VW Polo 5 2014 Axles Steering Eng

Service
Workshop Manual
Polo 2014 ➤
Running gear, axles, steering
Edition 01.2018
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
Technical information should always be available to the foremen and mechanics, because their
careful and constant adherence to the instructions is essential to ensure vehicle road-worthiness and
safety. In addition, the normal basic safety precautions for working on motor vehicles must, as a
matter of course, be observed.
Polo 2014 ➤
Running gear, axles, steering - Edition 01.2018
Contents
00 - Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1 Evaluating accident vehicles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.1 Checklist for evaluating running gear on accident vehicles . . . . . . . . . . . . . . . . . . . . . . . . 1
2 Safety information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
2.1 Safety measures when working on vehicles with a start/stop system . . . . . . . . . . . . . . . . 3
2.2 Safety precautions when working on subframe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
3 Repair instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
3.1 Steering rack . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
3.2 Gaskets and seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
3.3 Nuts and bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
3.4 Repairing damaged threads in longitudinal member (subframe to body) . . . . . . . . . . . . . . 4
3.5 Electrical components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
3.6 Raising suspension to unladen position (vehicles with coil springs) . . . . . . . . . . . . . . . . . . 5
40 - Front suspension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
1 Front axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
1.1 Overview - front axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
2 Subframe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
2.1 Assembly overview - subframe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
2.2 Fixing position of subframe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
2.3 Removing and installing subframe without steering rack . . . . . . . . . . . . . . . . . . . . . . . . . . 15
2.4 Removing and installing subframe with steering rack . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
2.5 Removing and installing anti-roll bar . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
2.6 Renewing anti-roll bar bushes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
3 Suspension strut, upper suspension link . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
3.1 Assembly overview - suspension strut, upper suspension link . . . . . . . . . . . . . . . . . . . . . . 24
3.2 Removing and installing suspension strut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
3.3 Repairing suspension strut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
4 Lower suspension link, swivel joint . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
4.1 Removing and installing lower suspension link . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
4.2 Checking swivel joint . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
4.3 Removing and installing swivel joint . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
4.4 Renewing front bonded rubber bush for lower suspension link . . . . . . . . . . . . . . . . . . . . . . 53
4.5 Renewing rear bonded rubber bush for lower suspension link . . . . . . . . . . . . . . . . . . . . . . 56
5 Wheel bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
5.1 Assembly overview - wheel bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
5.2 Removing and installing wheel bearing housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
5.3 Removing and installing wheel bearing unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
6 Drive shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
6.1 Overview - drive shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
6.2 Assembly overview - drive shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
6.3 Removing and installing drive shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
6.4 Removing and installing joint body . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
6.5 Removing and installing drive shaft heat shield . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
6.6 Dismantling and assembling drive shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
6.7 Checking outer constant velocity joint . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118
6.8 Checking inner constant velocity joint . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119
42 - Rear suspension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121

1 Rear axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121
1.1 Overview - rear axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121
1.2 Removing and installing rear axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123
Contents i
Polo 2014 ➤
2 Axle beam . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127

2.1 Assembly overview - axle beam . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127
2.2 Renewing bonded rubber bush for axle beam . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131
3 Suspension strut, shock absorber, spring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137
3.1 Assembly overview - suspension strut, shock absorber, spring . . . . . . . . . . . . . . . . . . . . . . 137
3.2 Removing and installing shock absorbers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139
3.3 Repairing shock absorber . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 142
3.4 Removing and installing spring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 146
4 Wheel bearing assembly, trailing arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149
4.1 Assembly overview - wheel bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149
4.2 Removing and installing wheel bearing unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 151
43 - Self-levelling suspension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 155

1 Electronically controlled damping system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 155
1.1 Assembly overview - electronically controlled damping system . . . . . . . . . . . . . . . . . . . . . . 155
1.2 Removing and installing electronically controlled damping control unit J250 . . . . . . . . . . 155
2 Vehicle level sender . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 157
2.1 Assembly overview - rear vehicle level senders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 157
2.2 Removing and installing rear vehicle level senders G76 / G77 . . . . . . . . . . . . . . . . . . . . . . 157
44 - Wheels, tyres, vehicle geometry . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 159

1 Wheels, tyres . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 159
1.1 Pressing tyre off wheel rim . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 159
1.2 Removing tyre from wheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 159
1.3 Mounting tyre . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 160
1.4 Wheel change . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 160
1.5 Specified torques for wheel bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 164
1.6 Tyre sealant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 164
1.7 Tyre sealant disposal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 164
1.8 Models with breakdown set . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 164
2 Tyre pressure monitoring system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 165
2.1 System description - tyre pressure monitoring system . . . . . . . . . . . . . . . . . . . . . . . . . . . . 165
3 Wheel alignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 167
3.1 Notes for wheel alignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 167
3.2 Conditions for testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 167
3.3 Test preparations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 168
3.4 Specifications for wheel alignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 170
3.5 Wheel alignment procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 172
3.6 Necessity of wheel alignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 173
3.7 Vehicle data sticker . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 174
3.8 Adjusting camber at front wheels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 174
3.9 Adjusting camber on rear axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 175
3.10 Adjusting toe at rear axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 176
3.11 Adjusting front axle toe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 176
3.12 Checking maximum wheel lock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 176
4 Vibration due to wheels/tyres - causes and rectification . . . . . . . . . . . . . . . . . . . . . . . . . . 178
4.1 Causes of rough running . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 178
4.2 Conducting a road test before balancing wheels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 178
4.3 Balancing wheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 179
4.4 Vibration control system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 183
4.5 Checking radial and lateral runout of wheels and tyres . . . . . . . . . . . . . . . . . . . . . . . . . . . . 183
4.6 Checking radial and lateral run-out on wheel rim . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 184
4.7 Matching wheels and tyres . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 185
4.8 Determining flat spots on tyres . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 186
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Polo 2014 ➤
5 Adaptive cruise control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 188

5.1 Calibrating adaptive cruise control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 188
48 - Steering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 194
1 Steering wheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 194
1.1 Assembly overview - steering wheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 194
1.2 Removing and installing steering wheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 194
2 Steering column . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 197
2.1 Assembly overview - steering column . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 197
2.2 Removing and installing steering column . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 198
2.3 Handling and transporting steering column . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 207
2.4 Removing and installing intermediate steering shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 209
2.5 Repairing steering column . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 210
2.6 Removing and installing power steering control unit J500 . . . . . . . . . . . . . . . . . . . . . . . . 211
3 Steering rack . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 221
3.1 Assembly overview - steering rack . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 221
3.2 Removing and installing steering rack . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 222
3.3 Repairing steering rack . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 225
3.4 Removing and installing track rod . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 227
3.5 Removing and installing track rod ball joint . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 230
3.6 Adjusting steering rack . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 231
4 Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 232
4.1 Removing and installing steering angle sender G85 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 232
Contents iii
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iv Contents
Polo 2014 ➤
00 – Technical data
1 Evaluating accident vehicles
(VRL011289; Edition 01.2018)
⇒ “1.1 Checklist for evaluating running gear on accident vehicles”,
page 1
1.1 Checklist for evaluating running gear on

accident vehicles
Damage to running gear may go unnoticed during repairs to load-
bearing and suspension parts of accident vehicles. Under certain
circumstances, this undiscovered damage could lead to serious
consequential damage during later vehicle operation. Therefore,
the following parts of accident vehicles must be examined in the
manner and order described independent of wheel alignment
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.
Visual and functional examination of steering system
♦ Visual examination for deformation and cracks
♦ Examination for play in track rod joints and steering rack
♦ Visual examination for tears in boots
♦ Examine electrical and hydraulic lines and hoses for chafing,
cuts and kinks.
♦ Check hydraulic lines, threaded connections and steering rack
for leaks.
♦ Check steering rack and lines for secure seating
♦ Check for flawless function from lock to lock by moving the
steering from stop to stop. In the process, the steering wheel
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 tread and on flanks.
⇒ page 178
♦ Check tyre pressure; for information on tyre pressure see
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.
1. Evaluating accident vehicles 1

Polo 2014 ➤
If in doubt, the following always applies:

• Whenever a safety risk cannot be excluded, the tyre(s) must
be renewed.
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 or electro‐
hydraulic steering and other driver assist systems must be read
with the ⇒ Vehicle diagnostic tester for possibly stored fault mes‐
sages. If faults are saved in the event memories of the systems
mentioned above, repair them according to instructions in work‐
shop manuals in ELSA. Following repairs, read event memories
of the affected systems again to ensure that complete function
has been restored.
2 Rep. gr.00 - Technical data

Polo 2014 ➤
2 Safety information
⇒ “2.1 Safety measures when working on vehicles with a start/
stop system”, page 3
⇒ “2.2 Safety precautions when working on subframe”,
page 3
2.1 Safety measures when working on ve‐

hicles with a start/stop system
WARNING
All bolts and nuts must be fully tightened according to specifi‐

cations before the vehicle is driven on public roads.
WARNING
There is a risk of an accident through an automatic engine start

on vehicles with start/stop system.
♦ On vehicles with an active start/stop system the engine
may start automatically.
♦ Therefore it is essential to ensure that the start/stop sys‐
tem has been deactivated when working on the vehicle
(switch off ignition, then switch on again as required).
2.2 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 5 .
2. Safety information 3
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3 Repair instructions
⇒ “3.1 Steering rack”, page 4
⇒ “3.2 Gaskets and seals”, page 4
⇒ “3.3 Nuts and bolts”, page 4
⇒ “3.5 Electrical components”, page 5
⇒ “3.4 Repairing damaged threads in longitudinal member (sub‐
frame to body)”, page 4
⇒ “3.6 Raising suspension to unladen position (vehicles with coil
springs)”, page 5
3.1 Steering rack

♦ 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.
♦ If repair work cannot be performed immediately, cover new
parts which have been removed from their packing.
3.2 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.
3.3 Nuts and bolts

♦ Loosen and tighten bolts and securing nuts for covers and
housings diagonally.
♦ Avoid canting sensitive parts, such as servo motor with control
unit. Loosen and tighten them diagonally in stages.
♦ Specified torques given are for unoiled nuts, bolts and screws.
♦ Always renew self-locking nuts and bolts.
3.4 Repairing damaged threads in longitu‐

dinal member (subframe to body)
Repairing the thread in captive nuts in the longitudinal member is
possible only under certain conditions ⇒ Body Repairs; Rep. gr.
50 .

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3.5 Electrical components

You have certainly felt an electric shock when you have touched
something metallic. This is due to the electrostatic charge of the
human body. This charge can cause malfunctions if you touch the
electric steering rack components.
– Before working on electrical components, touch an earned
object, such as a water pipe or a lifting platform. Do not directly
touch connector contacts.
3.6 Raising suspension to unladen position

(vehicles with coil springs)
⇒ “3.6.1 Raising wheel bearing assembly to unladen position (ve‐
hicles with coil springs), front axle”, page 5
⇒ “3.6.2 Raising wheel bearing assembly to unladen position (ve‐
hicles with coil springs), rear axle”, page 7
3.6.1 Raising wheel bearing assembly to unladen position (vehicles with coil
springs), front axle
3. Repair instructions 5
Polo 2014 ➤
Special tools and workshop

equipment required
♦ 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- .

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Before the axle on one side is raised, both sides of the vehicle
must be strapped to the lifting platform arms with tensioning
straps - T10038- .
WARNING
If the vehicle is not strapped down, there is a danger that the

vehicle will slip off the lifting platform/hoist.
– Turn wheel hub until one of the wheel bolt holes is at the top.
– Attach support - T10149- to wheel hub using wheel bolt.
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.
The dimension -a- depends on the ride height of the installed run‐
ning gear:
Running gear 1) Ride height -a- in mm

Standard running gear (G72) 366 ± 10 mm
Sports running gear (G12/G70) 351 ± 10 mm
“Sport Select” running gear 351 ± 10 mm
(G53)
GTI with “Sport Select” running 351 ± 10 mm
gear (G54)
Raised running gear (G13/ 381 ± 10 mm
G73)
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 174 .
– 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- .
3.6.2 Raising wheel bearing assembly to unladen position (vehicles with coil
springs), rear axle
Polo 2014 ➤

equipment required

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 axle on

one side using the engine and gearbox jack - V.A.G 1383 A- and
support - T10149- .

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Before the axle on one side is raised, both sides of the vehicle
must be strapped to the lifting platform arms with tensioning
straps - T10038- .
WARNING
If the vehicle is not strapped down, there is a danger that the

vehicle will slip off the lifting platform/hoist.
– Turn wheel hub until one of the wheel bolt holes is at the top.
– Attach support - T10149- with a wheel bolt.
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.
Measuring dimension -a-

The dimension -a- depends on the ride height of the installed run‐
ning gear:
Running gear 1) Ride height -a- in mm

Standard running gear (G72) 383 ± 10 mm
Sports running gear (G12/G70) 368 ± 10 mm
“Sport Select” running gear 368 ± 10 mm
(G53)
GTI with “Sport Select” running 368 ± 10 mm
gear (G54)
Raised running gear (G13/ 398 ± 10 mm
G73)
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 174 .
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.
– Pull engine and gearbox jack out from under vehicle.
– Remove support - T10149- .
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40 – Front suspension
1 Front axle
⇒ “1.1 Overview - front axle”, page 10
1.1 Overview - front axle
I-
⇒ “2.1 Assembly overview -
subframe”, page 11
II -
wheel bearing”, page 59
III -
suspension strut, upper sus‐
pension link”, page 24
10 Rep. gr.40 - Front suspension

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2 Subframe
⇒ “2.1 Assembly overview - subframe”, page 11
⇒ “2.2 Fixing position of subframe”, page 13
⇒ “2.3 Removing and installing subframe without steering rack”,
page 15
⇒ “2.4 Removing and installing subframe with steering rack”, page
17
⇒ “2.5 Removing and installing anti-roll bar”, page 19
⇒ “2.6 Renewing anti-roll bar bushes”, page 21
2.1 Assembly overview - subframe
Caution
♦ It is not permitted to weld or straighten load-bearing or

wheel-guiding components of the suspension.
♦ Always renew self-locking nuts.
1 - Subframe
❑ Removing and installing
⇒ page 15
❑ Various versions
❑ Allocation ⇒ Electronic
parts catalogue “ETKA”
2 - Nut
❑ Self-locking
❑ Renew after each re‐
moval
❑ 40 Nm
3 - Anti-roll bar
⇒ page 19
The subframe must be lowered
to remove and install
4 - Rubber mounting
⇒ page 21
❑ Always replace on both
sides
5 - Clip
6 - Nut
❑ Self-locking
moval
❑ 40 Nm
Volkswagen Technical Site: http://vwts.ru http://vwts.info 2. Subframe 11

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7 - Coupling rod
❑ Link between anti-roll bar and suspension strut
❑ Allocation ⇒ Electronic parts catalogue “ETKA”
❑ Coupling rods with a U cross-section must be fitted with the open side facing the suspension strut.
8 - Nut
9 - Support
10 - Bolt
❑ Renew after each removal
If the thread of the welded nut is damaged, the thread can be repaired with a Heli-coil thread insert.
Repairing thread in longitudinal member ⇒ page 4

❑ 20 Nm +90°
11 - Rear bonded rubber bush
❑ Removing and installing ⇒ page 56
12 - Bolt
If the thread of the welded nut is damaged, the thread can be repaired with a Heli-coil thread insert.
Repairing thread in longitudinal member ⇒ page 4

❑ 70 Nm +90°
13 - Suspension link
14 - Nut
❑ Self-locking
❑ 20 Nm +90°
15 - Swivel joint
❑ Checking ⇒ page 50
16 - Nut
❑ 40 Nm +45°
17 - Bolt
❑ 70 Nm +90°
18 - Front bonded rubber bush
19 - Bolt
❑ 70 Nm +90°
20 - Bolt
❑ 70 Nm +90°
21 - Bolt
❑ 20 Nm +90°

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2.2 Fixing position of subframe

equipment required
♦ Locating pins - T10096-

♦ Locating pins - T10486 A-
Removing
– Remove noise insulation ⇒ General body repairs, exterior;
Rep. gr. 66 ; Noise insulation; Assembly overview - noise in‐
sulation .
2. Subframe 13
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– Unscrew the bolts for the pendulum support -1- and -2- from
the gearbox.
Vehicles with 7-speed dual clutch gearbox or 6-speed manual
gearbox 0A8
– Unbolt pendulum support bolts -1- from gearbox.

Vehicles with exhaust pipe beneath subframe
– Remove front exhaust pipe ⇒ Rep. gr. 26 ; Exhaust pipes and
silencers; Removing and installing front exhaust pipe .
Continued for all vehicles
– Position engine and gearbox jack - V.A.G 1383 A- -1- under
subframe
– Clean thread of locating pins - T10096- .
To fix position of subframe, successively screw in locating pins -

T10096- at positions -1- and -2-, and locating pins from supple‐
mentary set - T10486/1- at positions -3- and -4-.
Positions -3- and -4- must be fixed first.
Note
The locating pins - T10096- as well as the locating pins from the
supplementary set - T10486/1- may be tightened only to a maxi‐
mum of 20 Nm; otherwise the threads of the locating pins will be
damaged.
– Replace securing bolts -2- with locating pins - T10486 A/1- one
after other on both sides of vehicle, and tighten to 20 Nm.
– Unscrew bolts -arrows- for support.
– Unscrew securing bolt -1- on one side of vehicle and remove

support.
– Insert locating pins - T10096- and tighten to 20 Nm.

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– If locating pins - T10096- cannot be inserted, sleeve in sub‐

frame must be centred using assembly mandrel - 10 - 508-
-1-.
– The process of locating the subframe is complete when all of
the 4 bolts have been replaced one after other with a locating
pin from locating pin set - T10096- or locating pin set - T10486
A/1- .
– Lower subframe approx. 4 cm.
Installing
Carry out installation in the reverse sequence, noting the follow‐
ing:
– Only unscrew one locating pin at a time and replace it with a

new bolt -1- and -2-.
– Screw in bolts -arrows- for support, and tighten them to speci‐
fied torque.
If the steering wheel is found to be off centre during the road test
even though locating pins - T10096/ T10486 A/1- were used,
check wheel alignment. In this case the wheel alignment test re‐
sults must be archived in the vehicle files.
Specified torques
♦ ⇒ “2.1 Assembly overview - subframe”, page 11
♦ ⇒ “3.1 Assembly overview - steering rack”, page 221
♦ Bolts for pendulum support ⇒ Rep. gr. 10 ; Assembly mount‐
ings; Assembly overview - assembly mountings .
♦ Bolts for noise insulation ⇒ General body repairs, exterior;
sulation .
2.3 Removing and installing subframe with‐

out steering rack
Special tools and workshop equipment required
♦ Torque wrench - V.A.G 1331-
2. Subframe 15
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Removing
– Remove front wheels.
– Remove noise insulation.
– Remove nuts -arrows-
– Remove hexagon nut -1- from coupling rod (left and right
sides).
– Pull coupling rod -3- out of anti-roll bar -2- on left and right
sides.
– Turn anti-roll bar upwards.
Vehicles with exhaust pipe above subframe
– Pull retaining rings for exhaust pipe from subframe.


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– Open clips -arrows- of retainer on subframe.

