nform
ercia
– Remove control unit for electronic steering column lock - J764-

m
a
-item 4-.
com
tion in
r
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thi
s
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Note
do
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rp
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If the shear-head bolt cannot be removed using special socket -

n
t.
yi Co
T10424- , drill out using an angle drill and an 8.5 mm ∅ twist drill. Cop py
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Installing
c by lksw
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Prote AG.
Install in the reverse order of removal, observing the following:
– Tighten new bolts -arrows- until shear heads break off.

– Perform steps to initiate ⇒ Vehicle diagnostic tester.

olkswagen AG
en AG. V
Golf Sportsvan 2015 ➤ , Golf Sportsvan ksw 2018 ➤
ag does
not
Vol
Running gear, axles, steering -edEdition 03.2018
by gu
ara
ris nte
utho eo
ra
a c
ss
3 Steering rack
ce
e
nl
pt
du
an
itte
⇒ “3.1 Assembly overview - steering rack”, page 280
y li
erm
ab
⇒ “3.2 Removing and installing steering rack”, page 284
ility
ot p
wit
, is n
⇒ “3.3 Removing and installing bellows”, page 299
h re
hole
spec
⇒ “3.4 Removing and installing track rod”, page 302
es, in part or in w
t to the co
⇒ “3.5 Removing and installing track rod ball joint”, page 305
⇒ “3.6 Repairing steering rack”, page 306
rrectness of i
3.1 Assembly overview - steering rack
l purpos
⇒ “3.1.1 Assembly overview - steering rack, left-hand drive”, page

280
nf
ercia
or
⇒ “3.1.2 Assembly overview - steering rack, right-hand drive”,
m
m
atio
page 282
om
n in
or c
⇒ “3.1.3 Assembly overview - steering rack, right-hand drive”,
thi
te
page 283
sd
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rp
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3.1.1 Assembly overview - steering rack, left-hand drive
o
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Cop py
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Caution
ht
pyri by
Vo
co lksw
by
cted agen
Prote
AG.

♦ Connect battery

1 - Wire
KA”
2 - Bolt
❑ Either qty. 3 or qty. 4 are
fitted depending on en‐
gine version. Refer to ⇒
Electronic parts cata‐
logue “ETKA”
❑ 8 Nm
3 - Heat shield
ble depending on en‐
Electronic parts cata‐ agen
AG. Volkswagen AG d
oes
logue “ETKA” olksw not
V gu
d by ara
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4 - Steering rack horis nte
eo
ut ra
❑ Assembly overview ss a c
⇒ page 283
ce
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nl
pt
du
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⇒ page 284
erm
ab
ility
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hole
spec
KA”
es, in part or in w
❑ With power steering
t to the co
control unit - J500-
❑ Can be tested in “Gui‐
rrectness of i
ded fault finding” using
⇒ Vehicle diagnostic
l purpos
tester.
5 - Right wheel bearing hous‐
nform
ercia
ing
m
at
6 - Nut
om
ion
c

in t
or
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te
❑ 20 Nm +90°
a
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7 - Bolt
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Co
Cop py
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❑ 70 Nm +90°
gh ht
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Vo
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by c lksw
8 - Subframe Prote
cted AG.
agen
9 - Left wheel bearing housing

10 - Seal
❑ Renew after removing steering rack
11 - Fastener
3. Steering rack 281

3.1.2 Assembly overview - steering rack, lkright-hand

swa
gen AG drive does n
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ris
Caution tho
tee
or
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♦ Connect battery
ab
ility
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h re
♦ Turn steering mechanism ole,
spec
t to the co
rrectness o
1 - Wire
cial p
f inform
2 - Heat shield
mer
atio
m

o
n
c
ble depending on en‐
i
or
n thi
te
sd
a

iv
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pr
c
logue “ETKA”
um
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fo
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ng
t.
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3 - Bolt
Co
Cop py
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❑ Either qty. 3 or qty. 4 are gh ht
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fitted depending on en‐
op Vo
by c lksw
cted
agen
Prote AG.
logue “ETKA”
❑ 8 Nm
4 - Seal
❑ Renew after removing
steering rack
5 - Steering rack
⇒ page 284
❑ Assembly overview
⇒ page 283
KA”
❑ With power steering
control unit - J500-
❑ Can be tested in “Gui‐
ded fault finding” using
⇒ Vehicle diagnostic
tester.
6 - Right wheel bearing hous‐
ing
7 - Nut
❑ 20 Nm +90°