– Remove cable -1-.
– Unbolt steering rack from subframe -arrows- and tie up with

wire (or similar).
– Fix position of subframe ⇒ page 13 .
– Lower subframe using engine and gearbox jack - V.A.G 1383
A- .
Installing
– Secure subframe ⇒ page 15 .
Continue installation in reverse order of removal.
– Install wheels and tighten bolts or nuts ⇒ page 164 .
Specified torques
2.4 Removing and installing subframe with

steering rack
2. Subframe 17
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Removing
– Unscrew bolt -arrow- from universal joint -1- and pull off uni‐
versal joint in -direction of arrow-.
– Loosen nut -1- on track rod end -2- but do not remove com‐
pletely.
Caution
To protect thread, leave nut screwed a few turns onto joint pin.
– Press track rod ball joint -2- off steering arm.

Polo 2014 ➤
sides).
sides.


A- .
Installing
Specified torques
2.5 Removing and installing anti-roll bar

2. Subframe 19
Polo 2014 ➤
Removing
sides).
sides.


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– Unbolt steering rack from subframe -arrows- and tie up with

wire (or similar).

A- until anti-roll bar -1- can be guided past drive shafts.
– Unscrew bolts -arrows-.
– Remove anti-roll bar -1- backwards.
Installing anti-roll bar
– Insert anti-roll bar and secure to subframe using clamps.
Specified torques
2.6 Renewing anti-roll bar bushes

2. Subframe 21
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Removing rubber bush

– Disconnect right drive shaft from gearbox, and secure it with
wire ⇒ page 80 .
– Remove bolts -arrows- on both sides.
– Pull anti-roll bar clamp off rubber bush.
– Detach rubber bush from anti-roll bar.
Installing rubber bush
– Insert new rubber bush -1- on anti-roll bar via opening

-arrow-.
Note
♦ Ensure that the outer edge of rubber bush -1- lies against stop
-2-.
♦ Depending on version, the stop -2- can be located on the left
or on the right of rubber bush.

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– Secure clamps to subframe -arrows-.

– Install right drive shaft.
– Install noise insulation.
Specified torques
♦ ⇒ “6.2 Assembly overview - drive shaft”, page 72
2. Subframe 23
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3 Suspension strut, upper suspension

link
⇒ “3.1 Assembly overview - suspension strut, upper suspension
link”, page 24
⇒ “3.2 Removing and installing suspension strut”, page 27
⇒ “3.3 Repairing suspension strut”, page 41
3.1 Assembly overview - suspension strut,

upper suspension link
⇒ “3.1.1 Assembly overview – suspension strut, upper suspen‐
sion link, basic version of running gear”, page 24
⇒ “3.1.2 Assembly overview – suspension strut, upper suspen‐
sion link, Sport Select running gear”, page 26
3.1.1 Assembly overview – suspension strut, upper suspension link, basic version
of running gear
Note
Depending on equipment, a spacer may be installed between the items 7 and 8 ⇒ Electronic parts catalogue
“ETKA” .

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1 - Cap
2 - Nut
❑ Self-locking
moval
❑ 60 Nm
3 - Stop
4 - Suspension turret
5 - Nut
❑ Self-locking
moval
❑ 60 Nm
6 - Suspension strut mounting
❑ Note installation posi‐
tion ⇒ page 25
7 - Deep groove ball thrust
bearing
8 - Spring plate
9 - Coil spring
⇒ page 41
❑ Observe colour coding
Spring allocation via PR No.
These numbers are located on

the vehicle data sticker.
❑ Surface of coil must not be damaged.
10 - Protective cover
11 - Buffer stop
12 - Damper
❑ Can be renewed separately
Suspension strut bearing installation position

Shoulder of suspension strut bearing -arrow- must point to spring
plate.
3. Suspension strut, upper suspension link 25

Polo 2014 ➤
3.1.2 Assembly overview – suspension strut, upper suspension link, “Sport Se‐
lect” running gear
1 - Cap
2 - Cover
3 - Nut
❑ Self-locking
moval
❑ 60 Nm
4 - Stop
5 - Suspension turret
6 - Nut
❑ Self-locking
moval
❑ 60 Nm
7 - Suspension strut mounting
❑ Note installation posi‐
tion ⇒ page 27
8 - Deep groove ball thrust
bearing
9 - Spring plate
10 - Coil spring
⇒ page 41
Spring allocation via PR No.
These numbers are located on the vehicle data sticker.

❑ Surface of coil must not be damaged.
11 - Protective cover
12 - Buffer stop
13 - Damper
❑ Can be renewed separately

Polo 2014 ➤
Suspension strut bearing installation position

plate.
3.2 Removing and installing suspension

strut
⇒ “3.2.1 Removing and installing suspension strut, basic version
of running gear”, page 27
⇒ “3.2.2 Removing and installing suspension strut, Sport Select
running gear”, page 33
3.2.1 Removing and installing suspension strut, basic version of running gear

equipment required

Polo 2014 ➤
♦ Spreader - 3424-
♦ 36 mm socket - T10125-
♦ Shock absorber tool set - T10001-

♦ Ring spanner insert - V.A.G 1332/7-

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♦ Ejector - T10520-
Removing
– Lift vehicle far enough to take weight off front axle.
– Undo 12-point drive shaft nut using 36 mm socket - T10125- .
– Remove wheel.
– Unscrew nut -arrow- and pull coupling rod -1- out from sus‐
pension strut.
– Detach wire for speed sensor from suspension strut.
– Remove clip for brake line -arrow- and unhook brake line at
spring strut.
– Pull connector off ABS speed sensor.

– Pull swivel joint out of suspension link.
– Pull outer joint of drive shaft out of wheel hub.
– Secure drive shaft to body with wire.
If the drive shaft cannot be pulled out of the wheel bearing by
hand, use press tool - T10520- .

Polo 2014 ➤
Before using pressure tool - T10520- , make sure that thrust piece
-1- is inserted.
Using ejector - T10520- :

– To press out drive shaft -3-, secure ejector - T10520- -1- to
wheel hub using 3 wheel bolts -2-.
– It is essential to follow specified sequence.

I - Tighten knurled nut -1- hand-tight.
II - Using spanner, turn only bolt -2-, not the press tool itself. Pull
out drive shaft using press tool - T10520- .
Note
At the end of the procedure or for pressing out drive shaft further,
the spindle must be moved to its original position in order to apply
the hydraulic force.
Caution
Do not allow the drive shaft to hang down under its own weight,
for this would allow the inner joint to bend too far and be dam‐
aged.
– Bolt swivel joint to suspension link again.

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– Use wheel bolt to attach engine and gearbox jack - V.A.G 1383
A- with support - T10149- to wheel hub.
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.

– Turn ratchet handle through 90° and pull off from spreader -
3424- .
– Press brake disc towards suspension strut by hand.
Otherwise the shock absorber tube can cant in the bore of the
wheel bearing housing.
– Pull wheel bearing housing downwards off shock absorber
tube and lower with engine and gearbox jack - V.A.G 1383 A-
until shock absorber tube is free.
– Use wire to secure wheel bearing housing to engine/gearbox
mounting.
support - T10149- .
WARNING

– Remove plenum chamber cover ⇒ General body repairs, ex‐

terior; Rep. gr. 50 ; Bulkhead; Removing and installing plenum
chamber cover .
– If fitted, detach cap from shock absorber mounting.

Polo 2014 ➤
– Unbolt upper shock absorber mounting and remove spring

strut downwards.
1- Ratchet, commercially available
2- -T10001/8-
3- -T10001/11-
4- -T10001/5-
Installing
– Place suspension strut on wheel bearing housing and fix in
place with the multi-point socket head bolt and a new nut.
The tip of the multi-point socket head bolt must point in the direc‐
tion of travel.
– Remove wire on wheel bearing housing.
– Remove spreader - 3424- .
until suspension strut lies against inner suspension turret.
– Position stop on suspension strut turret and tighten nuts for

upper shock absorber mounting to tightening torque.
2- -T10001/8-
3- Ring spanner insert - V.A.G 1332/7-
4- -T10001/5-
5- Torque wrench - V.A.G 1332-
– Remove support - T10149- from wheel hub.
– Remove engine and gearbox jack - V.A.G 1383 A- from under
vehicle.
– If removed beforehand, attach cap to shock absorber mount‐
ing.
– Install plenum chamber cover ⇒ General body repairs, exte‐
rior; Rep. gr. 50 ; Bulkhead; Removing and installing plenum
chamber cover .
– Tighten threaded connection between wheel bearing housing

and suspension strut -arrow-

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– Fit drive shaft into wheel bearing.
Make sure that deflector ring -1- is clipped completely onto outer
joint.
Note
Deflector ring -1- must align with contact surface of outer joint
-arrow-.
– Bolt swivel joint to suspension link with new nuts -arrows-.

Use new nuts!
Note
Tighten nuts -arrows- in unladen state ⇒ page 5 .
Ensure that boot is not damaged or twisted.

– Install wheel and tighten bolts or nuts ⇒ page 164 .
– Tighten 12-point drive shaft nut using 36 mm socket -
T10125- .
Specified torques
♦ ⇒ “3.1 Assembly overview - suspension strut, upper suspen‐
sion link”, page 24
♦ ⇒ “5.1 Assembly overview - wheel bearing”, page 59
3.2.2 Removing and installing suspension strut, “Sport Select” running gear

Polo 2014 ➤

equipment required
♦ 36 mm socket - T10125-

Polo 2014 ➤

Removing

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– Remove wheel.
– Unscrew nut -arrow- and pull coupling rod -1- out from sus‐
pension strut.
– Detach wire for speed sensor from suspension strut.
– Remove clip for brake line -arrow- and unhook brake line at
spring strut.
– Pull connector off ABS speed sensor.

-1- is inserted.

Polo 2014 ➤


Note
Caution
Do not allow the drive shaft to hang down under its own weight,
for this would allow the inner joint to bend too far and be dam‐
aged.
– Bolt swivel joint to suspension link again.
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-.

Polo 2014 ➤

– Turn ratchet handle through 90° and pull off from spreader -
3424- .
– Press brake disc towards suspension strut by hand.
Otherwise the shock absorber tube can cant in the bore of the
wheel bearing housing.
– Pull wheel bearing housing downwards off shock absorber
tube and lower with engine and gearbox jack - V.A.G 1383 A-
until shock absorber tube is free.
– Use wire to secure wheel bearing housing to engine/gearbox
mounting.
support - T10149- .
WARNING

– Remove plenum chamber cover ⇒ General body repairs, ex‐

terior; Rep. gr. 50 ; Bulkhead; Removing and installing plenum
chamber cover .
– Remove cap -1- from cover -2-.
– Press lugs -arrows- inwards, and pull connector -1- off shock
absorber.

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– Lever off cover -1-.
– Unbolt upper shock absorber mounting and remove spring

strut downwards.
2- -T10001/8-
3- -T10001/11-
4- -T10001/5-
Installing
– Place suspension strut on wheel bearing housing and fix in
place with the multi-point socket head bolt and a new nut.
The tip of the multi-point socket head bolt must point in the direc‐
tion of travel.
– Remove wire on wheel bearing housing.
– Remove spreader - 3424- .
until suspension strut lies against inner suspension turret.
– Position stop on suspension strut turret and tighten nuts for

upper shock absorber mounting to tightening torque.
2- -T10001/8-
4- -T10001/5-
– Remove support - T10149- from wheel hub.
– Remove engine and gearbox jack - V.A.G 1383 A- from under
vehicle.

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– Fit cover -1-.
– Fit connector -1- onto shock absorber. Lugs -arrows- must au‐
dibly engage.
– Fit cap -1- onto cover -2-.

– Install plenum chamber cover ⇒ General body repairs, exte‐
rior; Rep. gr. 50 ; Bulkhead; Removing and installing plenum
chamber cover .
– Tighten threaded connection between wheel bearing housing

and suspension strut -arrow-

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– Fit drive shaft into wheel bearing.
joint.
Note
-arrow-.

Use new nuts!
Note

T10125- .
Specified torques
3.3 Repairing suspension strut

Polo 2014 ➤

equipment required

♦ Suspension strut clamp - V.A.G 1752-
♦ Spring compressor - V.A.G 1752/1-
♦ Spring retainer - V.A.G 1752/7-
– Remove coil spring strut ⇒ page 27 .

Polo 2014 ➤
Removing coil spring

– Clamp suspension strut support clamp - V.A.G 1752/20- -5- in
a vice.
– Clamp suspension strut in suspension strut support clamp -
V.A.G 1752/20- -5-.
– Using spring compressor - V.A.G 1752/1- -4-, pre-tension coil
spring until deep groove ball thrust bearing is free at top.
1- Commercially available ratchet
2- Hexagon bit, long reach - T10001/8-
4- Spring compressor - V.A.G 1752/1-
5- Strut support clamp - V.A.G 1752/20-
6- Spring retainer - V.A.G 1752/7-
7- Ratchet wrench - T10001/11-
WARNING
First compress spring far enough to ensure that upper spring

plate is free.
– Ensure that coil spring is correctly seated in spring retainer -

V.A.G 1752/7- -arrow-.
Installing coil spring
– Fit coil spring with suspension strut tensioner - V.A.G 1752-

onto lower spring seat.
End of spring coil must lie on stop -arrow A- and lug -arrow B-.
– Position spring plate, deep groove ball thrust bearing and sus‐
pension strut bearing on spring.

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plate.
– Tighten new hexagon nut on piston rod.

1- Commercially available ratchet
6- Strut support clamp - V.A.G 1752/20-
– Relieve tension on suspension strut tensioner - V.A.G 1752-
and remove from coil spring.
– Installing suspension strut:
♦ Basic version of running gear ⇒ page 32
♦ “Sport Select” running gear ⇒ page 39
Specified torques

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4 Lower suspension link, swivel joint

⇒ “4.1 Removing and installing lower suspension link”,
page 45
⇒ “4.2 Checking swivel joint”, page 50
⇒ “4.3 Removing and installing swivel joint”, page 50
⇒ “4.4 Renewing front bonded rubber bush for lower suspension
link”, page 53
⇒ “4.5 Renewing rear bonded rubber bush for lower suspension
link”, page 56
4.1 Removing and installing lower suspen‐

sion link
⇒ “4.1.1 Removing and installing lower suspension link, vehicles
with manual gearbox”, page 45
⇒ “4.1.2 Removing and installing lower suspension link, vehicles
with automatic or dual clutch gearbox”, page 47
4.1.1 Removing and installing lower suspen‐

sion link, vehicles with manual gearbox
Removing
– Remove front wheel.
– Pull suspension link out of swivel joint and turn wheel bearing
housing outwards to relieve suspension link.
4. Lower suspension link, swivel joint 45

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– Swivel suspension link backwards and pull out of subframe in

direction of -arrow-.
Installing
– Insert rear suspension link into subframe in direction of

-arrow- and swivel forwards.
– Fit and tighten bolts -arrows-.

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– Insert swivel joint in suspension link and tighten bolts

-arrows-.
Use new nuts!
Note

Specified torques
4.1.2 Removing and installing lower suspen‐

sion link, vehicles with automatic or dual
clutch gearbox
♦ Engine support - T10533-
Removing
– Remove front wheel.

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– Pull suspension link out of swivel joint and turn wheel bearing
housing outwards to relieve suspension link.
– Remove pendulum support ⇒ Rep. gr. 10 ; Assembly mount‐
ings; Removing and installing pendulum support .
– Loosen double clamp of exhaust system ⇒ Rep. gr. 26 ; Ex‐
haust pipes/silencers; Assembly overview - silencer .

– Screw engine support - T10533- completely together to make
it as short as possible.
– Bolt engine support - T10533- -2- onto gearbox with the thicker
bracket -arrow-. Use the shorter pendulum support securing
bolt -1-.
– Press engine and gearbox far enough forward so that threa‐
ded rod - T10533/5- -3- can be inserted in pendulum support
mounting.
– Extend engine support - T10533- until distance -a- between

suspension link bolt -1- and gearbox is attained.
a = 85 mm

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– Swivel suspension link backwards and pull out of subframe in

direction of -arrow-.
Installing
– Insert rear suspension link into subframe in direction of

-arrow- and swivel forwards.
– Fit and tighten bolts -arrows-.

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– Insert swivel joint in suspension link and tighten bolts

-arrows-.
Use new nuts!
Note
– 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 .
Specified torques
♦ Bolts for pendulum support ⇒ Rep. gr. 10 ; Assembly mount‐
ings; Assembly overview - assembly mountings .
♦ Double clamp for exhaust pipes ⇒ Rep. gr. 26 ; Exhaust pipes/
silencers; Assembly overview - silencer .
4.2 Checking swivel joint

Checking axial play
– Firmly pull suspension link down in -direction of arrow- and
press up again.
Checking radial play
– Press lower part of wheel forcefully inwards and outwards in

-direction of arrow-.
Note
♦ There must be no palpable or visible “play” during both tests.

♦ Observe swivel joint while performing tests.
♦ Take into account possible existing wheel bearing play or
“play” in upper suspension strut mounting.
♦ Check rubber boot for damage and renew swivel joint if nec‐
essary.
4.3 Removing and installing swivel joint

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equipment required
♦ Ball joint puller - 3287A-

♦ Torque angle wrench - V.A.G 1756-
♦ 36 mm socket - T10125-
Removing swivel joint


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Caution
When bolt is loosened or tightened, vehicle must not be stand‐

ing on its wheels.
The wheel bearing can be damaged by the vehicle's own
weight when the bolt is loosened.
If vehicle is moved with drive shaft removed, an outer joint must
be installed and tightened to 50 Nm.
– Remove wheel.
– Pull drive shaft slightly out of wheel hub. Pull out completely if
necessary.
– Loosen nut for swivel joint.
Note
Leave nut screwed on a few turns to protect thread on swivel joint.
– Apply ball joint splitter - 3287 A- as shown in figure and press

out swivel joint.
Note
Place engine and gearbox jack - V.A.G 1383 A- or similar under‐

neath (danger of accident through falling parts when pressing out
the swivel joint).
Installing
Observe installation position of swivel joints!
Left swivel joint

Arrow with “L4” mark points in direction of travel on 14"/15" run‐
ning gear.

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Right swivel joint

Arrow with “R4” mark points in direction of travel on 14"/15" run‐
ning gear.
Observe exact installation position of swivel joints!
Caster will be incorrect if swivel joints are not installed in correct
position.
– Fit swivel joint in wheel bearing housing.
– Screw on new self-locking nut and counterhold at swivel joint
with -T40- Torx key.
– Fit drive shaft in wheel hub.
joint.
Note
-arrow-.
– Tighten nuts -arrows-.
Note

– Tighten 12-point nut using 36 mm socket - T10125- .
Specified torques
4.4 Renewing front bonded rubber bush for lower suspension link

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equipment required
♦ Drift - T10219/2-
♦ Thrust plate - VW 402-
♦ Press tool - VW 411-
♦ Tube - 2010-

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– Remove suspension link ⇒ page 45 .

Pressing out bonded rubber bush
– Press out bonded rubber bush as illustrated.
1- Press tool - VW 411-
2- Tube - 2010- (Larger internal diameter of wheel bearing
faces suspension link)
3- Pressure plate - VW 402-
Pressing in bonded rubber bush
– 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-
2- Bonded rubber bush
Note
At start of pressing-in process, bonded rubber bush is temporarily

slanted. During further procedure, it then straightens. It does not
have to be pushed further.
– Press in bonded rubber bush until core of bush -1- and hole in
suspension link -2- are flush.

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– Press bush back slightly in the suspension link.

The dimensions -a- and -b- must be the same.

– Install suspension link, vehicles with manual gearbox
⇒ page 46 .
– Install suspension link, vehicles with automatic or dual clutch
gearbox ⇒ page 49 .
4.5 Renewing rear bonded rubber bush for lower suspension link

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equipment required
♦ Tube for wheel bearing - 3345-

♦ Assembly tool - 3346-
♦ Crankshaft seal installing tool - VW 204 B-
♦ Assembly tool - T10356-

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– Remove suspension link ⇒ page 45 .

Pressing out bonded rubber bush
– Press out bonded rubber bush as illustrated.
2- Press tool - 3346/1-
3- Press tool - T10356/2-
Installation position of rear bonded rubber bush in suspension link

One of the embossed arrows points between the two markings
-Arrow A- in the suspension link.
The cam -arrow B- must always point to outside of vehicle.
Pressing in bonded rubber bush
– Press in bonded rubber bush as illustrated.

2- Crankshaft seal installing tool - VW 204 B-
4- Tube for wheel bearing - 3345- (Smaller outer circumfer‐
ence to suspension link)
Note
Press bonded rubber bush in until thrust piece of crankshaft seal

installing tool - VW 204 B- is on the suspension link.
– Install suspension link ⇒ page 46 .

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5 Wheel bearing
⇒ “5.1 Assembly overview - wheel bearing”, page 59
⇒ “5.2 Removing and installing wheel bearing housing”,
page 60
⇒ “5.3 Removing and installing wheel bearing unit”, page 62
5.1 Assembly overview - wheel bearing
1 - Drive shaft
2 - Suspension strut
⇒ page 27
❑ Repairing ⇒ page 41
3 - Nut
moval
❑ 60 Nm +90°
4 - Multi-point socket head bolt
❑ Tip of bolt must point in
direction of travel
5 - Hexagon socket head bolt
❑ 8 Nm
6 - Speed sensor
❑ Before inserting sensor,
clean inner surface of
hole and coat with lubri‐
cating paste - G 000
650- .
7 - Nut
moval
❑ 20 Nm +90°
8 - Bolt
❑ 12 Nm
9 - Cover plate
10 - Track rod ball joint
11 - 12-point nut (self-locking)
moval
❑ 50 Nm +45°
12 - Bolt
❑ 4 Nm
13 - Internally ventilated brake disc
14 - Wheel hub with wheel bearing
❑ The ABS sensor ring is installed in the wheel hub
❑ Different versions for 14" and 15" running gear
❑ Removing ⇒ page 62
❑ Installing ⇒ page 69
5. Wheel bearing 59
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❑ Always renew; is destroyed when pulled out.
15 - Wheel bearing housing
❑ For brake caliper FN3
❑ For vehicles with 15" running gear
❑ For brake caliper FS III
❑ For vehicles with 14" running gear
5.2 Removing and installing wheel bearing housing

equipment required
♦ Ball joint puller - 3287A-


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♦ Torque angle wrench - V.A.G 1756-
Removing
– Remove wheel.
– Remove brake caliper, and secure it to body using wire ⇒
Brake system; Rep. gr. 46 ; Front brake; Removing and in‐
stalling brake caliper .
– Remove ABS speed sensor ⇒ Brake system; Rep. gr. 45 ;
Sensors; Removing and installing speed sensor on front axle
-G45- / -G47- .
– Remove brake disc.
– Remove splash plate from wheel bearing housing.
pletely.
Caution

– Position engine and gearbox jack - V.A.G 1383 A- under wheel
bearing housing.
5. Wheel bearing 61
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– Remove threaded connection between wheel bearing housing

and suspension strut -arrow-.

– 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
ing:
joint.
Note
-arrow-.

T10125- .
Note
During this step, vehicle must not be standing on its wheels or

wheel bearing will be damaged.
If wheel bearing housing is renewed, wheels must be aligned

⇒ page 170 .
Specified torques
5.3 Removing and installing wheel bearing unit

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equipment required
♦ Assembly tool - 3253-

5. Wheel bearing 63
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♦ Open-end spanner (50 mm) - 3254-

♦ 36 mm socket - T10125-
♦ Hydraulic cylinder - VAS 6178-
♦ Foot pump - VAS 6179-

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Removing
– Remove wheel.
– Unscrew bolt for brake hose bracket.
sides).
sides.

– Pivot suspension strut outwards and hold in place with a wood‐

en block or similar -1-; at the same time pull drive shaft out of
wheel bearing.
5. Wheel bearing 65
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-1- is inserted.


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Note

The drive shaft must not hang down under its own weight.
Otherwise the inner joint will be bent too far and will be damaged.
– Remove brake carrier together with brake caliper, or just brake
caliper, and secure it to body with wire ⇒ Brake system; Rep.
gr. 46 ; Front brake; Removing and installing brake caliper .
– Remove bolt for brake disc and remove brake disc.
– Take off cover.
– Remove ABS speed sensor ⇒ Brake system; Rep. gr. 45 ;
Sensors; Removing and installing speed sensor on front axle
-G45- / -G47- .
Note
Place engine/gearbox jack - V.A.G 1383/A- underneath (danger

of accident from parts dropping out when wheel hub and wheel
bearing are pulled out).
5. Wheel bearing 67
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Pulling out wheel hub with wheel bearing

– Insert open-end spanner, 50 mm - 3254- between tube -
3253/1- and mounting surface -arrow- on steering arm.
– Hold appliance firmly and pull out wheel hub with wheel bear‐
ing.
1- Spindle - T10205/8-1-
2- Nut - T10205/8-2-
3- Hydraulic press - VAS 6178- and thrust piece - T10205/13-
4- Pressure plate - T10205/4-
5- Foot pump - VAS 6179-
6- Bracket - 3253/2-
7- Open-end spanner AF 50 - 3254-
8- Tube - 3253/1-
9- Thrust piece - T10205/3- , with large diameter facing to‐
wards wheel bearing
10 - Nut - T10205/8-2-
Installing
– Remove remains of circlip from the bore and groove of wheel
bearing housing.
– Clean bore of wheel bearing housing.
– Fully coat bore with Moly paste - G 052 723 A2- .

Use grease sachet from repair kit.
– Screw wheel bolts -2- into wheel hub.

– Fit gripping pieces - T10064/6A- onto the wheel bolts.
2 - Wheel bolts
3 - -T10064/6A-
Wheel bolts -2- must not protrude from backs of gripping pieces
- T10064/6A- .

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Installing wheel hub with wheel bearing

Make sure wheel hub/wheel bearing unit is kept straight when
installing.
– Pull in wheel hub together with wheel bearings until circlip en‐
gages audibly.
1- Spindle - T10205/8-1-
2- Nut - T10205/8-2-
6- Tube - T10064/1-
7- Gripping pieces - T10064/6A-
8- Thrust piece - T10064/4- , with large diameter facing to‐
wards wheel bearing housing
9- Nut - T10205/8-2-
– Unscrew wheel bolts -2- from wheel hub with wheel bearings
-1-.
– Remove gripping pieces - T10064/6A- .
– Insert drive shaft into wheel hub with wheel bearings.
joint.
Note
-arrow-.
5. Wheel bearing 69
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Use new nuts!
Note

– Install ABS speed sensor.
– Install cover plate, brake disc, brake carrier together with
brake caliper, or just brake caliper ⇒ Brake system; Rep. gr.
46 ; Front brake; Removing and installing splash plate .
– Fit bracket for brake hose to wheel bearing housing.
– Attach coupling rod to anti-roll bar.
T10125- .
Specified torques

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6 Drive shaft
⇒ “6.1 Overview - drive shaft”, page 71
⇒ “6.2 Assembly overview - drive shaft”, page 72
⇒ “6.3 Removing and installing drive shaft”, page 80
⇒ “6.5 Removing and installing drive shaft heat shield”,
page 96
⇒ “6.6 Dismantling and assembling drive shaft”, page 96
⇒ “6.7 Checking outer constant velocity joint”, page 118
⇒ “6.8 Checking inner constant velocity joint”, page 119
6.1 Overview - drive shaft
I-
⇒ “6.2.1 Assembly overview –
drive shaft, joint body
TS1800”, page 72
II -
drive shaft, constant velocity
joints VL90 and VL100”,
page 74
III -
joint VL107, threaded connec‐
tion”, page 76
IV -
joint VL107, plug-in connec‐
tion”, page 78
6. Drive shaft 71
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6.2 Assembly overview - drive shaft

⇒ “6.2.1 Assembly overview – drive shaft, joint body TS1800”,
page 72
⇒ “6.2.2 Assembly overview – drive shaft, constant velocity joints
VL90 and VL100”, page 74
⇒ “6.2.3 Assembly overview – drive shaft, constant velocity joint
VL107, threaded connection”, page 76
⇒ “6.2.4 Assembly overview – drive shaft, constant velocity joint
VL107, plug-in connection”, page 78
6.2.1 Assembly overview – drive shaft, joint body TS1800
1 - 12-point nut
❑ Self-locking
moval
❑ Remove any corrosion
on the thread of the out‐
er joint before the nut is
screwed on.
❑ 50 Nm +45°
2 - Deflector ring
❑ Ensure deflector ring is
seated correctly before
installing drive shaft
⇒ page 99 .
3 - Outer constant velocity joint
❑ Renew only as com‐
plete unit
❑ Installing: drive onto
shaft with plastic ham‐
mer until compressed
retaining ring seats
4 - Retaining ring
❑ Insert in groove in shaft
5 - Spacer ring
❑ Fitting position
⇒ page 98
6 - Dished spring
⇒ page 98
7 - Clip
❑ Tightening ⇒ page 98
8 - Boot for constant velocity joint
❑ Check for splits and chafing
❑ Material: Hytrel (polyester elastomer)
❑ Coat sealing surface of constant velocity joint with -D 454 300 A2- before installing.

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9 - Clip
10 - Drive shaft
11 - Clip
12 - Boot for triple roller joint
13 - Clip
14 - Triple roller star with rollers
The chamfer -arrow- points towards drive shaft splines.
15 - Retaining ring
16 - Joint body
17 - Retaining ring
❑ Insert in groove in joint body.
6. Drive shaft 73
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6.2.2 Assembly overview – drive shaft, constant velocity joints VL90 and VL100
1 - 12-point nut
❑ Self-locking
moval
screwed on.
❑ 50 Nm +45°
2 - Deflector ring
⇒ page 105 .
plete unit
shaft to stop using plas‐
tic hammer
4 - Retaining ring
moval
5 - Spacer ring
⇒ page 105
6 - Dished spring
⇒ page 105
7 - Clip
❑ Tensioning, version 1 ⇒ page 106
8 - Boot
9 - Clip
10 - Drive shaft
❑ Pre-tighten diagonally to 10 Nm
❑ M8 x 48;

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❑ 40 Nm
12 - Locking plate
13 - Clip
14 - Boot for inner constant velocity joint
❑ Drive off with drift
15 - Dished spring
❑ Splines in inner diameter
❑ Installation position: larger ∅ (concave side) contacts constant velocity joint
16 - Inner constant velocity joint
❑ Renew only as complete unit
❑ Pressing off ⇒ page 106
❑ Pressing on ⇒ page 106
17 - Seal
❑ Renew: Pull off protective foil and stick onto joint.
18 - Retaining ring
❑ Remove and install using -VW 161 A-
6. Drive shaft 75
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6.2.3 Assembly overview – drive shaft, constant velocity joint VL107, threaded
connection
1 - 12-point nut
❑ Self-locking
moval
screwed on.
❑ 50 Nm +45°
2 - Deflector ring
⇒ page 110 .
plete unit
tic hammer
4 - Retaining ring
moval
5 - Spacer ring
⇒ page 110
6 - Dished spring
⇒ page 110
7 - Clip
8 - Boot
9 - Clip
10 - Drive shaft
11 - Clip

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12 - Boot for constant velocity joint

❑ Without breather hole
❑ Drive off constant velocity joint with a drift
13 - Clip
14 - Locking plate
15 - Cap
❑ Drive off carefully with drift
❑ Adhesive surface must be free of oil and grease!
16 - Inner constant velocity joint
❑ Pressing on ⇒ page 111
17 - Retaining ring
18 - Cover
❑ Pre-tighten diagonally to 10 Nm
❑ M10 x 52
❑ Always renew bolts after removing
❑ 70 Nm
6. Drive shaft 77
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6.2.4 Assembly overview – drive shaft, constant velocity joint VL107, plug-in con‐
nection
1 - 12-point nut
❑ Self-locking
moval
screwed on.
❑ 50 Nm +45°
2 - Deflector ring
⇒ page 117 .
plete unit
tic hammer
4 - Retaining ring
moval
5 - Spacer ring
⇒ page 116
6 - Dished spring
⇒ page 116
7 - Clip
8 - Boot
9 - Clip
10 - Drive shaft
11 - Clip
12 - Boot for constant velocity slip joint
❑ Without breather hole

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13 - Clip
14 - Retaining ring
15 - Constant velocity slip joint
❑ Installing: drive onto shaft to stop using plastic hammer
6. Drive shaft 79
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6.3 Removing and installing drive shaft

⇒ “6.3.1 Removing and installing drive shaft, joint body TS1800”,
page 80
⇒ “6.3.2 Removing and installing drive shaft, constant velocity
joint, threaded connection”, page 84
⇒ “6.3.3 Removing and installing drive shaft, constant velocity
joint, plug-in connection”, page 87
6.3.1 Removing and installing drive shaft, joint body TS1800

equipment required

♦ 36 mm socket - T10125-

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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, wheel
bearings will be damaged and service life of wheel bearings
will be considerably reduced.
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.
Removing
– Unscrew twelve-point nut for drive shaft.
– Loosen wheel bolts.
– Raise vehicle.
– Remove wheel.
– Open clamp -1-.

– Push bellows -2- off joint body -3-.
– Pull drive shaft out of joint body.
– Pull drive shaft out of wheel bearing and remove.
hand, use ejector - T10520- .
6. Drive shaft 81
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-1- is inserted.


Note
Installing
Remove any paint residues and/or corrosion on thread and
splines of outer joint.

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joint.
Note
♦ The lugs of deflector ring -1- must face towards outer joint.
♦ Deflector ring -1- must lie on contact surface of outer joint
-arrow-.
Note
If deflector ring -1- is not positioned correctly or if it fell off outer

joint, it must be driven onto outer joint to stop using thrust piece -
T10049- .
– Lightly coat thread and splines of stub axle and contact sur‐
faces of wheel hub/twelve-point nut with pressure-resistant oil
Fuchs Renolin B15 VG46.
– Guide outer joint into wheel hub splines as far as possible.
– Secure outer joint in wheel hub splines with 12-point nut of
drive shaft.
– Push drive shaft into joint body.
– Press half the drive shaft grease from the repair kit into the
joint body.
– Press remaining drive shaft grease from the repair kit into the
bellows.
– Push bellows -2- onto joint body -3-.

– Fit new clamp -1- in position.
– Tightening hose clip ⇒ page 98
6. Drive shaft 83
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Use new nuts!
Note

– Tighten twelve-point nut for drive shaft.
Note

Specified torques
6.3.2 Removing and installing drive shaft, constant velocity joint, threaded con‐
nection

Polo 2014 ➤

equipment required

♦ 36 mm socket - T10125-
Removing
– Unscrew 12-point nut from drive shaft with 36 mm socket -
T10125- .
– Unbolt drive shaft from gearbox flange shaft.
– Remove wheel.
6. Drive shaft 85
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– Pivot suspension strut outwards and support with e.g. a wood‐

en block -1-; at the same time pull drive shaft out of wheel
bearing and remove outwards.
-1- is inserted.


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Note
Installing
– Insert drive shaft.
joint.
Note
-arrow-.

Use new nuts!
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.
– Tighten 12-point drive shaft nut with 36 mm socket - T10125- .
Specified torques
6.3.3 Removing and installing drive shaft, constant velocity joint, plug-in connec‐
tion
6. Drive shaft 87
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equipment required

♦ 36 mm socket - T10125-
Removing
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.

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– Unscrew twelve-point nut for drive shaft.
– Raise vehicle.
– Remove wheel.
– Unbolt coupling rods from anti-roll bars on both sides.
– Push drive shaft outer joint out of wheel hub by hand.
hand, use ejector - T10520- .
-1- is inserted.

– Secure press tool - T10520- -1- to wheel hub using 3 wheel
bolts.
6. Drive shaft 89
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Note
– Secure drive shaft to prevent it from falling.

– Remove lower noise insulation ⇒ General body repairs, ex‐
terior; Rep. gr. 66 ; Noise insulation; Assembly overview -
noise insulation .
– Using suitable tool, e.g. wooden block -2-, drive the drive shaft
-1- off gearbox stub shaft.
– Remove drive shaft from vehicle.
Installing
joint.
Note
♦ The lugs of deflector ring -1- must face towards outer joint.
♦ Deflector ring -1- must lie on contact surface of outer joint
-arrow-.

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Note

T10049- .
– Insert new retaining ring in groove in stub shaft on gearbox.

– Lightly grease splines of stub shaft with universal grease - G
060 735 A2- .
– Mesh outer and inner splines of gearbox and constant velocity
slip joint.
– Slide drive shaft into constant velocity joint to stop by hand.
– Now push constant velocity joint onto stub shaft of gearbox
with a »sudden, hard push«.
Note
Never use a hammer or other driving tools.
– Check that constant velocity slip joint is securely seated by

pulling constant velocity slip joint against resistance of retain‐
ing ring.
Caution
For this check, pull only on the constant velocity joint, not on
the drive shaft.
– Remove tensioning strap - T10038- .

6. Drive shaft 91
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Use new nuts!
Note

– Install lower noise insulation ⇒ General body repairs, exterior;
sulation .
Note

Specified torques
6.4 Removing and installing joint body

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equipment required
♦ Wedge - T10161-
♦ Closure cap - T10381-
♦ Used oil collection and extraction unit - VAS 6622-
Removing
– Raise vehicle.
6. Drive shaft 93
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– Drain gearbox oil -arrow- ⇒ Rep. gr. 34 ; Gearbox oil; Draining

and filling gearbox oil .
– Open clamp -1-.

– Push bellows -2- off joint body -3-.
– Pull drive shaft out of joint body, and lay it to one side.
– Insert wedge - T10161- -2- between gearbox housing and tri‐

ple roller joint -1-.
– Press inner joint -1- out of gearbox by striking wedge - T10161-
-1- with a rubber-headed hammer.

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– Insert closure cap - T10381/1- into gearbox.

Installing
– Fit new retaining ring into groove of joint pin.
– Mesh outer and inner splines of joint body and gearbox.
– Push joint body as far as stop into gearbox. If necessary, use
rubber-headed hammer to drive it all way in.
– Check if joint body is securely seated in gearbox by pulling
joint body against resistance of retaining ring.
– Push drive shaft into joint body.
joint body.
– Press remaining drive shaft grease from the repair kit into the
bellows.
– Push bellows -2- onto joint body -3-.