8 - Subframe
9 - Bolt
❑ 70 Nm +90°
10 - Left wheel bearing housing
11 - Fastener
3.1.3 Assembly overview - steering rack, right-hand drive
1 - Left track rod ball joint

⇒ page 304
⇒ page 305
⇒ page 304
❑ Allocation ⇒ Electronic
parts catalogue “ETKA”
2 - Nut
❑ Counterhold on track
rod ball joint with a span‐
ner when loosening or
tightening nut.
❑ 70 Nm
3 - Clip
4 - Boot n AG. Volkswagen AG do
swage es n
❑ Must not be twisted after byV
olk ot g
ua
toe setting has been ad‐ rised ran
tee
justed. utho
or
a ac
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⇒ page 299
un
pt
an
d
itte
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5 - Clip
erm
ab
❑ Renew
ility
ot p
wit
is n

h re
ole,
6 - Track rod
spec

t to the co
⇒ page 302
❑ 100 Nm
rrectne
7 - Threaded bush
ss
⇒ page 306
o
cial p
f inform
8 - Steering rack
mer

atio
om

c
i
or
n thi
te
sd
9 - Right track rod ball joint

iva
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pr

um
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fo
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ng
t.
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Cop py
t. rig
gh ht
pyri by
co Vo
by lksw
cted agen
Prote AG.

3.2 Removing and installing steering rack

⇒ “3.2.1 Removing and installing steering rack, left-hand drive
vehicle”, page 284
⇒ “3.2.2 Removing and installing steering rack, RLD vehicle”,
page 291
3.2.1 Removing and installing steering rack, left-hand drive vehicle

equipment required
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
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un
pt
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ab
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wit
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hole
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es, in part or in w
t to the co
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l purpos
nform
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r
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thi

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Co
Cop py
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gh ht
♦ Engine and gearbox jack - V.A.G 1383 A- yri
p by
co Vo
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cted
Removing
agen
Prote AG.

lock engages.


– Unscrew bolt -arrow- from universal joint -1- and pull off uni‐
versal joint in -direction of arrow-.
Caution

♦ Connect battery
AG. Volkswagen AG d
agen
♦ Switch on ignition Volksw
oes
not
by gu
d ara
♦ Turn steering mechanism orise nte
eo
h
ut ra
♦ Turn steering column ss a c
ce
le

un
pt
an
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ab
pe
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– Loosen wheel bolts. h re

hole
– Raise vehicle.
spec
es, in part or in w
t to the co
– Remove wheels.
rrectness of i
noise insulation .
l purpos

nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
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rp
cum
fo
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t.
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Cop py
t. rig
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pyri by
Vo
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by c lksw
cted agen
Prote AG.

AG. Volkswagen AG d
agen oes
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byV gu
ara
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ris nte
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aut ra
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nl
pt
du
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hole
spec
es, in part or in w
sides).
t to the co
rrectness of i
l purpos
nform
mercia
at
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c
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ate
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t.
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Cop py
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rig ht
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ly.
Caution
nut.


applicable.

sender - G266- .
lkswage es n
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nl
pt
du
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ing rack.
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
orm
m
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or c
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Cop py
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subframe
Vehicles with longer head shield
– Unscrew bolts -arrows- and remove heat shield -1- from steer‐
ing rack. lkswage es n
Vo ot gu
by ara
ed nte
oris eo
th
Note ss
au ra
c
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un
pt
Different heat shields -1- are installed depending on the engine.
an
d
itte
On some engines it is possible to access the connectors for the
y li
rm
ab
steering rack without removing the heat shield.
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
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
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t.
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op
C py
t. rig
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co lksw
by
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Prote AG.

Running
AG. Volkswagen AG d gear, axles, steering - Edition 03.2018
agen oes
olksw not
– Pull out spreader clip -arrow-. yV gu
db ara
rise nte
o
– Lower subframe withauengine
th and gearbox jack - V.A.G 1383 eo
ra
A- . ss c
ce
e
nl
pt
– Lever off steering rack from subframe with a large screwdriver,
du
an
for example, and remove backwards. itte
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hole
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es, in part or in w
t to the co
rrectness of i
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nform
mercia
at
om
ion
c
– Place steering rack on a surface as shown.
in t
or
his
ate
This prevents damage to the control unit -1-.
do
priv
cum
or
Installing
f
en
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t.
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op
Install in reverse order. During this procedure, observe the fol‐ C py
ht. rig
lowing: rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
– Plug in connectors -1- and -2- so that they audibly engage.

– Renew seal -1-.

Note
– Position steering rack -1- on subframe.

– Threaded sleeves -2- of steering rack must be inserted in
holes in subframe -arrow-.
AG. Volkswagen AG d
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– Screw in bolts -1- for steering rack, and tighten them.

rrectnes
Note
s o
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form
mer
atio
m

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c
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or

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lkswage es n
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Note orised ran
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th or
au ac
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un
pt
an
d
itte
– Bolt universal joint to steering rack.
y li
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ab
ility
– Connect battery ⇒ Electrical system; Rep. gr. 27 ; Battery;
ot p
Disconnecting and connecting battery .
wit
is n
h re
ole,
– Carry out basic setting for steering angle sender - G85- using
spec
t to the co
If new steering rack has been installed, adapt electromechanical
power steering using ⇒ Vehicle diagnostic tester.
rrectne
Specified torques
ss
joint”, page 66
o
cial p
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form
mer
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n
c
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or
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Cop py
ings; Assembly overview - assembly mountings ⇒ Rep. gr.
t. rig
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10 ; Assembly mountings; Assembly overview- assembly p by
co Vo
lksw
mountings
by
cted agen
Prote AG.

sulation .
3.2.2 Removing and installing steering rack, RLD vehicle


equipment required
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c
ce
e
nl
pt
du
an
itte
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ab
ility
ot p
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, is n
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hole
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es, in part or in w
t to the co
rrectness of i
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nf
ercia
orm
m
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n in
or c
thi
te
sd
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Cop py
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Prote
AG.

Removing
lock engages.


lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss
ce
le
– Unscrew bolt -arrow- from universal joint -1- and pull off uni‐
un
pt
an
d
versal joint in -direction of arrow-.

itte
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rm
ab
pe
ility
ot
Caution
wit
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hole
spec
es, in part or in w
t to the co
♦ Connect battery
rrectness of i
l purpos
nform
ercia

m
a
com
tion in
r
te o
thi
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– Raise vehicle.
um
fo
en
ng
t.
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– Remove wheels.
Co
Cop py
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by lksw
cted agen
noise insulation . Prote AG.

AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
ho eo
– Remove hexagon nut -1-
s a from coupling rod -3- (left and right
ut ra
c
sides). s
ce
e
nl
pt
du
an
itte
y li
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
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nform
mercia
at
om
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c
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or
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ate
do
priv
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for
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t.
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Cop py
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ly.
Caution
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applicable. olkswage es n
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Continued for all vehicles db ara
ir se nte
ho eo
aut ra
ss c
ce
e
nl
pt
du
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ab
ility
ot p
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hole
spec
sender - G266- .
es, in part or in w
t to the co
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nf
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orm
m
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n in
or c
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Cop py
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Prote AG.
ing rack.


subframe
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A- .
– Lever off steering rack from subframe with a large screwdriver,
for example, and remove backwards.

– Place steering rack on a surface as shown.

This prevents damage to the control unit -1-.
Installing
lowing:
Threaded sleeves of steering rack must seat in holes in subframe.
– Plug in connectors -1- and -2- so that they audibly engage.
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– Renew seal -1-. by V o gu
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– Slide seal -1-ut
hover
or
collar of steering rack -2- so that rubber elip
or
makes contacts
ss a with collar all round -arrows-. ac
ce
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Note
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– Screw in bolts -1- for steering rack, and tighten them.
spec
es, in part or in w
t to the co
Note
rrectness of i
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nf
ercia
sulation .
orm
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Note
– Bolt universal joint to steering rack. agen