– Fit new clamp -1- in position.
– Tightening hose clip ⇒ page 98

Use new nuts!
Note

– Lightly coat thread and splines of stub axle and contact sur‐
faces of wheel hub/twelve-point nut with pressure-resistant oil
Fuchs Renolin B15 VG46.
Note

– Fill gearbox oil ⇒ Rep. gr. 34 ; Gearbox oil; Draining and filling
gearbox oil .
Specified torques
6. Drive shaft 95
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6.5 Removing and installing drive shaft heat

shield
Front-wheel drive:
Component Specified torque
Hexagon bolt -1- 25 Nm
6.6 Dismantling and assembling drive shaft

⇒ “6.6.1 Dismantling and assembling drive shaft, joint body
TS1800”, page 96
⇒ “6.6.2 Dismantling and assembling drive shaft, constant veloc‐
ity joints VL90 and VL100”, page 101
ity joint VL107, threaded connection”, page 107
ity joint VL107, plug-in connection”, page 113
6.6.1 Dismantling and assembling drive shaft, joint body TS1800

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equipment required
♦ Thrust piece - T10049-

♦ Puller - T10382-
♦ Multi-purpose tool - VW 771-
♦ Clamp tensioner - V.A.G 1682-
♦ Three-arm puller - Kukko 45-1-
Removing outer constant velocity joint
– Clamp drive shaft in vice using jaw protectors.
– Open O-type clip.
– Fold back boot.
– Set puller - T10382- up so that smooth side of puller plate -
T10382/1- points to spindles - T10382/2- .
– Assemble puller - T10382- complete with multi-purpose tool -
VW 771- .
6. Drive shaft 97
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– Pull constant velocity joint from drive shaft with puller -

T10382- and multi-purpose tool - VW 771- .
1- Puller plate - T10382/1-
2- Spindles - T10382/2-
Driving on outer constant velocity joint
Installation position of dished spring and spacer ring on outer joint

1- Dished spring
2- Spacer ring
– Install new retaining ring.
– If necessary, push new joint boot onto drive shaft.
– Drive constant velocity joint onto shaft using plastic hammer
until retaining ring engages.
Tightening new clamp on constant velocity joint

– Position clamp tensioner - V.A.G 1682- as shown in diagram.
Ensure jaws of tensioner lie in corners -arrows B- of clamp.
– 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.

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Tightening new clamp on small diameter

Ensure jaws of tensioner lie in corners -arrows B- of clamp.
– Tighten clamp by turning spindle with a torque wrench (do not
cant pliers).
Note

1682- .
joint.
Note
-arrow-.
Note

T10049- .
Dismantling
– Open both clip on inner joint and push back boot.
– Pull joint body off drive shaft.
6. Drive shaft 99
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– Remove retaining ring -1-.
– Pull triple roller star -1- off drive shaft using a three arm puller ,
e.g. -Kukko 45-1- -2-.
– Pull boot off shaft.
– Clean shaft, joint body and groove for seal.
Installing
– Push small hose clip for boot onto shaft.
– Push joint boot onto shaft.
– Fit triple roller star -1- onto drive shaft -2-.
Note
Ensure that chamfer -arrow- of triple roller star -1- faces towards
drive shaft -2-.

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– Drive triple roller star -1- onto drive shaft using thrust piece -
T10421- -2-.
– Insert circlip -1-, ensuring that it is seated correctly.

triple roller joint.
– Slide joint body over rollers and hold.
– Press the other half of the drive shaft grease from the repair
kit into the back of the triple roller joint.
– Install joint boot.
– Tighten clamp on small diameter ⇒ page 99 .
– Tighten new clamp on constant velocity joint ⇒ page 98 .
6.6.2 Dismantling and assembling drive shaft, constant velocity joints VL90 and
VL100
6. Drive shaft 101

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equipment required

♦ Press tool - VW 408 A-
♦ Tube - VW 416 B-
♦ Thrust plate - VW 447 H-

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♦ Snap ring pliers - VW 161 A-

6. Drive shaft 103

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♦ Puller - T10382-
– Fold back boot.
VW 771- .

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2- Spindles - T10382/2-

1- Dished spring
2- Thrust washer
– Knock onto shaft with plastic hammer until retaining ring en‐
gages.
joint.
Note
-arrow-.
Note

T10049- .
6. Drive shaft 105

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Pressing off inner constant velocity joint

First drive bellows off with drift.
Pressing on inner constant velocity joint

– Press joint on to stop.
– Install retaining ring.
Chamfer on internal circumference of ball hub (splines) must face
contact shoulder on drive shaft.
Tensioning clamp on outer joint - variant 1

– Insert lug -1- of clamp into guide -arrow-.

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– Compress clamp with pliers, e.g. locking pliers for Phaeton

steering rack - VAS 6199- until upper part -1- locks with guide
-arrow-.

– Position clamp tensioner - V.A.G 1682- as shown in illustra‐
tion. Ensure jaws of tensioner lie in corners -arrows B- of ear
on O-type clip.
– Tighten clip by turning spindle with a torque wrench (do not
cant pliers).
Note

1682- .
♦ Use torque wrench -C- with adjustment range 5 … 50 Nm, (e.g.
Tightening clip on small diameter of inner/outer joint
6.6.3 Dismantling and assembling drive shaft, constant velocity joint VL107,
threaded connection
6. Drive shaft 107

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equipment required

♦ Support sleeve - VW 522-
♦ Joint tensioner - 40 - 204 A-

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♦ Puller - T10382-
– Fold back boot.
VW 771- .
6. Drive shaft 109

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2- Spindles - T10382/2-

1- Dished spring
2- Thrust washer
gages.
joint.
Note
-arrow-.
Note

T10049- .

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Driving off cover for inner joint

– Remove retaining ring.
– Remove both clips and slide boot towards outer joint.
– Drive off boot with drift.
Pressing off inner constant velocity joint

Installing
Pressing on inner constant velocity joint

– Press joint on to stop.
– Install retaining ring.
– Coat sealing surface of cover with -D 454 300 A2- .

– Apply an unbroken bead of sealant of 2…3 mm in diameter
onto clean surface of cover in area of inner holes -arrow-.
6. Drive shaft 111

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– Using bolts -arrows-, align new cover in relation to bolt holes.

The alignment must be very accurate, because no further align‐
ment is possible once the part has been hammered on.
– Drive on cover with a plastic hammer.
– Wipe off surplus sealant.

– Insert lug -1- of clamp into guide -arrow-.
– Compress clamp with pliers, e.g. locking pliers for Phaeton

steering rack - VAS 6199- until upper part -arrow 1- locks with
guide -2-.

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– Position clamp tensioner - V.A.G 1682- as shown in illustra‐
tion. Ensure jaws of tensioner lie in corners -arrows B- of ear
on O-type clip.
cant pliers).
Note

1682- .
♦ Use torque wrench -C- with adjustment range 5 … 50 Nm, (e.g.
Tightening clip on small diameter of inner/outer joint

Checking outer constant velocity joint ⇒ page 118
Checking inner constant velocity joint ⇒ page 119
Checking function of constant velocity joint ⇒ page 120
6.6.4 Dismantling and assembling drive shaft, constant velocity joint VL107, plug-
in connection
6. Drive shaft 113

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equipment required

♦ Support sleeve - VW 522-
♦ Joint tensioner - 40 - 204 A-

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♦ Puller - T10382-
– Fold back boot.
VW 771- .
6. Drive shaft 115

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2- Spindles - T10382/2-

1- Dished spring
2- Thrust washer
gages.
Removing inner constant velocity slip joint

– Fold back boot.
– Drive constant velocity slip joint off drive shaft using drift -A-.
Drift must be positioned exactly on triple roller spider of constant
velocity joint.
Driving joint on
gages.

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Tighten clip on outer joint

Ensure jaws of tensioner lie in corners -arrows B- of ear on O-
type clip.
cant pliers).
Note

1682- .
Tightening clip on small diameter
joint.
Note
-arrow-.
6. Drive shaft 117

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Note

T10049- .
6.7 Checking outer constant velocity joint

Joint must be dismantled:
♦ to replace grease,
♦ if joint is severely soiled or
♦ if contact surfaces of balls are to be checked for wear and
damage
Removing
– Before dismantling, mark position of ball hub in relation to ball
cage and joint body with an electric scriber or oil stone.
– Swing ball hub and ball cage.
– Remove balls one at a time.
– Turn cage until the two rectangular windows -arrow- lie on joint
body.
– Take out cage with hub.

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– 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 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 change
the joint.
Installing
– Pack half the total quantity of grease into the 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.
– Distribute remaining grease in boot.
6.8 Checking inner constant velocity joint

Removing
Joint must be dismantled:
♦ to replace grease,
♦ if joint is severely soiled or
♦ if contact surfaces of balls are to be checked for wear and
damage
– Swing ball hub and ball cage.
– Press out joint in -direction of arrow-.
– Press balls out of cage.
The ball hub and joint body are paired. Do not interchange them.
– Tip ball hub out of ball cage via ball track -arrows-.
– Check joint body, ball hub, ball cage and balls for pitting and
traces of seizing.
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 119

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– Insert hub into cage via the two chamfers. The hub can be
installed in any position. Press balls into cage.
– 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.
– Swivel the hub into the joint body; at the same time the hub
must be swivelled out of the cage -arrows- far enough to allow
the balls to fit into the ball tracks.
– Swivel in hub with balls by applying firm pressure to cage

-arrow-.
Checking function of constant velocity joint
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.

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42 – Rear suspension
1 Rear axle
⇒ “1.1 Overview - rear axle”, page 121
⇒ “1.2 Removing and installing rear axle”, page 123
1.1 Overview - rear axle
I-
axle beam, drum brake”,
page 127
II -
axle beam, disc brake”,
page 129
III -
suspension strut, shock ab‐
sorber, spring”, page 137
1. Rear axle 121

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IV -
wheel bearings, drum brake”,
page 149
V-
wheel bearings, disc brake”,
page 150
122 Rep. gr.42 - Rear suspension

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1.2 Removing and installing rear axle

equipment required

♦ Brake pedal depressor - V.A.G 1869/2-
1. Rear axle 123

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Removing
– Depending on equipment version, remove one of the following
components:
♦ Storage compartment ⇒ General body repairs, interior; Rep.
gr. 68 ; Centre console; Removing and installing centre con‐
sole
♦ Cup holder ⇒ General body repairs, interior; Rep. gr. 68 ;
Centre console; Removing and installing centre console
♦ Centre armrest ⇒ General body repairs, interior; Rep. gr. 68 ;
Front centre armrest
– Release handbrake.
– Loosen adjustment nut -arrow- until the handbrake cables can
be pulled out from the compensator.
– Apply brake pedal depressor - V.A.G 1869/2- .
This prevents the brake pipes and the ABS hydraulic unit from
running dry.
– Raise vehicle to working height.
Securing vehicle to lifting platform
The vehicle must be secured to the support arms of the lifting
platform before the rear axle is removed.
If the vehicle is not strapped down, there is a danger that the ve‐
hicle will slip off the lifting platform/hoist.
– Remove plug from longitudinal member -3-, and pull in ten‐

sioning strap .
1- Lifting platform arm
2- Tensioning strap - T10038-
The vehicle must be strapped on the left and right side with ten‐
sioning strap .
– Remove wheels.
– Pull connector off speed sensor.
– Unclip wire -1- for speed sensor from brackets -arrows-.

– Remove coil spring (vehicles with small rear silencer
⇒ page 146 ).
– Remove coil spring (vehicles with large rear silencer
⇒ page 147 ).

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– Unscrew bolts for wheel housing liners -arrows- on both sides.
Vehicles with dynamic headlight range control

– Unbolt coupling rod of rear left vehicle level sender - G76- from
rear axle -arrow-.
– Disconnect left brake line -arrow A- and remove clip

-arrow B-.
– Pull left brake hose -1- out of retainer.
– Unscrew bolt -arrow- and remove retainer -1- from mounting

bracket.
1. Rear axle 125

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– Disconnect right brake line -arrow A- and remove clip

-arrow B-.
– Pull right brake hose -1- out of axle beam.
– Bring engine and gearbox jack - V.A.G 1383 A- into position
underneath.
– Remove handbrake cables from retainers -arrows-.

– Pull handbrake cables out of guide tubes.
– Secure rear axle with a strap or similar when lowering and re‐
moving.
– Unscrew bolts -1- for right and left axle beams.
– Unbolt rear axle from shock absorbers -arrows-.

– Lower rear axle with engine and gearbox jack - V.A.G 1383 A- .
Installing
– Grease the kidney-shaped cavities on the bonded rubber bush
with assembly paste - G 052 150 A2- before installing rear
axle.
Noises can occur when the vehicle is driven if the rear axle is
installed “dry”.
– Tighten rear axle in unladen position ⇒ page 7 .
– Bleed brake system ⇒ Brake system; Rep. gr. 47 ; Hydraulic
system; Bleeding hydraulic system following standard proce‐
dure .
– Adjust handbrake ⇒ Brake system; Rep. gr. 46 ; Handbrake;
Adjusting handbrake .
Specified torques
♦ ⇒ “2.1 Assembly overview - axle beam”, page 127
♦ ⇒ “2.1 Assembly overview - rear vehicle level senders”,
page 157
♦ Brake lines to brake hose ⇒ Brake system; Rep. gr. 46 ; Rear
brake

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2 Axle beam
⇒ “2.1 Assembly overview - axle beam”, page 127
⇒ “2.2 Renewing bonded rubber bush for axle beam”, page 131
2.1 Assembly overview - axle beam

⇒ “2.1.1 Assembly overview – axle beam, drum brake”,
page 127
⇒ “2.1.2 Assembly overview – axle beam, disc brake”,
page 129
2.1.1 Assembly overview – axle beam, drum brake
Note
The axle beam and stub axles must not be straightened or welded.
1 - Axle beam
❑ Keep contact surface
and tapped hole for stub
axle free from paint and
dirt
⇒ page 123
2 - Lower spring plate
❑ Check lower spring
plate for damage
3 - Coil spring
❑ Take different running
gear types into account
⇒ page 174 .
❑ Surface of coil must not
be damaged.
❑ Removing and instal‐
ling, vehicles with small
rear silencer
⇒ page 146
ling, vehicles with large
rear silencer
⇒ page 147
4 - Spring seat
5 - Bolt
moval
❑ 30 Nm +90°
6 - Shock absorbers
2. Axle beam 127

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7 - Bolt
❑ Tighten in unladen state ⇒ page 7 .
❑ 40 Nm +90°
8 - Nut
❑ Self-locking
9 - Bolt
❑ 8 Nm
10 - ABS speed sensor
❑ Before inserting sensor, clean inner surface of hole and coat with lubricating paste - G 000 650- .
11 - Stone deflector
12 - Stub axle
❑ Straightening operations are not permitted
❑ Recutting the thread is not permitted
13 - Brake drum
14 - Bolt
❑ 4 Nm
15 - Dust cap
❑ Pressing off and driving in ⇒ page 151
A proper seal can be achieved only by installing a new grease cap.
This is essential for optimum function and service life of wheel bearing.
16 - 12-point nut
❑ Self-locking
❑ 70 Nm +30°
❑ The ABS sensor ring is installed in the wheel hub
The wheel bearing and wheel hub are assembled in one housing.
The wheel hub with wheel bearing unit is maintenance and adjustment-free. Adjustments and repairs are not
possible!
18 - Bolt
❑ With dished spring
❑ 30 Nm +90°
19 - Brake backplate with brake shoes
❑ Repairing ⇒ Brake system; Rep. gr. 46 ; Rear brake; Assembly overview - rear brake
20 - Bolt
❑ Insert from outside.
❑ 45 Nm +90°

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21 - Bonded rubber bush

22 - Nut
❑ Self-locking
2.1.2 Assembly overview – axle beam, disc brake
Note
The axle beam and stub axles must not be straightened or welded.
1 - Axle beam
❑ Keep contact surface
and tapped hole for stub
axle free from paint and
dirt
⇒ page 123
2 - Lower spring plate
❑ Check lower spring
plate for damage
3 - Coil spring
❑ Take different running
gear designs into ac‐
count ⇒ page 174 .
❑ Surface of coil must not
be damaged.
ling, vehicles with small
rear silencer
⇒ page 146
ling, vehicles with large
rear silencer
⇒ page 147
4 - Spring seat
5 - Bolt
❑ 30 Nm +90°
moval
6 - Shock absorbers
7 - Bolt
❑ 40 Nm +90°
2. Axle beam 129

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8 - Nut
❑ Self-locking
9 - Bolt
❑ 8 Nm
10 - ABS speed sensor
❑ Before inserting sensor, clean inner surface of hole and coat with lubricating paste - G 000 650- .
11 - Stone deflector
12 - Stub axle
❑ Straightening operations are not permitted
❑ Recutting the thread is not permitted
13 - Brake disc
14 - Bolt
❑ 4 Nm
15 - Dust cap
16 - 12-point nut
❑ Self-locking
❑ 70 Nm +30°
The wheel bearing and wheel hub are assembled in one housing.
The wheel hub with wheel bearing unit is maintenance and adjustment-free. Adjustments and repairs are not
possible!
18 - Bolt
❑ 30 Nm +90°
19 - Cover plate
20 - Bolt
❑ Insert from outside.
❑ 45 Nm +90°
21 - Bonded rubber bush
22 - Nut
❑ Self-locking

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2.2 Renewing bonded rubber bush for axle beam

equipment required
♦ Thrust piece - 3416/1-

♦ Thrust piece - 3416/2-
2. Axle beam 131

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♦ Hydraulic cylinder - VAS 6178-
♦ Foot pump - VAS 6179-
Removing
– Release handbrake.
– Remove wheels.
– Pull connector off speed sensor.

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– Unclip wire -1- for speed sensor from brackets -arrows-.
– Unscrew bolts for wheel housing liners -arrows- on both sides.
Vehicles with dynamic headlight range control

– Unbolt coupling rod of rear left vehicle level sender - G76- from
rear axle -arrow-.
– Disconnect left brake line -arrow A- and remove clip

-arrow B-.
– Pull left brake hose -1- out of retainer.
2. Axle beam 133

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– Unscrew bolt -arrow- and remove retainer -1- from mounting

bracket.
– Disconnect right brake line -arrow A- and remove clip

-arrow B-.
– Pull right brake hose -1- out of axle beam.
– Remove handbrake cables from retainers -arrows-.

– Pull handbrake cables out of guide tubes.
– Secure rear axle with a strap or similar when lowering and re‐
moving.
– Unscrew bolts -1- for right and left axle beams.
– Lower rear axle with engine and gearbox jack - V.A.G 1383 A- .
– Fit special tools as shown in illustration.

1- Spindle - T10254/5-
2- Nut - T10254/4-
3- Press tool - 3416/2-
5- Tube - T10263/6-
9- Nut - T10254/4-
– Take up play in special tools.

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– Tube - T10263/6- -1- must be positioned on bonded rubber

bush so that outer circumference is able to rest evenly on axle
beam -arrow-.
– Pull out bonded rubber bush by operating the pump.
Note
The outer ring of the bush shears off when the bonded rubber
bush is pulled out. This occurs with a loud bang.
– The bonded rubber bush must be removed from the tube -

T10356/6- once the bush has been pulled out.
– Clamp tube - T10356/6- on the intended surfaces in a vice.
– Insert a screwdriver between tube - T10356/6- and bonded
rubber bush and lever bush out of tube -arrow-. If necessary,
apply a drift to bush and drive out with light hammer blows.
Installing
– Bolt new bonded rubber bush with specified special tools.