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– Connect battery ⇒ Electrical system; Rep. gr. ed by27
V
; Battery; gu
ara
Disconnecting and connecting battery . ho ris nte
eo
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– Carry out basic setting for steering angle
ss sender - G85- using c
ce
le
un
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an
d
itte
If new steering rack has been installed, adapt electromechanical
y li
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power steering using ⇒ Vehicle diagnostic tester.
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Specified torques
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joint”, page 66
es, in part or in w
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nform
ercia

m
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com
tio
10 ; Assembly mountings; Assembly overview- assembly
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mountings
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♦ Bolts for noise insulation ⇒ General body repairs, exterior; Cop py
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3.3 Removing and installing bellows


equipment required
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♦ Hose clip pliers - V.A.G 1275-

le
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♦ Insert tool, 24 mm - V.A.G 1332/11-

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♦ Locking pliers for Phaeton steering rack - VAS 6199-

h re
ole,
spec
Removing
t to the co
Note
rrectne
♦ If boot is defective, moisture and dirt will enter steering rack.

There must be a palpable film of grease in the area of the teeth
ss
on the steering rack. If there is no film of grease, the steering

o
cial p
rack must be renewed.

inform
mer
♦ The steering rack must be renewed:

atio
om
♦ In the event of corrosion.

n
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♦ In the event of damage.

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♦ In the event of excessive wear

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♦ In the event of soiling on the steering rack. t. Cop py
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– Turn steering wheel to straight-ahead position.
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– Raise vehicle.
– Remove wheel.
– Mark position of nut on track rod.
– Remove track rod ball joint ⇒ page 305 .
– Clean outside of steering rack in vicinity of boot.
No dirt must be allowed to enter the steering rack through a de‐
fective rubber boot during this operation.
– Open hose clips.
– Pull boot off steering rack housing and track rod.
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♦ If the steering rack shows signs of corrosion, damage, wear or
ss c
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soiling, renew the complete steering rack.

un
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♦ Likewise, if there is no film of grease on the steering rack, the
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steering rack must be renewed.
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Installing
h re
hole
spec
es, in part or in w
Caution
Do not grease steering rack. t to the co

rrectness of i
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– Thread new clamps and rubber boot onto track rod.
nform
ercia
RHD only
m
a
com
tio
– Lightly grease sealing surface between boot and track rod with
n in
r
grease - G 052 168 A1- from repair kit.

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– Push rubber boot -2- onto track rod -1- as shown in figure.
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Cop py
– Secure spring-type clip on rubber boot using hose clip pliers - ht. rig
rig ht
V.A.G 1275- . py by
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RHD only Prote AG.
– Lightly grease sealing surface between boot and steering rack

housing with grease - G 052 168 A1- from repair kit.
– Push rubber boot onto steering rack housing to stop.

– Install new clip, as shown in figure, with locking pliers for

Phaeton steering rack - VAS 6199- .
– Screw in track rod ball joint up to mark made during removal
and install ⇒ page 305 .
– Install front wheel and tighten.
– Check wheel alignment ⇒ page 233 .
– If both track rods have been exchanged, basic setting must be
carried out for steering angle sender - G85- ⇒ Vehicle diag‐
nostic tester.
– Then carry out basic setting of steering ⇒ Vehicle diagnostic
tester.
Specified torques
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3.4 Removing and installing track rod ol not
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Special tools and workshop ss
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equipment required
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♦ Open end spanner insert, AF 38 mm - V.A.G 1923-
♦ Locking pliers for Phaeton steering rack - VAS 6199-
Carry out the following work: AG. Volkswagen AG d
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Removing d by ara
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– Turn steering wheel to straight-ahead
aut position. ra
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– Raise vehicle.
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– Remove wheel.
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– Clean outside of steering rack in vicinity of boot.
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Caution
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nut.
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– Open clips and push boot back.

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– Turn steering as follows:
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- For right track rod, turn steering to full left lock. yri
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– Unscrew track rod.
1- Open-end spanner attachment - V.A.G 1923-
Note
♦ If the steering rack shows signs of corrosion, damage, wear or

soiling, renew the complete steering rack.
♦ Likewise, if there is no film of grease on the steering rack, the
steering rack must be renewed.
Installing track rod

lowing:
Caution
Do not grease steering rack.

– Make sure that correct track rod ball joint is installed on each
side.
I - Track rod ball joint on right marked with an “A”
II - Track rod ball joint on left marked with a “B”
– Thread new clamps and rubber boot onto track rod.
– Screw track rod into track rod ball joint until dimension -a- is
attained.
Dimension -a- = 373 ± 1 mm
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– Tighten track rod. d by gu
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1- Open-end aut spanner attachment - V.A.G 1923-
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– Lightly grease sealing surface between boot and track rod with
pe
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grease - G 052 168 A1- from repair kit.

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spec
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rrectness of i
– Push rubber boot -2- onto track rod -1-, making sure that boot
is correctly positioned.
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– Secure spring-type clip on rubber boot using hose clip pliers -

V.A.G 1275- .
nform
ercia
RHD only
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– Lightly grease sealing surface between boot and steering rack

n in
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housing with grease - G 052 168 A1- from repair kit.

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– Push rubber boot onto steering rack housing as far as it will

ng
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– Install new clip, as shown in figure, with locking pliers for

Phaeton steering rack - VAS 6199- .
– If both track rods have been exchanged, basic setting must be
carried out for steering angle sender - G85- ⇒ Vehicle diag‐
nostic tester.
– Then carry out basic setting of steering ⇒ Vehicle diagnostic
tester.
Specified torques
3.5 Removing and installing track rod ball

joint
Special tools and workshop equipment
Volkswa
required
AG. gen AG
agen does
♦ Ball joint puller
Vol - T10187-
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Carry out the following work:
by lksw
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Prote AG.
Removing
– Raise vehicle.
– Remove wheel.

– Loosen nut -1-.

– Mark position of track rod ball joint on track rod.
– Loosen nut -2- on track rod ball joint but do not remove com‐
pletely.
Caution
– Push track rod off wheel bearing housing and remove nut.
– Unscrew track rod ball joint from track rod.
Installing
lowing: olks
wage es n
o
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db ara
ise nte
– Make sure that correct track rod ball
tho joint is
r
installed on each eo
side. ss au ra
c
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le
I - Track rod ball joint on right marked with an “A”

un
pt
an
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itte
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II - Track rod ball joint on left marked with a “B”
erm
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ility
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– Screw track rod ball joint onto track rod as far as previously
wit
is n
applied mark and secure with lock nut.
h re
ole,
– Insert track rod ball joint into wheel bearing housing.
spec
t to the co
– Bolt track rod ball joint with new nut.
rrectne
Specified torques
ss o
cial p

f inform
mer

atio
m

o
n
c
i
or

thi
te
sd
iva
o
pr
3.6 Repairing steering rack

um
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fo
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ng
t.
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⇒ “3.6.1 Removing and installing threaded bush”, page 306 Cop py
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3.6.1 Removing and installing threaded bush
p by
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Removing
– Raise vehicle.
noise insulation .
– Remove noise insulation at rear from subframe ⇒ General
body repairs, exterior; Rep. gr. 66 ; Noise insulation; Assem‐
bly overview - noise insulation .
– Detach noise insulation from subframe ⇒ General body re‐
pairs, exterior; Rep. gr. 66 ; Noise insulation; Assembly over‐
view - noise insulation .
– If fitted, remove centre underbody cladding ⇒ General body
repairs, exterior; Rep. gr. 66 ; Underbody cladding; Overview
of fitting locations - underbody cladding
lkswage es n
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ir se tee
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a ac
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pe
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, is n
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es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
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tion in
r
te o
thi
s
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do
r
rp
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ng
t.
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Cop py
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sides).

– Separate electrical connector -1- from front left vehicle level
sender - G78- .
AG. Volkswagen AG d
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– Pull wiring harness -3- clips -1- andVo-2-
lkswoff subframe and steer‐es not
gu
ing rack. se
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ac
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le
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t to the co

rrectne
– Prise steering rack out of dowel sleeves of subframe.

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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rig ht
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by lksw
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– Position engine and gearbox jack - VAS 6931- -1- under sub‐
frame
– Drive out threaded bush -1- in -direction of arrow-.

Installing
ing:
Note
Always drive in threaded bush from above and from direction of

the steering shaft.
– Insert threaded bush in a straight line.