1- Spindle - T10254/5-
2- Nut - T10254/4-
3- Press tool - 3416/1-
5- Press tool - 3416/2-
6- Nut M12 x 1.5, commercially available
Face end of bonded rubber bush is equipped with a lug, which fits
precisely into recess on thrust piece - 3416/2- -5-.
– Mark position of lug on long side of bonded rubber bush
-arrow-.
2. Axle beam 135

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– Fit bonded rubber bush and special tools to the rear axle.
1- Spindle - T10254/5-
2- Nut - T10254/4-
6- Tube - T10263/6-
8- Press tool - 3416/1-
9- Nut - T10254/4-
– Before pressing in bonded rubber bush, make sure that mark‐

ing you previously made aligns with edge -arrow- of axle
beam.
– Pressing in bonded rubber bush.
– After mounting, check installed position of bonded rubber
bush.
– Grease the kidney-shaped cavities on the bonded rubber bush
with assembly paste - G 052 150 A2- before installing rear
axle.
Noises can occur when the vehicle is driven if the rear axle is
installed “dry”.
– Tighten rear axle in unladen position ⇒ page 7 .
– Bleed brake system ⇒ Brake system; Rep. gr. 47 ; Hydraulic
system; Bleeding hydraulic system following standard proce‐
dure .
Specified torques
page 157
♦ Brake lines to brake hose ⇒ Brake system; Rep. gr. 46 ; Rear
brake

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3 Suspension strut, shock absorber,

spring
⇒ “3.1 Assembly overview - suspension strut, shock absorber,
spring”, page 137
⇒ “3.2 Removing and installing shock absorbers”, page 139
⇒ “3.3 Repairing shock absorber”, page 142
⇒ “3.4 Removing and installing spring”, page 146
3.1 Assembly overview - suspension strut,

shock absorber, spring
⇒ “3.1.1 Assembly overview – suspension strut/shock absorber,
spring, basic version of running gear”, page 137
⇒ “3.1.2 Assembly overview – suspension strut/shock absorber,
spring, Sport Select running gear”, page 138
3.1.1 Assembly overview – suspension strut/shock absorber, spring, basic ver‐

sion of running gear
1 - Cap
2 - Nut
❑ Self-locking
moval
❑ Unscrewing
⇒ page 138
❑ 25 Nm
3 - Shock absorber mounting
4 - Buffer stop
5 - Securing ring
6 - Protective tube
7 - Cap
8 - Gas-filled shock absorber
❑ Can be renewed sepa‐
rately
Checking function
Compress shock absorber by

hand. It should be possible to
press in the piston rod smooth‐
ly and with uniform force over
the full travel.
The piston rod will return to its

initial position if there is suffi‐
cient gas pressure in the shock
absorber.
If the piston rod does not return to its initial position by itself, the shock absorber may still be usable, provided
there is no loss of fluid.
3. Suspension strut, shock absorber, spring 137

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Remove hexagon nut from gas-filled shock absorber.

1- Commercially available ratchet handle
2- Insert - T10001/9-
3- -T10001/11-
4- Insert - T10001/1-
3.1.2 Assembly overview – suspension strut/shock absorber, spring, “Sport Se‐

lect” running gear
1 - Shock absorbers
⇒ page 139
2 - Protective tube
3 - Buffer stop
4 - Shock absorber mounting
5 - Nut
❑ Self-locking
moval
❑ 30 Nm
6 - Cable guide
7 - Cap
8 - Clip

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3.2 Removing and installing shock absorb‐

ers
⇒ “3.2.1 Removing and installing shock absorber, basic version
of running gear”, page 139
⇒ “3.2.2 Removing and installing shock absorber, Sport Select
running gear”, page 140
3.2.1 Removing and installing shock absorb‐

er, basic version of running gear
Removing
– Unscrew and remove bolts -1-. If necessary, lift vehicle until
bolts are accessible.

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– Unscrew and remove nut -1-, take out hexagon bolt -2- for
shock absorber -3- from rear axle.
– Take out shock absorber.
Installing
– Fit shock absorber.
– Bolt shock absorber -3- to rear axle using new hexagon bolt
-2- and new nut -1-.
– Bolt shock absorber to body.
– Tighten bolts in unladen state ⇒ page 7 .
Specified torques
3.2.2 Removing and installing shock absorb‐

er, “Sport Select” running gear

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Removing
– Disconnect connector -1-.
– Unscrew and remove bolts -1-. If necessary, lift vehicle until

bolts are accessible.
– Unscrew and remove nut -1-, take out hexagon bolt -2- for
shock absorber -3- from rear axle.
– Take out shock absorber.
Installing
– Fit shock absorber.
– Bolt shock absorber -3- to rear axle using new hexagon bolt
-2- and new nut -1-.
– Bolt shock absorber to body.

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– Connect connector -1-.

– Tighten bolts in unladen state ⇒ page 7 .
Specified torques
3.3 Repairing shock absorber

⇒ “3.3.1 Repairing shock absorber, basic version of running gear”,
page 142
⇒ “3.3.2 Repairing shock absorber, Sport Select running gear”,
page 143
3.3.1 Repairing shock absorber, basic version

of running gear
♦ Ring spanner insert (commercial type, e.g. »Hazet 6630c-21«)

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– Remove shock absorber ⇒ page 139 .

Loosening and tightening threaded connection for shock absorb‐
er mounting
1- Ring spanner insert (commercial type, e.g. »Hazet
6630c-21«)
2- Insert - T10001/9-
3- Commercially available ratchet handle
5- Insert - T10001/1-
6- Shock absorber mounting
Install in reverse order. During this procedure, observe the fol‐
lowing:
Specified torques
♦ ⇒ “3.1.1 Assembly overview – suspension strut/shock absorb‐
er, spring, basic version of running gear”, page 137
3.3.2 Repairing shock absorber, “Sport Select” running gear

equipment required

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♦ Socket, 18 mm - 3353-
♦ Release tool set - VAS 1978/35-
– Knock terminals out of shock absorber connector using re‐
lease tool set - VAS 1978/35- .
– Pull cap -1- off shock absorber mounting -2-.
– Remove line -2- from cable guide -1-.

– Lever cable guide -1- off nut for shock absorber.
Loosening threaded connection for shock absorber mounting

– When loosening nut for shock absorber mounting, counterhold
on hexagon of shock absorber rod -3- with 9 mm open-end
spanner.
1- Socket AF 18 - 3353-
3- Hexagon of shock absorber rod
4- 9 mm open-end spanner
lowing:

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Tightening threaded connection for shock absorber mounting

– When tightening nut for shock absorber mounting, counterhold
on hexagon of shock absorber rod -3- with 9 mm open-end
spanner.
1- Socket AF 18 - 3353-
3- Hexagon of shock absorber rod
4- 9 mm open-end spanner
– Fit cable guide -1- onto nut for shock absorber.

– Position cable guide -1- so that it points toward recess
-arrow- in shock absorber mounting.
– Insert line -2- into cable guide -1-.
– Fit cap -1- onto shock absorber mounting -2-.

– Make sure that cable is guided through cable gland
-arrow A-.
– Position cap -1- on shock absorber mounting -2- so that lug
-arrow B- makes contact with shock absorber mounting.
– Push cable through grommet.
– Insert cable lug into connector housing.
Pin assignment
1- Brown
2- Black
– Install shock absorber ⇒ page 139 .
Specified torques
♦ ⇒ “3.1.2 Assembly overview – suspension strut/shock absorb‐
er, spring, Sport Select running gear”, page 138

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3.4 Removing and installing spring

⇒ “3.4.1 Removing and installing spring, vehicles with small rear
silencer”, page 146
⇒ “3.4.2 Removing and installing spring, vehicles with large rear
silencer”, page 147
3.4.1 Removing and installing spring, vehicles

with small rear silencer
♦ Spring retainer - V.A.G 1752/3A-

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Removing
– Insert spring compressor -1-.
2- Spring retainer - V.A.G 1752/3A-
WARNING
Make sure that the coil spring is seated correctly in the spring
retainer - V.A.G 1752/3A- -3- (risk of accident).
– Compress coil springs until they can be removed.
Note
Use a spanner or a reversible ratchet handle to compress spring

compressor.
Installing
– Check that the lower spring plate is not damaged.
– If necessary, renew lower spring plate.
– Insert upper spring seat into upper end of spring.

– Bead of spring seat -arrow- must lie against coil spring cor‐
rectly.
– Take the pressure off the spring and remove the spring com‐
pressor (do not damage protective surface of the spring).
3.4.2 Removing and installing spring, vehicles

with large rear silencer

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♦ Spring retainer - V.A.G 1752/3A-
♦ Adapter - V.A.G 1752/9-

Removing
– Insert spring compressor -1-.
2- Adapter - V.A.G 1752/9-
3- Spring retainer - V.A.G 1752/3A-
WARNING
Make sure that the coil spring is seated correctly in the spring
retainer - V.A.G 1752/3A- -3- (risk of accident).
– Compress coil springs until they can be removed.
Note
Use a spanner or a reversible ratchet handle to compress spring

compressor.
Installing
– Check that the lower spring plate is not damaged.
– If necessary, renew lower spring plate.
– Insert upper spring seat into upper end of spring.

– Bead of spring seat -arrow- must lie against coil spring cor‐
rectly.
– Take the pressure off the spring and remove the spring com‐
pressor (do not damage protective surface of the spring).
– Install shock absorber ⇒ page 139 .
Specified torques

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4 Wheel bearing assembly, trailing arm

⇒ “4.1 Assembly overview - wheel bearing”, page 149
⇒ “4.2 Removing and installing wheel bearing unit”, page 151
4.1 Assembly overview - wheel bearing

⇒ “4.1.1 Assembly overview – wheel bearings, drum brake”, page
149
⇒ “4.1.2 Assembly overview – wheel bearings, disc brake”, page
150
4.1.1 Assembly overview – wheel bearings, drum brake
1 - Axle beam
⇒ page 123
2 - Brake backplate with brake
shoes
❑ Repairing ⇒ Brake sys‐
tem; Rep. gr. 46 ; Rear
brake; Assembly over‐
view - rear brake
3 - Bolt
❑ 30 Nm +90°
moval
4 - Stub axle
❑ Must not be straight‐
ened
❑ Recutting the thread is
not permitted
5 - Wheel hub with wheel bear‐
ing
❑ The ABS sensor ring is
installed in the wheel
hub
⇒ page 151
The wheel bearing and wheel
hub are assembled in one
housing.
The wheel hub with wheel

bearing unit is maintenance
and adjustment-free. Adjust‐
ments and repairs are not pos‐
sible!
6 - 12-point nut Volkswagen Technical Site: http://vwts.ru http://vwts.info

❑ Self-locking
❑ 70 Nm +30°
7 - Dust cap
4. Wheel bearing assembly, trailing arm 149

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8 - Brake drum
9 - Bolt
❑ 4 Nm
4.1.2 Assembly overview – wheel bearings, disc brake
1 - Axle beam
⇒ page 123
2 - Bolt
⇒ Brake system; Rep. gr. 46 ;
Rear brake; Assembly over‐
view - rear brake
3 - Cover plate
4 - Brake caliper
5 - Stub axle
❑ Straightening opera‐
tions are not permitted
❑ Recutting the thread is
not permitted
6 - Bolt
moval
❑ 30 Nm +90°
7 - Wheel hub with wheel bear‐
ing
⇒ page 153
The wheel bearing and wheel
hub are assembled in one
housing.
The wheel hub with wheel

bearing unit is maintenance
and adjustment-free. Adjust‐
ments and repairs are not pos‐
sible!
8 - 12-point nut
❑ Self-locking
❑ 70 Nm +30°
9 - Dust cap

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10 - Brake disc
11 - Bolt
❑ 4 Nm
4.2 Removing and installing wheel bearing

unit
⇒ “4.2.1 Removing and installing wheel bearing unit, vehicles with
drum brake”, page 151
⇒ “4.2.2 Removing and installing wheel bearing unit, vehicles with
disc brake”, page 153
4.2.1 Removing and installing wheel bearing unit, vehicles with drum brake

equipment required
♦ Hub grease cap puller - VW 637/2-

♦ Drift sleeve - 3241/4-

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Removing
– Raise vehicle.
– Remove wheel.
– Release brake.
– To do this, insert a screwdriver through a hole in the brake
drum and push the wedge upwards.
– Unscrew bolt for brake drum and remove brake drum.
– Loosen grease cap from seat by tapping lightly on the claw of

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

– Remove twelve-point nut.
– Pull wheel hub/wheel bearing unit from stub axle.
Installing
– Carefully push wheel hub/wheel bearing unit onto stub axle.
Ensure that wheel hub/wheel bearing unit does not cant.
– Use and tighten new 12-point nut.

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– Drive in dust cap.

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
4.2.2 Removing and installing wheel bearing unit, vehicles with disc brake

equipment required
♦ Hub grease cap puller - VW 637/2-

♦ Drift sleeve - 3241/4-

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Removing
– Raise vehicle.
– Remove wheel.
– Loosen grease cap from seat by tapping lightly on the claw of
the hub grease cap puller - VW 637/2- .
– Pry off grease cap.

– Unscrew brake caliper and hang up on body.
– Remove bolt for brake disc and remove brake disc.
– Remove twelve-point nut.
– Pull wheel hub/wheel bearing unit from stub axle.
Installing
– Carefully push wheel hub/wheel bearing unit onto stub axle.
Ensure that wheel hub/wheel bearing unit does not cant.
– Tighten new 12-point nut.
– Drive in dust cap.

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

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43 – Self-levelling suspension
1 Electronically controlled damping
system
⇒ “1.1 Assembly overview - electronically controlled damping
system”, page 155
⇒ “1.2 Removing and installing electronically controlled damping
control unit J250 ”, page 155
1.1 Assembly overview - electronically controlled damping system
1 - Front right shock absorber

suspension strut
⇒ page 33 .
❑ Repairing suspension
strut ⇒ page 41 .
2 - Shock absorber (rear right)
shock absorber
⇒ page 140 .
❑ Repairing shock ab‐
sorber ⇒ page 143 .
3 - Shock absorber (rear left)
shock absorber
⇒ page 140 .
❑ Repairing shock ab‐
sorber ⇒ page 143 .
4 - Front left shock absorber
suspension strut
⇒ page 33 .
❑ Repairing suspension
strut ⇒ page 41 .
5 - Electronically controlled
damping control unit - J250-
⇒ page 155
❑ Fitting location: elec‐
tronically controlled
damping control unit -
J250- is installed under
dash panel on driver
side.
❑ Function Replace control unit must be performed with ⇒ Vehicle diagnostic tester if electronically
controlled damping control unit - J250- is renewed.
1.2 Removing and installing electronically

controlled damping control unit - J250-
♦ Vehicle diagnostic tester
1. Electronically controlled damping system 155

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Removing
Fitting location: electronically controlled damping control unit -
J250- is installed under dash panel on driver side.
– Unbolt the earth strap from the battery ⇒ Electrical system;
Rep. gr. 27 ; Battery; Disconnecting and connecting battery .
– Withdraw ignition key.
Vehicles with keyless entry and start system “Keyless Access”
– Switch off ignition and open driver’s door so that the steering
lock engages.
– Remove dash panel end cover ⇒ General body repairs, inte‐
rior; Rep. gr. 70 ; Dash panel; Removing and installing dash
panel end cover .
– Release the release lever of connector -1-.
– Push lugs -arrows- upwards.
– Pull electronically controlled damping control unit - J250- -2-
out of bracket.
Installing
ing:
– Function Replace control unit must be performed with
⇒ Vehicle diagnostic tester if electronically controlled damping
control unit - J250- has been renewed.
156 Rep. gr.43 - Self-levelling suspension

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2 Vehicle level sender

⇒ “2.1 Assembly overview - rear vehicle level senders”,
page 157
⇒ “2.2 Removing and installing rear vehicle level senders G76 /
G77 ”, page 157
2.1 Assembly overview - rear vehicle level senders
Note
The vehicle level sender is available as a replacement part only complete with coupling rod and retaining plate.
1 - Bolt
❑ 20 Nm
2 - Rear left vehicle level send‐
er - G76-
❑ Complete with attach‐
ments
⇒ page 157
❑ Once new part has been
fitted, carry out basic
setting ⇒ Vehicle diag‐
nostic tester
3 - Bolt
❑ 20 Nm
4 - Bracket
5 - Bolt
❑ 15 Nm
6 - Axle beam
2.2 Removing and installing rear vehicle

level senders -G76- / -G77-
2. Vehicle level sender 157

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Removing
– Unscrew bolt -2- from axle body.
– Unscrew bolt -3- from bracket.
– Remove rear left vehicle level sender - G76- .
Installing
lowing:
– On vehicles with vehicle level sender, carry out basic setting
⇒ Vehicle diagnostic tester.
Specified torques
page 157
158 Rep. gr.43 - Self-levelling suspension

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44 – Wheels, tyres, vehicle geometry

1 Wheels, tyres
⇒ “1.1 Pressing tyre off wheel rim”, page 159
⇒ “1.2 Removing tyre from wheel”, page 159
⇒ “1.3 Mounting tyre”, page 160
⇒ “1.4 Wheel change”, page 160
⇒ “1.5 Specified torques for wheel bolts”, page 164
⇒ “1.6 Tyre sealant”, page 164
⇒ “1.7 Tyre sealant disposal”, page 164
⇒ “1.8 Models with breakdown set”, page 164
1.1 Pressing tyre off wheel rim

– Remove air from tyre by screwing out the nickel-plate valve
element.
– Always ensure when pressing off a tyre using tyre fitting equip‐
ment with a press-off plate, that the tyre valve -arrow- is
directly opposite the press-off plate -1-.
The bead breaker must be positioned no more than 2 cm away
from the rim flange.
– Remove balancing weights and dirt from wheel rim.
– Press both tyre beads off all round and liberally coat tyre and
wheel rim flange with tyre assembly paste -arrow-.
1.2 Removing tyre from wheel

Tyres which have been filled or sealed using tyre sealant must be
drained before removal.
1. Wheels, tyres 159

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Caution
♦ Avoid eye and skin contact with tyre sealant.

♦ It is damaging to health and can cause eye irritation and
allergies.
♦ During this work, wear protective gloves and safety gog‐
gles.
– Place the wheel on an even surface.

– Unscrew and remove the valve insert of tyre valve.
– Use a suitable drill or mill to carefully drill a hole in shoulder
area of tyre.
– Hold wheel over a suitable container and drain sealant.
– Pull tyre from rim.
– Clean wheel rim with, for example, a moist cloth.
1.3 Mounting tyre

• Ensure that the wheel rim is clean.
– Insert new tyre valve with -VAS 6459- -1-.
– Unscrew and remove valve insert.
– Inflate tyre to approx. 3 … 4 bar. The bead of the tyre must slip
audibly over the hump of the rim.
– Screw in valve insert.
– Check tyre pressure to make sure prescribed pressure has
been reached.
– Balance wheel.
1.4 Wheel change

⇒ “1.4.1 Wheel change, protecting wheel centring seat against
corrosion”, page 160
⇒ “1.4.2 Wheel change, installation requirements”, page 161
⇒ “1.4.3 Wheel change, installation instructions for wheel
change”, page 162
⇒ “1.4.4 Wheel change, wheel installation”, page 163
1.4.1 Wheel change, protecting wheel cen‐

tring seat against corrosion
Applies to alloy and steel wheels
When changing a wheel, wheel centring seat should be waxed
using wax spray to prevent corrosion between wheel centring seat
and wheel rim ⇒ Electronic parts catalogue “ETKA” .
160 Rep. gr.44 - Wheels, tyres, vehicle geometry

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– Remove wheel.
– Thoroughly clean wheel centring seat on wheel hub and the
centring ring of the wheel rim.
– Apply wax to centring area -arrow- with a brush.
Ensure that only centring ring -arrow- but not contact surface of
wheel rim has been waxed. Otherwise, the brakes will be soiled,
which would reduce the braking efficiency.
WARNING
Wheel bolts, contact surfaces of wheel hub and wheel rim and
wheel hub threads must not be waxed. Never treat wheel se‐
curing bolts with lubricant or corrosion protection materials!
1.4.2 Wheel change, installation require‐

ments
Warming cold tyres to minimum fitting temperature
Note
This instruction also applies to ultra-high performance tyres (as‐

pect ratio less than or equal to 45 % and speed symbol V or
higher).
WARNING
The minimum fitting temperature of a tyre should be between

15 °C and 30 °C in the core of the tyre.
• To install tyres without damage, it is especially important to

warm the upper part of the sidewall and the inside of the upper
bead to at least 15℃.
• This internal temperature is referred to as the core tempera‐
ture.
• Rubber is a poor conductor of heat. Therefore, a cold tyre must
be left in an area with the correct temperature for a sufficiently
long period so the inner rubber layers can warm up to at least
15°C.
• The surface temperature of the tyre during the warming up
phase is no indication of the internal temperature of the tyre.
• To enable cold tyres to absorb heat from the ambient air as
quickly as possible, they should not be stacked on top of one
another. Instead, the tyres should be stored individually in or‐
der to allow the warm air to “circulate” around them effectively.
• Tyres must never be placed in front of a radiator or hot air
blower for warming, since this can very quickly lead to critical
surface temperatures.
• Heating the tyres without damage can only be achieved by
heating with warm water or warm air (max. 50°C)!
• If cold tyres (below 0℃) are transferred to a warm environment
(above 0℃), a layer of condensation immediately forms on the
surface of the tyre. This layer of condensation indicates that
the tyre is intensively absorbing heat from its environment

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through the process of water vapour in the air condensing out

on the tyre surface.
• Once the layer of frost has thawed, condensate water forms.
The condensation should be dried with a cloth so that the fur‐
ther warming process is not delayed due to a temperature drop
caused by evaporation.
Warming times:
♦ Tyres with a temperature of above 0°C must be kept at least
at 19℃ for at least 2 hours.
♦ Tyres with a temperature of below 0°C must be kept at least
at 19℃ for at least 2.5 hours.
Warming recommendations:
♦ If possible, tyres should be stored in the workshop 1 day before
they are fitted (order preparation).
♦ Store on an insulated base, pallet or on a similar surface raised
from the floor.
♦ Position the tyres individually to allow the warm air to “circu‐
late” around them effectively.
♦ Wipe off condensation
♦ Never heat with a radiator or hot air blower!
♦
1.4.3 Wheel change, installation instructions

for wheel change
WARNING
Perform the checks and follow the instructions listed below.

This is important to ensure that the wheel bolts and the wheels
are properly secured.
Note
On vehicles with Tyre Pressure Loss Indicator, the Tyre Pressure

Loss Indicator has to be recalibrated any time one or more wheels
are removed or fitted ⇒ page 166 .
– Check to ensure that contact surfaces -arrows- on brake disc

are free of corrosion and dirt.

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– Check to ensure that contact surface -arrow- on centring seat

of brake disc are free of corrosion and dirt.
– Check to ensure that contact surface -arrow- on inner side of

wheel (rim) and also centring seat of rim are free of corrosion
and dirt.
– The lug seats* in the holes for the wheel bolts and the threads
of the wheel bolts must also be free of corrosion and dirt, oil
or grease.
*The lug seat is the curved surface of a section of a sphere cut
by a plane.
– Check whether the wheel bolts can be easily screwed in by

hand. The thread of the wheel bolts must not come into contact
with the bore in the brake disc -arrow-.
If the thread of the wheel bolt touches the hole -arrow-, turn the
brake disc relative to the wheel hub accordingly.
If necessary, remove dirt and corrosion:
♦ Oil or grease from contact surfaces
♦ Oil or grease from threads in wheel hub
♦ Oil or grease from threads in wheel bolts
WARNING
Damaged, badly corroded or difficult to remove wheel bolts

must be renewed.
1.4.4 Wheel change, wheel installation

– Preserving wheel centring seat ⇒ page 160 .
1- When fitting the wheel, pull in all wheel bolts uniformly by
hand.
2- Tighten diagonally to 30 Nm.
3- Lower vehicle onto floor. Use torque wrench to firmly tighten
wheel bolts diagonally to specified torque ⇒ page 164 .
WARNING
Do not use an impact screwdriver to screw in the bolts.

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1.5 Specified torques for wheel bolts

Wheel bolt to wheel hub for all vehicles:
Specified torque: 120 Nm
– Before fitting wheel, protect wheel centring seat against cor‐
rosion ⇒ page 160 .
♦ Install anti-theft wheel bolts using adapter set for wheel bolts .
1.6 Tyre sealant

The tyre sealant in the bottle has a limited shelf life.
Therefore, the expiry date is indicated on the bottle -arrow-.
In this example, the expiry date 05/2003 has expired. The bottle
must then be renewed.
If the bottle was opened e.g. at a "flat tyre", it must also be re‐
newed.
1.7 Tyre sealant disposal

♦ Tyre sealant or residue must not be mixed or disposed of with
other fluids.
♦ Excess tyre sealant must be collected and stored in a plastic
container. The plastic container can be disposed of through
the disposal system along with the breakdown set (when the
expiry date is exceeded)
♦ The items can be returned or disposed of through the existing
workshop disposal system.
♦ Contact the service provider or the waste disposal officer of
the sales centre or importer.
1.8 Models with breakdown set

Polo vehicles are equipped with either a spare wheel or a break‐
down set.
The tyre mobility set can be found in the luggage compartment
where normally the spare wheel would sit. It consists of a com‐
pressor -2- and a bottle of tyre sealant -1-.

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2 Tyre pressure monitoring system

⇒ “2.1 System description - tyre pressure monitoring system”,
page 165
2.1 System description - tyre pressure mon‐

itoring system
The tyre pressure monitoring system is part of the software in the
ABS control unit - J104- . The system is used to detect slow tyre
pressure loss from a wheel. Event memory entries for the Tyre
Pressure Loss Indicator are stored in the ABS control unit - J104- .
The Tyre Pressure Loss Indicator compares the speed and the
rolling circumference of the individual wheels via the ABS sen‐
sors.
After the following work or modifications, the tyre pressure mon‐
itor display button - E492- must be pressed and held until a
confirmation is sounded.
♦ Change in tyre pressures
♦ Changing one or more wheels
♦ Interchanging wheels, e.g. from front to rear
♦ Removing and fitting one or more wheels
A change in a wheel's rolling circumference will be indicated by
the tyre pressure monitor warning lamp - K220- lighting up in the
dash panel insert. A tyre's rolling circumference may change as
a result of:
♦ Insufficient tyre pressure
♦ Structural tyre damage
♦ Uneven load distribution in the vehicle
♦ Increased load on one axle, e.g. due to towing a trailer
♦ Use of snow chains.
♦ Temporary spare wheel installed
♦ Wheel renewal
2. Tyre pressure monitoring system 165

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System fault in the ABS system

If a fault in the ABS is displayed by the ESP and TCS warning
lamp - K155- or the traction control system warning lamp - K86- ,
then the tyre pressure loss indicator warning lamp - K220-
-arrow- will also light up. However, no fault will be stored in the
Tyre Pressure Loss Indicator system.
The warning lamp cannot be extinguished by pressing the TPM
button - E492- . In this case, please carry out the following steps:
– Connect ⇒ Vehicle diagnostic tester, and select “Guided Fault
Finding” ⇒ Vehicle diagnostic tester.
Follow instructions on screen to perform basic setting.
Perform basic settings
Running gear
Brake system
01 - Self-diagnosis compatible system
Anti-lock brake system ABS Bosch 8.2 or Anti-lock

brake system ABS/EDS/ASR/ESP Bosch 8.2i (depending on
version)
Functions
Tyre pressure monitor display / Tyre pressure warning
Follow instructions on screen to perform basic setting.

Perform basic settings
Following each wheel change, the SET button must be actuated

whilst the ignition is switched on and the vehicle is stationary until
an audible signal is sounded. An audible signal confirms that ba‐
sic setting has been performed.
Note
The SET button is located in the glove compartment.

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3 Wheel alignment
⇒ “3.1 Notes for wheel alignment”, page 167
⇒ “3.2 Conditions for testing”, page 167
⇒ “3.3 Test preparations”, page 168
⇒ “3.4 Specifications for wheel alignment”, page 170
⇒ “3.5 Wheel alignment procedure”, page 172
⇒ “3.6 Necessity of wheel alignment”, page 173
⇒ “3.7 Vehicle data sticker”, page 174
⇒ “3.8 Adjusting camber at front wheels”, page 174
⇒ “3.9 Adjusting camber on rear axle”, page 175
⇒ “3.10 Adjusting toe at rear axle”, page 176
⇒ “3.11 Adjusting front axle toe”, page 176
⇒ “3.12 Checking maximum wheel lock”, page 176
3.1 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.
Otherwise, the steering rack may not be centred!
– Perform all measurements with wheel alignment computer.
All the information on wheel alignment can be found in the wheel
alignment computer.
Current data »updates« are located in VW ServiceNet.
⇒ VW ServiceNet; Systems; Wheel alignment computer soft‐
ware; Wheel alignment; Beissbarth
ware; Wheel alignment; Hunter
ware; Wheel alignment; Corghi
ware; Wheel alignment; John Bean
Note
♦ Wheel alignment should not be checked before the vehicle has

completed 1000 to 2000 km after the coil springs have settled.
♦ When making adjustments, adhere to the relevant specifica‐
tions as closely as possible.
3.2 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.
3. Wheel alignment 167

Polo 2014 ➤
• 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:
• The test equipment must be properly adjusted and attached
to the vehicle; observe device manufacturer's operating in‐
structions.
If necessary, ask the manufacturer to show you how to use the
wheel alignment machine.
Wheel alignment platforms and wheel alignment computers can
lose their original calibration over a period of time.
Wheel alignment platforms and computers should be checked
and adjusted as necessary during inspection and maintenance at
least once per year!
– Handle these highly sensitive devices carefully and conscien‐
tiously.
3.3 Test preparations

⇒ “3.3.1 Test preparations, wheel alignment with no driver assist
systems”, page 168
⇒ “3.3.2 Test preparations, wheel alignment with driver assist
systems”, page 170
3.3.1 Test preparations, wheel alignment with no driver assist systems

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equipment required
♦ Wheel alignment computer - V.A.G 1813F- or VW/Audi-ap‐

proved wheel alignment units
♦ Insert tool, 18 mm - T10179-
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.
– Use brake pedal depressor to depress brake pedal.

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Preparations required before calibration of driver assist systems
3.3.2 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):
• Before driving the vehicle onto the alignment platform, make
sure there is sufficient space between the vehicle and the cal‐
ibration unit. The distance between the calibrating device and
the vehicle must be 120 cm ± 2.5 cm.
• If the available space is not adequate, move the vehicle back‐
wards on the alignment platform as required. This allows the
use of the respective floor area.
• Before starting calibration, read out event memory and rectify
any faults.
• Vehicle accurately aligned, suspension bounced and rocked
several times.
• When checking wheel alignment, ensure that sliding plates
and turn tables are not touching end stop.
• Connect battery charger ⇒ Electrical system; Rep. gr. 27 ;
Battery; Disconnecting and reconnecting battery .
• Move front wheels to straight-ahead position.
• Connect ⇒ Vehicle diagnostic tester to vehicle, route diagnos‐
tic cable through open door window.
• Vehicle exterior lighting switched off.
• All doors of vehicle are closed.
• Press button to select required calibration on wheel alignment
computer.
3.4 Specifications for wheel alignment

These specifications apply to all engines.
♦ Explanation of PR numbers can be found here ⇒ page 174 .
The ride heights shown in the table refer to dimension -a-.
Front axle Standard running Sports running gear “Sport Select” running
gear gear
PR numbers G10/G72 G12, G70 G53
Total toe (without load) +10' ± 10’ +10' ± 10’ +10' ± 10’
Camber (in straight-ahead position) -28’ ± 30’ -39’ ± 30’ -39’ ± 30’
Maximum permissible difference be‐ max. 30′ max. 30′ max. 30′
tween sides

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Front axle Standard running Sports running gear “Sport Select” running
gear gear
PR numbers G10/G72 G12, G70 G53
Toe-out on turns at 20° left and right 1° 19′ ± 20′ 1° 20′ ± 20′ 1° 20′ ± 20′
lock 1)
Castor +4° 54’ ± 30’ +5° 09′ ± 30′ +5° 09′ ± 30′
(not adjustable)
tween sides
Ride height 366 ± 10 mm 351 ± 10 mm 351 ± 10 mm
1)
Toe-out on turns can be displayed as a negative value on the
wheel alignment computer, depending on the manufacturer.
These specifications are valid for all engines at “zero position” of
transverse vehicle inclination.
♦ Explanation of “zero position” of transverse vehicle inclination
⇒ page 172
♦ Explanation of PR numbers can be found here ⇒ page 174
Front axle GTI Raised running gear

with “Sport Select”
running gear
PR numbers G54/G74 G13/G73
Total toe (without load) +10' ± 10’ +10' ± 10’
Camber (in straight-ahead position) -39’ ± 30’ -15’ ± 30’
Maximum permissible difference be‐ max. 30′ max. 30′
tween sides
Toe-out on turns at 20° left and right 1° 20′ ± 20′ 1°18’ ± 20’
lock 1)
Castor +5° 09′ ± 30′ +4° 40′ ± 30′
(not adjustable)
tween sides
Ride height 351 ± 10 mm 381 ± 10 mm
1)
Toe-out on turns can be displayed as a negative value on the
wheel alignment computer, depending on the manufacturer.
These specifications are valid for all engines at “zero position” of
transverse vehicle inclination.
♦ Explanation of “zero position” of transverse vehicle inclination
⇒ page 172
♦ Explanation of PR numbers can be found here ⇒ page 174
Rear axle Standard running Sports running gear “Sport Select” running
gear gear
Camber -1° 30′ ± 10′ -1° 30′ ± 10′ -1° 30′ ± 10′
tween sides
Total track (at prescribed camber) +21’ ± 10’ +26’ ± 10’ +26’ ± 10’
Max. permissible deviation from di‐ max. 20′ max. 20′ max. 20′
rection of travel

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Rear axle Standard running Sports running gear “Sport Select” running
gear gear
Ride height 383 ± 10 mm 368 ± 10 mm 368 ± 10 mm
Rear axle GTI Raised running gear

with “Sport Select”
running gear
Camber -1° 30′ ± 10′ -1° 30′ ± 10′
tween sides
Total track (at prescribed camber) +26’ ± 10’ +16’ ± 10’
Max. permissible deviation from di‐ max. 20′ max. 20′
rection of travel
Ride height 368 ± 10 mm 398 ± 10 mm
If measured values are outside specified tolerances, this may be

because the vehicle is inclined.
Right-hand drive vehicles or e.g. vehicles with an automatic gear‐
box may lean to one side slightly.
This is due to the installation position of the assemblies and their
associated weight transfer and is normal.
– Then make sure to check the distance -a- on the left and right
at the rear.
– Correct any difference is there is any.
On the front axle, compensate by adding weights to the top of the
respective suspension turret.
On the rear axle, compensate by adding weights to the respective
side of the luggage compartment.
Sand-filled sacks (weighing approx. 10 kg) are suitable for this.
3.5 Wheel alignment procedure

Always adhere to the following procedure!
– Take note of the information in the wheel alignment unit.
Alignment procedure
Start → Carry out wheel runout com‐ → Bounce springs.

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 lock in place 1)
↓
Check front axle camber → Is actual value within toler‐ → no
ance?
↓ ↓
↓ ← ← yes Camber correction ⇒ page 174
↓ ↓
↓ ← ← ← ← ←
↓
Check rear axle camber → Is actual value within toler‐ → no
ance?
↓ ↓
↓ ← ← yes Checking ⇒ page 175
↓ ↓
↓ ← ← ← ← ←
↓
Check rear axle toe → Is actual value within toler‐ → no
ance?
↓ ↓
↓ ← ← yes Checking ⇒ page 176
↓ ↓
↓ ← ← ← ← ←
↓
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 176
↑ ↓
↑ ← ← ← ← ←
1)If steering wheel is not centred, it must be straightened after
wheel alignment is finished. Then, perform basic setting of steer‐
ing angle sender - G85- using vehicle diagnostic tester ⇒ Vehicle
diagnostic tester.
3.6 Necessity of wheel alignment

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

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♦ 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
Suspension link X Shock absorbers X
Wheel bearing housing X Coil spring X
Track rod/track rod ball joint X Torsion beam axle X
Steering rack X
Subframe X
Suspension strut X
Anti-roll bar X
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
Suspension link X Shock absorbers X
Wheel bearing housing X Coil spring X
Track rod/track rod ball joint X Torsion beam axle X
Steering rack X
Subframe X 1)
Suspension strut X
Anti-roll bar X
1)Prerequisite: the position of the subframe was fixed before the
part was removed ⇒ page 13 .
3.7 Vehicle data sticker

Information on the individual running gear that is fitted is currently
not available on the data sticker.
To find information about the running gear, please search in EL‐
SA/Vehicle-specific notes.
In this example the vehicle is equipped with standard running gear
G10 -arrow-.
3.8 Adjusting camber at front wheels


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

ber cannot be adjusted. However, it can be mediated by
shifting the subframe!
♦ Move subframe only to left or right, but never in or opposite to
direction of normal travel.

– Remove bolts -1- to -4- for the subframe on the body.
The camber adjustment range is limited by the tolerances of the
holes in the subframe. If the specified value is not reached by
shifting the subframe, this and the body must be inspected
⇒ page 1 .
– Now camber may be adjusted to specification by moving sub‐
frame.
– Tighten new bolts for subframe to body to specified torque plus
extra turn angle.
After shifting subframe, check clearance between steering col‐
umn universal joint and cut-out in bulkhead.
– Fold floor covering back slightly.
There must be a clearance of 5 mm all around between universal

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

Camber cannot be adjusted.
If a value lies outside the tolerances, the vehicle's transverse in‐
clination must be checked and, if necessary, compensated for
⇒ page 172 .