– Drive in threaded bush as far as stop.
AG. Volkswagen AG d
agen oes
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ara
ed
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aut ra
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ce
le
un
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an
d
itte
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ility
ot p
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is n
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ole,
spec
t to the co
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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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Specified torques
sulation .
Volkswa
♦ Exhaust system to subframe s⇒wagRep.
en AGgr.
.
26 ;gExhaust
en AG
doespipes/
silencers; Assembly overview
by
Volk
- silencer . not
gu
a
e an d r
ris
If the steering wheel isthofound to be off centre during the road test tee o
even though locatingss
aupins - T10486/1- were used, check wheel ra
c
alignment. In this case the wheel alignment test results must be ce
e
nl
archived in the vehicle files. pt

du
an
itte
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4 Sensors
⇒ “4.1 Removing and installing steering angle sender G85 ”, page
311
4.1 Removing and installing steering angle

sender - G85-
Note
♦ The steering angle sender - G85- is a component of the steer‐

ing rack.
♦ It cannot be renewed as an individual part.
♦ If the steering angle sender - G85- is defective, the steering
rack must be renewed a⇒gepage
n AG. V284
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do w es n
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ris tee
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es, in part or in w
t to the co
rrectness of i
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4. Sensors 311

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Service

Service Department. Technical Information

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Copyright © 2018 Volkswagen AG, Wolfsburg D4B80423F1E

2.4 Steering rack . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

2.7 Electrical components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

2.8 Raising suspension to unladen position (vehicles with coil springs) . . . . . . . . . . . . . . . . . . 4

3 Evaluating accident vehicles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

3.1 Checklist for evaluating running gear on accident vehicles . . . . . . . . . . . . . . . . . . . . . . . . 9

6.5 Removing and installing drive shaft heat shield . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119

42 - Rear suspension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137

5.4 Removing and installing lower transverse link . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 171

6 Suspension strut, shock absorber, spring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 175

7.1 Assembly overview - wheel bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 191

7.3 Removing and installing wheel bearing housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 193

7.4 Removing and installing wheel bearing unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 197

7.7 Repairing trailing arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 209

44 - Wheels, tyres, vehicle geometry . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 227

1 Wheel alignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 227

2.1 Calibrating adaptive cruise control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 243

2.2 Checking steering column for damage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 268

2.4 Removing and installing steering column . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 269

3 Steering rack . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 280

3.1 Assembly overview - steering rack . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 280

3.2 Removing and installing steering rack . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 284

3.3 Removing and installing bellows . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 299

4.1 Removing and installing steering angle sender G85 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 311

1.1 Safety measures when working on vehicles with a start/stop system

1.2 Safety precautions when working on

⇒ “2.8 Raising suspension to unladen position (vehicles with coil

that in the majority of cases this replacement is not justified.

2.2 Noises from shock absorbers

2 Rep. gr.00 - Technical data

2.3 Checking shock absorbers when re‐

Shock absorbers are maintenance-free; shock absorber fluid can‐

with uniform resistance and without jolts.

• If the shock absorber has sufficient gas pressure the piston

rod will return by itself to its original position.

of fluid, it will still be as effective as a conventional shock ab‐

However, it may produce more noise.

2.4 Steering rack

To achieve the desired results when performing repairs on the

which can otherwise be found in the relevant sections of the

♦ If repair work cannot be performed immediately, cover new

2.5 Gaskets and seals

2.6 Nuts and bolts

2.7 Electrical components

touch connector contacts.

2.8 Raising suspension to unladen position

4 Rep. gr.00 - Technical data

Special tools and workshop

♦ Engine and gearbox jack - V.A.G 1383 A-

All bolts on running gear components with bonded rubber

To simulate this position on the lifting platform, raise the respec‐

Before the respective wheel suspension is raised, the vehicle

Running gear 1) Ride height -a- in mm

Basic (G01/G02/G05/G07/ 383 ± 10 mm

G07/ G21+2UC/G01/ G14+

Raised running gear (G01/G02/ 398 ± 10 mm

♦ Do not raise or lower the vehicle while the engine and

– Tighten respective nuts and bolts.

6 Rep. gr.00 - Technical data

Special tools and workshop

♦ Engine and gearbox jack - V.A.G 1383 A-