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If the measured values lie outside the permitted tolerances, the

axle beam must be checked for damage and if necessary re‐
newed.
3.10 Adjusting toe at rear axle

Toe cannot be adjusted.
If a value lies outside the tolerances, the vehicle's transverse in‐
clination must be checked and, if necessary, compensated for
⇒ page 172 .
If the measured values lie outside the permitted tolerances, the
axle beam must be checked for damage and if necessary re‐
newed.
3.11 Adjusting front axle toe

– Loosen lock nut -1-.
– Adjust toe by turning left and/or right track rod.
To do this use an open-end spanner on the hexagon -arrow- on
the track rod.
After turning track rods, ensure that boots are not twisted.
Twisted boots wear out quickly.
– Tighten lock nut -1-.
– Check toe values again.
It is possible that the value will change slightly when lock nut -1-
is tightened.
However, if the measured toe value lies within the tolerance, the
adjustment is correct.
Specified torques
♦ ⇒ “3.3 Repairing steering rack”, page 225
3.12 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?
♦ Are track rods visually OK.?
♦ Is the symmetry of the track rods OK.?
Damaged components must be renewed.
– If the steering wheel is found to be off centre, check the fol‐
lowing:
♦ Check steering components for damage and deformation. If
necessary, renew damaged components.
♦ Check suspension components for damage and deformation.
If necessary, renew damaged components.
♦ Check symmetry of track rods also.

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– Measure dimension -a- of “shorter” track rod. Shorten “longer”

track rod to same dimension. Screw track rod ball joint -1-
deeper onto track rod -2-.
Dimension -a- must be the same on left side and right side track
rod ball joints.
Maximum permissible difference between left and right < 2.5 mm.
– When returning steering to central position, “swivel” steering
wheel with even movements.
Specified torques

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4 Vibration due to wheels/tyres - cau‐

ses and rectification
⇒ “4.1 Causes of rough running”, page 178
⇒ “4.2 Conducting a road test before balancing wheels”,
page 178 .
⇒ “4.3 Balancing wheel”, page 179
⇒ “4.4 Vibration control system”, page 183
⇒ “4.5 Checking radial and lateral runout of wheels and tyres”,
page 183
⇒ “4.6 Checking radial and lateral run-out on wheel rim”,
page 184
⇒ “4.7 Matching wheels and tyres”, page 185
⇒ “4.8 Determining flat spots on tyres”, page 186
4.1 Causes of rough running

Rough running can have a number of different causes. It can also
be caused by tyre wear. Tyre wear caused by driving is not always
evenly spread across the entire running surface of the tyre. This
causes slight imbalances which affect the smooth running of a
wheel which was previously exactly balanced.
Minor imbalances will not be felt at the steering wheel, but that
does not mean that they are not there. They increase wear on the
tyre and thus reduce the tyre service life.
Recommendation
To ensure
• optimal safety,
• smoothest possible running and
• even wear
throughout a tyre's service life, we recommend having the wheels
and tyres balanced at least twice during the tyre's service life.
4.2 Conducting a road test before balancing

wheels
If a customer brings a vehicle to the workshop complaining about
“vibration”, a road test is essential prior to balancing the wheels.
♦ This will give you information about the nature of the rough
running.
♦ You will be able to determine the speed range in which rough
running occurs.
– Raise the vehicle on a lifting platform immediately after the
road test.
– Mark installation position on tyre.
Tyre position Marked with …
Front left tyre FL
Front right tyre FR
Rear left tyre RL
Rear right tyre RR
– Remove wheels.

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– Balance wheels.
4.3 Balancing wheel

⇒ “4.3.1 Balancing wheel, conditions”, page 179
⇒ “4.3.2 Balancing wheel, balancing wheel on stationary wheel
balancer”, page 179
⇒ “4.3.3 Balancing wheel, balancing wheel with finish balancer ”,
page 182
4.3.1 Balancing wheel, conditions

Before you start balancing the wheels, the following requirements
must be met.
• Tyre pressure must be OK.
• Tread must not be worn on one side. Tread depth should be
at least 4 mm.
• The tyre must not show any signs of damage, for example
cuts, piercing, foreign bodies, etc.
• Wheel suspension and steering, including shock absorbers,
must be in perfect condition.
• You must have conducted a road test.
4.3.2 Balancing wheel, balancing wheel on

stationary wheel balancer
• Road test has been carried out ⇒ page 178 .
Clamp wheel into wheel balancing machine
Note
When balancing tyres, please remember that cleanliness is ab‐

solutely essential, as is the case in any other repair work you carry
out. Only then can you attain a flawless result!
Dirt and rust in the area of the contact surfaces and centre of the
wheel distort the result.
– Clean contact surface, centring element and inside of wheel
using e.g. pneumatic brush grinding set - VAS 6446- ⇒ Volks‐
wagen ServiceNet; Workshop Equipment, Catalogue before
clamping wheel on wheel balancing machine!
Note
It is very important that the correct tools for centring and clamping
the wheels are used on the wheel balancing system. Before com‐
mencing any work, find out about the respective centring system
for wheel balancing machines ⇒ Volkswagen ServiceNet; Work‐
shop Equipment, Catalogue .
4. Vibration due to wheels/tyres - causes and rectification 179

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– Attach the wheel (together with tyre) to the wheel balancing

machine.

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Note
♦ To clamp the wheel in place, use centring system for wheel

balancing machines - VAS 5271- , for example.
♦ This ensures that the wheel is 100% centred and that the
wheel is clamped without its being damaged.
♦ The wheel cannot be centralised 100% with conical clamping
elements on the wheel balancing machine.
♦ A deviation of 0.1 mm from the centre results in an imbalance
of 10 g at the wheel/rim.
Procedure for balancing wheels and tyres

– Allow the wheel (together with tyre) to rotate on the wheel bal‐
ancing machine.
– Check that the indicator lines on the sidewalls of the tyre near
the wheel rim flange run evenly.
– Check tyre profile with wheel/tyre rotating.
Note
If one-sided wear, flat spots from braking or severely washed out

spots are apparent, balancing cannot achieve smooth running. In
this case, the tyre must be renewed.
– Check true running of wheel/tyre. If the wheel and tyre do not

run true although there are no flat spots, radial or lateral runout
may be the cause.
– Check the wheel for radial or lateral run-out ⇒ page 184 .
– If radial and lateral runout are within the specified tolerance,
balance the wheel and tyre.
Note
♦ More than 60 g of weight per tyre should not be used.

♦ If more weight is required, you may be able to achieve smooth‐
er running by "matching" the tyre and rim. Matching tyres
⇒ page 185 .
♦ The wheel balancer display should indicate 0 g.
♦ As an alternative to match mounting, you could use the vibra‐
tion control system - VAS 6230 A- ⇒ page 183 .
– Bolt wheel onto vehicle.

– First, hand-tighten the lowest wheel bolt to about 30 Nm.
– Then, tighten the remaining wheel bolts diagonally to about
30 Nm. This process centres the wheel on the hub.
– Lower vehicle onto its wheels.
– Now use the torque wrench to firmly tighten the wheel bolts
diagonally to the prescribed torque.
Carrying out road test
– After balancing the wheel/tyre, carry out a road test.

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If you detect vibration during the road test, it may be due to wheel
centring tolerances.
In unfavourable circumstances, the component tolerances of
wheels and hubs could cumulate. This too can lead to vibration.
This can be alleviated using a finish balancer. ⇒ page 182
4.3.3 Balancing wheel, balancing wheel with

finish balancer
Note
♦ Before working with a finish balancer , the mechanic needs to

have been instructed by the manufacturer of the balancer.
♦ To balance the wheels, set the wheels of the driven axle on
the sensor platforms. On front-wheel drive models, front
wheels must be set. On four-wheel drive models, all 4 wheels
must be set.
If a residual imbalance greater than 20 g is determined when bal‐

ancing the wheels, rotate the mounting position of the wheel on
the hub.
– Mark the point at which the imbalance is indicated.
– Then, unbolt the wheel and rotate its position on the hub so
that the marking points downwards.
Note
The hub must not rotate during this procedure.
– First, hand-tighten the lowest wheel bolt to about 30 Nm.

– Then, tighten the remaining wheel bolts diagonally to about
30 Nm. This process ensures that the wheel is centred prop‐
erly on the hub.
– Check whether the imbalance is less than 20 g using the finish
balancer.
Note
The imbalance must be less than 20 grammes before you change

the balance weight.
– Loosen the wheel bolts again if necessary.

– Rotate wheel again by 1 or 2 wheel bolt holes in relation to
wheel hub.
– Tighten wheels using the method described above.
Note
Do not try to reduce the imbalance using balancing weights un‐

less the imbalance is less than 20 grams.
– Balance wheels if imbalance is less than 5 grams.

– Tighten wheel bolts to specified torque if you have not already
done so.

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WARNING
Always tighten wheel bolts to specified tightening torque using

a torque wrench!
4.4 Vibration control system

Using the vibration control system - VAS 6230 A- you can perform
more functions than just stationary balancing.
A special feature of this system is the testing of the radial force of
the wheel and tyre while rolling.
A roller presses against the wheel with a force of about 635 kg.
This simulates the vertical tyre force against the road surface
during travel.
Radial and lateral runout in the wheel and tyre and differences in
the stiffness of the tyre cause the vertical force of the wheel to
vary.
The -VAS 6230 A- detects and stores the position of the maximum
measured radial force in the tyre. Then the position of the smallest
distance between the wheel rim flange and the centre of the rim
is measured.
4.5 Checking radial and lateral runout of

wheels and tyres
⇒ “4.5.1 Checking radial and lateral runout of wheels and tyres,
tolerances”, page 183
⇒ “4.5.2 Checking radial and lateral runout on wheels and tyres
with tyre gauge”, page 184
4.5.1 Checking radial and lateral runout of

wheels and tyres, tolerances
Radial and lateral runout occur when the wheel and tyre do not
run absolutely true.
For technical reasons, 100% true running is not possible.
Therefore, the manufacturers of these components allow a pre‐
cisely determined tolerance.
Aligning the tyre in an unfavourable position on the wheel can
cause the maximum allowed tolerance for wheel with tyre to be
exceeded.
The table shows the maximum permissible tolerances for a wheel
with mounted tyre.
Tolerances for radial and lateral runout of rim with tyre
Wheel with tyre Radial runout (mm) Lateral runout (mm)
Passenger car 0.9 1.1
(1.3 in vicinity of lettering)

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4.5.2 Checking radial and lateral runout on

wheels and tyres with tyre gauge
Checking lateral run-out
– Preload tyre gauge approx. 2 mm.
– Fit tyre gauge to side wall of tyre.
– Turn wheel slowly.
– Make a note of the smallest and largest deflection of the indi‐
cator needle.
Note
If the difference is greater than 1.3 mm, the lateral runout is too
great.
In this case, you can reduce lateral runout by match mounting the
tyre ⇒ page 185 .
Extreme values on the tyre gauge due to small irregularities in the
rubber may be disregarded.
Checking radial runout
– Fit tyre gauge to running surface of tyre.

– Turn wheel slowly.
cator needle.
Note
If the difference is greater than 1 mm, the radial runout is too great.
In this case, you can reduce radial runout by match mounting the
tyre ⇒ page 185 .
4.6 Checking radial and lateral run-out on

wheel rim
– Attach rim to wheel balancing machine .
– Use the centring system for wheel balancing machines - VAS
5271- .
– Turn rim slowly.

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cator needle.
S - Lateral runout
H - Radial runout
– Compare the measured values with the specifications in the
table ⇒ page 185 .
Note
Extreme values on the tyre gauge due to small irregularities may

be disregarded.
Specifications for radial and lateral runout on wheel

Wheel rim Radial runout (mm) Lateral runout (mm)
Steel wheel 0.5 0.5
Alloy wheel 0.5 0.8
Note
If the measured value exceeds the specification, acceptably

smooth running cannot be attained.
4.7 Matching wheels and tyres

General information
When radial or lateral runout of the wheel and tyre coincide, the
imbalance of the wheel is amplified by the tyre.
For technical reasons, 100% true running is not possible
⇒ page 183 .
Before match mounting the used wheels which are fitted on the
vehicle, run the tyres warm. This will eliminate any flat spots
caused by storage or handling, ⇒ page 186 .
Procedure for match mounting
– Let air out of tyre.
– Press tyre beads off wheel rim flanges.
– Apply tyre assembly paste all around the tyre beads.
– Rotate tyre by 180° relative to wheel rim.
– Inflate tyre to approx. 4 bar.
– Attach the wheel (together with tyre) to the wheel balancing
machine.
– Check wheel for true running and for radial and lateral runout .

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Note
♦ If the specified values for radial and lateral runout are not ex‐
ceeded, the wheel can be balanced to 0 g. Specified values
appear on ⇒ page 183 .
♦ If the radial and lateral runout is not within the specifications,
the tyre must be rotated again.
– Let air out and press tyre beads off the wheel rim flanges.
– Rotate tyre by 90° relative to wheel (quarter of a turn).
– Inflate tyre again to 4 bar and check true running.
Note
♦ If the specified values for radial and lateral runout are not ex‐
ceeded, the wheel can be balanced to 0 g.
♦ If the radial and lateral runout are not within the specified val‐
ues, the tyre must be rotated again.
– Press tyre off wheel rim flange again as described above.

– Rotate tyre by 180° relative to wheel rim (half a rotation).
If the radial and/or lateral runout are still not within the specified
values, check the wheel for radial and/or lateral runout
⇒ page 184 .
If the measured values for radial and lateral runout of the wheel
are within the specified values, the tyre has unacceptably high
radial or lateral runout. In this case, the tyre must be renewed.
Note
♦ After fitting the tyres there will be fitting lubricant between the
tyres and the rim flanges.
♦ You should therefore avoid severe braking and acceleration
manoeuvres for the first 100 or 200 km driven. Otherwise, the
tyres can turn on the wheel rim. In this case, your work will
have been in vain!
4.8 Determining flat spots on tyres

What is a flat spot?
The terms flat area and flats are also used for the term flat spot.
Flat spots caused by storage or handling also cause vibration in
the same way as incorrectly balanced wheels do. It is important
that flat spots on the tread are identified as such.
Flat spots caused by storage or handling cannot be balanced and
they can reoccur at any time due to various circumstances. Flat
spots caused by storage or handling can be eliminated without
complicated special tools. Assuming it is not a flat spot caused by
full braking ⇒ Wheels and Tyres Guide - General Information;
Rep. gr. 44 ; Rolling noises due to tyres, locked-brake flat spots .

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Note
Flat spots caused by hard braking cannot be repaired. Such tyres

must be renewed.
Reasons for flat spots caused by storage or handling:

♦ The vehicle has been left standing in one place without being
moved for several weeks.
♦ The tyre pressure is too low.
♦ The vehicle was placed in a paint shop drying booth after being
painted.
♦ The vehicle was parked with warm tyres in a cool garage or
similar for a long period of time. In this case, a standing flat
spot may even occur overnight.
Eliminating flat spots caused by storage or handling
♦ Flat spots caused by storage or handling cannot be eliminated
from the tyre using workshop equipment.
♦ Flat spots caused by storage or handling can be removed only
by running the tyres warm.
♦ The method described below is not recommended in cold and
wintry weather.
Requirements and conditions:
– If necessary, check tyre pressure and correct.
– If possible, drive the vehicle onto a motorway.
– Traffic and road conditions permitting, drive a 20 to 30 km
stretch at a speed of 120 to 150 km/h (where legally permis‐
sible).
WARNING
♦ Do not endanger yourself or other road users during this

road test.
♦ Observe the highway code and speed limitations in force
when performing the road test.
– Jack up the vehicle immediately after the trip.

– Unbolt wheels from vehicle.
– Balancing wheels on stationary wheel balancer ⇒ page 179 .

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5 Adaptive cruise control

⇒ “5.1 Calibrating adaptive cruise control”, page 188
5.1 Calibrating adaptive cruise control

Before adjusting the adaptive cruise control (ACC) system, check
the sensor, its bracket and its securing elements for damage, ex‐
ternal influence and secure seating. Repair any damaged parts if
necessary.
Before adjusting the adaptive cruise control (ACC) system, read
out the event memory and rectify any faults found.
The “measured misalignment-angle value” of the ACC control unit
indicates whether or not the sensor is out of adjustment.
Use only a wheel alignment machine and adjusting devices ap‐
proved by VW/AUDI to adjust the adaptive cruise control (ACC)
system.
Correct adjustment 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 de-adjustment angle is outside the tolerance. Determine
the tolerance with the vehicle diagnostic tester.
♦ The vehicle has been brought into the service position.

♦ Adjusting tool - VAS 6190/2-

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♦ Setting device - VAS 6430- or setting device, basic kit - 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, the
setting of adjustment device - VAS 6430- must always be
checked (e.g. spirit levels, individual toe values on adjusting
beam, etc.).
• Before starting adjustment, read out event memory and rectify

any faults.
Adjustment procedure described here is based on adjustment
device - VAS 6430- .
The following setting 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.
3- Adjust adaptive cruise control unit - J428- .
If wheel alignment has just been carried out, the steps described
under “Setting without preceding wheel alignment” do not have to
be carried out.
Setting without preceding wheel alignment
– Press button to select ACC calibration in wheel alignment
computer.
– Note testing preconditions for wheel alignment ⇒ page 167 .
– Drive car onto wheel alignment platform.
– Connect battery charger ⇒ Electrical system; Rep. gr. 27 ;
Battery; Disconnecting and reconnecting battery .
– Connect ⇒ Vehicle diagnostic tester. (Route diagnostic cable
through open window.)
5. Adaptive cruise control 189

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Note
During the setting procedure, make sure that all the car doors
remain closed and that the car's exterior lighting is switched off.
– Move front wheels to straight-ahead position.

– Mount quick-release clamps on rear wheels.
– Mount measurement transducers on rear wheels.
– Carry out wheel run-out compensation at rear wheels.
Setting with or without preceding wheel alignment
– 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

alignment beam.
Sequence of steps for all

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

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– In the area -A-, move position -2- on rotary knob so that it co‐
incides with marking on mirror (the number 2 on the rotary
knob must point towards the vehicle).
– 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.
– Position the mirror on side of the alignment beam so that the

laser beam contacts the centre of the sensor lens.

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

computer is within tolerance.
– Level spirit levels -2- of the measurement transducer -1-.

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

beam does not coincide with the sensor lens.
– Press ⇒ Vehicle diagnostic tester GoTo button and select Se-

lect function/component function.
Selection on ⇒ Vehicle diagnostic tester for setting adaptive

cruise control unit - J428- :
– On the screen, click the following buttons one after the other:
♦ Running gear (Rep. Gr. 01; 40 - 49)
♦ 13 - Proximity control
♦ 01 - Self-diagnosis compatible system
♦ 13 - Proximity control
♦ 13 - Adaptive cruise control, functions
♦ 13 - Calibration
Follow instructions on screen to set the control unit.

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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 diagnosis

is completed” is displayed in the ⇒ Vehicle diagnostic tester.

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48 – Steering
1 Steering wheel
⇒ “1.1 Assembly overview - steering wheel”, page 194
⇒ “1.2 Removing and installing steering wheel”, page 194
1.1 Assembly overview - steering wheel
1 - Steering column
❑ The centre punch marks
-arrows- on the steering
wheel and the steering
column must align when
reinstalling.
2 - Steering wheel
⇒ page 194
❑ Different versions possi‐
ble. Refer to ⇒ Electron‐
ic parts catalogue
❑ The centre punch marks
-arrows- on the steering
wheel and the steering
column must align when
reinstalling.
3 - Bolt
❑ Renew after removal
❑ 30 Nm +90°
1.2 Removing and installing steering wheel

194 Rep. gr.48 - Steering

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Removing
– Remove airbag unit ⇒ General body repairs, interior; Rep. gr.
69 ; Driver side airbag; Assembly overview - driver side airbag .
Note
The steering wheel must be removed/installed in the middle position (wheels facing straight ahead).
1. Steering wheel 195

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– Remove bolt -3-.

– Pull steering wheel -2- off steering column.
Installing
– Put steering wheel -2- onto steering column.
– Centre markings of steering wheel and steering column
-arrows- must align.
– Guide connector for steering angle sender - G85- -1- into in‐
tended opening in the base of steering wheel.
– Secure steering wheel with bolt -3-.
– Install airbag unit ⇒ General body repairs, interior; Rep. gr.
69 ; Driver side airbag; Assembly overview - driver side airbag .
Specified torques
♦ ⇒ “1.1 Assembly overview - steering wheel”, page 194

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2 Steering column
⇒ “2.1 Assembly overview - steering column”, page 197
⇒ “2.2 Removing and installing steering column”, page 198
⇒ “2.3 Handling and transporting steering column”, page 207
⇒ “2.4 Removing and installing intermediate steering shaft”, page
209
⇒ “2.5 Repairing steering column”, page 210
⇒ “2.6 Removing and installing power steering control unit J500
”, page 211
2.1 Assembly overview - steering column
Note
♦ It is not permitted to weld or straighten load-bearing or wheel-guiding components of the suspension.

♦ Always renew self-locking nuts.
1 - Dash panel central tube

2 - Steering column
⇒ page 198
❑ Can be tested in guided
fault finding using ⇒ Ve‐
hicle diagnostic tester
Note
Before renewing the steering col‐

umn or the steering column elec‐
tronics control unit - J500- all causes
of entries in event memory must be
rectified ⇒ Vehicle diagnostic tester.
3 - Bolt
❑ 20 Nm
❑ Observe tightening se‐
quence ⇒ page 204
4 - Bolt
moval
❑ 20 Nm +180°
5 - Bolt
moval
❑ 20 Nm +180°
6 - Intermediate steering shaft
⇒ page 209
7 - Bolt
❑ 20 Nm
2. Steering column 197

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❑ Observe tightening sequence ⇒ page 204
2.2 Removing and installing steering col‐

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

the electrical system and removing the steering wheel:
♦ Disconnect earth strap from battery ⇒ Electrical system;
Rep. gr. 27 ; Battery; Disconnecting and reconnecting the
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!
– Turn wheels to straight-ahead position.

– Pull down lever on side of steering column.
– Swing steering column down as far as possible and pull out.
– Press lever on side of steering column back up.
– Remove lower steering column trim ⇒ General body repairs,
interior; Rep. gr. 68 ; Compartments/covers; Removing and
installing lower steering column trim .

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– Remove upper steering column trim ⇒ General body repairs,

installing upper steering column trim .
– Remove driver side airbag unit ⇒ General body repairs, inte‐
rior; Rep. gr. 69 ; Driver side airbag; Removing and installing
airbag unit with igniter .
– Remove steering wheel ⇒ page 194 .
– Remove steering column combination switch - E595- ⇒ Elec‐
trical system; Rep. gr. 94 ; Steering column switch module;
Removing and installing steering column combination switch .
– Pull cover -1- out of catches in lower area -arrow A-, and re‐
move it from dash panel.
– Mask dash panel -1- in area of steering column using e.g. tex‐
tile adhesive tape -2- to prevent damage to dash panel.
– Unscrew bolts -1-, move fuse holder -2- under dash panel to
side, and secure it in position.

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– Unscrew bolt -1-.

– Detach earth wire -2-.
– Disconnect connector -3- from steering lock.

– Unplug connector -2- from immobiliser reader coil - D2- .
– Push retainer for wiring harness -1- downwards in direction of

-arrow- off steering column lug -2-.

– Remove driver side footwell vent -2-.
LHD only

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– Disconnect connectors -1- and -2- from steering column elec‐

tronics control unit - J500- .
RHD only
– Disconnect connectors -1- and -2- from steering column elec‐


– Pull steering column articulated shaft -2- in
-direction of arrow- off steering column and lay to side.

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– Unscrew bolts -1- from steering column -2-.
Note
♦ Make sure not to damage the dash panel when removing.

♦ Make sure not to operate the steering column adjustment lever
when removing.
– Pull steering column -1- towards the rear off lugs -2- on cross
member.
– Lower steering column slightly, and pull it towards the rear off
tab -arrow-.
– Pull steering column -1- towards the rear while at the same
time turning it so that power steering control unit - J500- -2-
rests against dash panel.

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– Turn steering column -1- downwards and past dash panel

aperture -arrow B-.
– Turn power steering control unit - J500- -2- past dash panel
aperture -arrow A-.
– Turn steering column -1- in direction of -arrow- around its own

axis until it can be removed.
Note
Make sure that the power steering control unit - J500- can be gui‐
ded past the dash panel aperture -arrow-.
Caution
Take great care to ensure the steering column is handled and

transported correctly ⇒ page 207 .
Installing
Caution
The lever for steering column adjustment must not be released

prior to the installation of the upper bolts, since a predefined
distance has been adjusted between the upper and the lower
bolting points.
If the lever has nevertheless been released, perform installa‐
tion with the lever in released position. Otherwise, the locking
mechanism of the steering column will become damaged.
Note
When installing steering column, adhere strictly to bolting se‐

quence.
– Turn steering column -1- in opposite direction of -arrow-

around its own axis until it can be inserted in dash panel
aperture -arrow-.
Note
Make sure that the power steering control unit - J500- can be gui‐
ded past the dash panel aperture -arrow-.
– Turn and raise steering column until it can be attached to cross

member.

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– Insert steering column -1- into tab -arrow-.

– Fit steering column -1- onto lugs -2- on cross member.
– Screw in bolt -1-, and tighten it to specified torque.
– Screw in bolts -1- of steering column -2-, and tighten them to

specified torque.
– Fit steering column articulated shaft -2- to steering column in

opposite -direction of arrow- and tighten new bolt -1- to speci‐
fied torque.
LHD only

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– Connect connectors -1- and -2- to steering column electronics

control unit - J500- .
RHD only
– Connect connectors -1- and -2- from steering column elec‐

– Insert driver side footwell vent -2-.

– Insert bolt -1- and tighten.
– Connect connector -2- to immobiliser reader coil - D2- .

– Connect connector -1-.
Volkswagen Technical Site: http://vwts.ru http://vwts.info

Polo 2014 ➤
– Connect connector -3- to steering lock.

– Secure earth wire to steering column -2- by means of bolt
-1-.
– Push bracket -1- in opposite direction of -arrow- into guide on

steering column -2-.
– Insert fuse holder -2-.

– Screw in and tighten bolts -1-.
– Install cover -1- in lower area of dash panel.

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– Remove textile adhesive tape -2- from dash panel -1-.

– Install steering column combination switch - E595- ⇒ Electri‐
cal system; Rep. gr. 94 ; Steering column switch module;
Removing and installing steering column combination switch .
– Install steering wheel ⇒ page 194 .
– Install airbag unit ⇒ General body repairs, interior; Rep. gr.
69 ; Driver side airbag; Removing and installing airbag unit
with igniter .
– Install upper steering column trim ⇒ General body repairs,
installing upper steering column trim .
– Install lower steering column trim ⇒ General body repairs, in‐
terior; Rep. gr. 68 ; Compartments/covers; Removing and
installing lower steering column trim .
WARNING
When connecting battery ensure that no people are in the ve‐

hicle!
– Connect earth strap to battery ⇒ Electrical system; Rep. gr.

27 ; Battery; Disconnecting and connecting battery .
– Steering mechanism needs to be re-adapted every time after
the steering column has been renewed or reinstalled after re‐
moval ⇒ Vehicle diagnostic tester.
Specified torques
♦ ⇒ “2.1 Assembly overview - steering column”, page 197
♦ Footwell vent below steering column ⇒ Heating, air condi‐
tioning system; Rep. gr. 87 ; Air duct; Assembly overview - air
duct and air distribution in passenger compartment .
♦ Steering column switch module ⇒ Electrical system; Rep. gr.
94 ; Steering column switch module; Removing and installing
steering column switch module .
♦ Driver side airbag unit ⇒ General body repairs, interior; Rep.
gr. 69 ; Driver side airbag; Assembly overview - driver side
airbag .
♦ Lower steering column trim ⇒ General body repairs, interior;
Rep. gr. 68 ; Compartments/covers; Removing and installing
lower steering column trim .
♦ Upper steering column trim ⇒ General body repairs, interior;
Rep. gr. 68 ; Compartments/covers; Removing and installing
upper steering column trim .
2.3 Handling and transporting steering col‐

umn
WARNING
♦ Adherence to proper steering column handling is essen‐

tial.
♦ Improper handling of steering column may damage the
steering column, leading to safety risks.

Polo 2014 ➤
Proper steering column handling and transport

♦ Use both hands to transport steering column.
♦ Hold steering column on upper jacket tube and in area below
gearbox housing.
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°.
Preliminary damage is caused when the steering column is being
handled as follows:

Polo 2014 ➤
♦ Picking up and carrying steering column on clamping lever.

♦ Picking up and carrying steering column on counterbalance
spring.
♦ Picking up and carrying steering column on motor/ steering
column electronics control unit - J500- .
♦ Picking up and carrying steering column on wiring of steering
column electronics control unit - J500- .
2.4 Removing and installing intermediate

steering shaft
Removing

Polo 2014 ➤

– Pull steering column articulated shaft -2- in
-direction of arrow- off steering column and remove.
Installing
– Install in reverse order.
Specified torques
2.5 Repairing steering column
1 - Steering column
⇒ page 198
2 - Power steering control unit
- J500-
⇒ page 211
3 - Cap
moval
4 - Wiring harness
5 - Bolt
moval
❑ Qty. 3
❑ 6 Nm
6 - Bolt
moval
❑ Qty. 3
❑ 2.75 Nm

Polo 2014 ➤
2.6 Removing and installing power steering

control unit - J500-
⇒ “2.6.1 Distinguishing features of left-hand and right-hand drive”,
page 211
⇒ “2.6.2 Removing and installing power steering control unit
J500 , left-hand drive vehicle”, page 211
⇒ “2.6.3 Removing and installing power steering control unit
J500 , right-hand drive vehicle”, page 215
2.6.1 Distinguishing features of left-hand and

right-hand drive
LHD vehicles
The socket for connectors -1- for the power steering control unit
- J500- is on the left side.
RHD vehicles
The socket for connectors -1- for the power steering control unit
- J500- is on the right side.
2.6.2 Removing and installing power steering

control unit - J500- , left-hand drive ve‐
hicle
♦ ESD workplace - VAS 6613-

Polo 2014 ➤
Removing
• The failure of the power steering control unit - J500- must be
determined using ⇒ Vehicle diagnostic tester.
• Something other than an accident has caused the system fail‐
ure.
• The steering column and the power steering control unit -
J500- are undamaged.
• The power steering control unit - J500- has not been renewed
before.
– Remove steering column ⇒ page 198 .
– Distinguishing features of left-hand and right-hand drive
⇒ page 211
– Unscrew bolt -arrow- and remove power steering control unit

- J500- -1-
– Disconnect connectors -1- and -2- from power steering control

unit - J500- -3-.

Polo 2014 ➤
– Lever off cap -1-.
Note
The cap -1- will be damaged during removal and must be re‐
newed.
– Raise lugs -arrows- slightly.
Caution
♦ Lugs -arrows- can break off!

♦ If one or both lugs break off, the entire steering column
must be renewed!
– Disconnect connector -1- from power steering control unit -

J500- -2-.
Caution
♦ Do not damage the contacts.

♦ In the event of damage, the entire steering column must
be renewed.
Installing
Caution
♦ A power steering control unit - J500- from another steering

column cannot be used.
♦ Use only a new power steering control unit - J500- as a
replacement.

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– Connect connector -1- to power steering control unit - J500-

-2-.
– Lugs -arrows- must engage.
Caution

be renewed.
– Screw in new bolts -arrows- and tighten to specified torque.
– Fit new cap -1-, making certain that it engages audibly.
– Connect connectors -1- and -2- to power steering control unit

- J500- -3-.
– Hold power steering control unit - J500- in place.

Polo 2014 ➤
– Start bolts -arrows- but do not tighten yet.
– Start bolt -arrow- but do not tighten yet.

– Position power steering control unit - J500- -1-.
– Tighten bolt -arrow- to specified torque.
– Tighten bolts -arrows- to specified torque.

– Install steering column ⇒ page 198 .
– The steering must be re-adapted whenever the power steering
control unit - J500- has been either renewed or removed and
reinstalled ⇒ Vehicle diagnostic tester.
– Perform steps to initiate ⇒ Vehicle diagnostic tester.
DANGER!
The vehicle cannot be driven on public roads until after it has

been sufficiently tested in the workshop.
Specified torques
♦ ⇒ “2.5 Repairing steering column”, page 210
2.6.3 Removing and installing power steering

control unit - J500- , right-hand drive ve‐
hicle

Polo 2014 ➤
♦ ESD workplace - VAS 6613-

Removing
• The failure of the power steering control unit - J500- must be
determined using ⇒ Vehicle diagnostic tester.
• Something other than an accident has caused the system fail‐
ure.
• The steering column and the power steering control unit -
J500- are undamaged.
• The power steering control unit - J500- has not been renewed
before.
– Remove steering column ⇒ page 198 .
– Distinguishing features of left-hand and right-hand drive
⇒ page 211
– Unclip lines -arrows- from retainer -1-.

Polo 2014 ➤
– Unscrew bolt -arrow- and remove power steering control unit

- J500- -1-
– Disconnect connectors -1- and -2- from power steering control

unit - J500- -3-.
– Lever off cap -1-.
Note
The cap -1- will be damaged during removal and must be re‐
newed.

Polo 2014 ➤
– Raise lugs -arrows- slightly.
Caution
♦ Lugs -arrows- can break off!

♦ If one or both lugs break off, the entire steering column
must be renewed!
– Disconnect connector -1- from power steering control unit -

J500- -2-.
Caution

be renewed.
Installing
Caution
♦ A power steering control unit - J500- from another steering

column cannot be used.
♦ Use only a new power steering control unit - J500- as a
replacement.
– Connect connector -1- to power steering control unit - J500-

-2-.
– Lugs -arrows- must engage.
Caution

be renewed.
– Screw in new bolts -arrows- and tighten to specified torque.

Polo 2014 ➤
– Fit new cap -1-, making certain that it engages audibly.
– Connect connectors -1- and -2- to power steering control unit

- J500- -3-.
– Hold power steering control unit - J500- in place.
– Start bolts -arrows- but do not tighten yet.
– Start bolt -arrow- but do not tighten yet.

– Position power steering control unit - J500- -1-.
– Tighten bolt -arrow- to specified torque.

Polo 2014 ➤
– Tighten bolts -arrows- to specified torque.
– Clip lines -arrows- into retainer -1-.

– Install steering column ⇒ page 198 .
– The steering must be re-adapted whenever the power steering
control unit - J500- has been either renewed or removed and
reinstalled ⇒ Vehicle diagnostic tester.
– Perform steps to initiate ⇒ Vehicle diagnostic tester.
DANGER!
The vehicle cannot be driven on public roads until after it has

been sufficiently tested in the workshop.
Specified torques
⇒ “2.5 Repairing steering column”, page 210

Polo 2014 ➤
3 Steering rack
⇒ “3.1 Assembly overview - steering rack”, page 221
⇒ “3.2 Removing and installing steering rack”, page 222
⇒ “3.3 Repairing steering rack”, page 225
⇒ “3.4 Removing and installing track rod”, page 227
⇒ “3.5 Removing and installing track rod ball joint”, page 230
⇒ “3.6 Adjusting steering rack”, page 231
3.1 Assembly overview - steering rack

♦ The steering rack is not intended to be repaired. In the event
of concerns the steering rack must be renewed.
♦ To lubricate steering rack, only use steering rack grease - AOF
063 000 04- . However, do not over-apply grease to steering
rack. Air equalisation bores must remain free. Otherwise the
boot will be damaged.
1 - Steering rack
⇒ page 222
3 - Nut
moval
❑ 20 Nm +90°
4 - Subframe
❑ Follow repair instruc‐
tions ⇒ page 4
5 - Bolt
moval
❑ 50 Nm +180°
3. Steering rack 221

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3.2 Removing and installing steering rack

equipment required
♦ Ball joint puller - 3287 A-

♦ Flared ring spanner tool insert AF 17 - V.A.G 1331/10-

Polo 2014 ➤
Removing
– Raise vehicle.

pletely.
Caution
sides).
sides.

Polo 2014 ➤

– Remove steering rack bolts -arrows- from subframe.

– Lower subframe using engine and gearbox jack -
V.A.G 1383 A- .
– Take out steering rack towards the rear.
Installing
lowing:
Steering rack must be moved to centre position before installing
steering rack.
– Slide rack until dimension -a- is reached.

Dimension -a- = 72.5 mm
♦ After fitting the steering rack to the universal joint shaft ensure
that the seal is not kinked against the assembly plate on the
steering rack. The opening to the footwell must seal correctly.
Otherwise, this can result in water leaks and/or noise.
♦ Ensure sealing surface is clean.
♦ When renewing the steering rack also install new boots on the
track rods.
– Position steering rack on subframe.
– Start bolts for steering rack.

Note

Polo 2014 ➤
– Bolt steering rack to subframe -arrows-.

– Bolt track rod to steering arm.
– Position universal joint -1- onto steering pinion.

– Insert new bolt -arrow- and tighten.
– Check toe adjustment ⇒ page 167 .
Specified torques
3.3 Repairing steering rack

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1 - Right track rod ball joint

❑ Marked “D”
⇒ page 228
⇒ page 230
⇒ page 231
2 - Nut
❑ 70 Nm
3 - Clip
4 - Boot
❑ Must not be twisted after
adjusting toe.
❑ Remove steering rack to
renew.
5 - Clip
❑ Renew
6 - Seal
7 - Right track rod
⇒ page 227
❑ 80 Nm
8 - Steering rack
⇒ page 222
9 - Left track rod
❑ 80 Nm
10 - Left track rod ball joint
❑ Marked “C” ⇒ page 228
❑ Fitting position ⇒ page 231
Checking play, security and boots of track rod ends

– Check play by moving track rods and wheels with the vehicle
raised (wheels hanging free). Clearance: zero clearance
– Check attachment.
– Check boots are not damaged and are seated correctly.

Polo 2014 ➤
3.4 Removing and installing track rod

equipment required
♦ Ball joint puller - 3287 A-

♦ Open-end spanner attachment AF 38 - V.A.G 1923-
♦ Locking pliers for Phaeton steering rack - VAS 6199-
Removing
– Turn steering wheel to straight-ahead position.
– Raise vehicle.
– Remove wheel.
– Clean outside of steering rack in vicinity of boot.

Polo 2014 ➤
pletely.
Caution

– Remove lower suspension link ⇒ page 45 .
– Open clips and push boot back.
– Turn steering as follows:
- For left track rod, turn steering to full right lock
- For right track rod, turn steering to full left lock.
– 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
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 “C”
II - Track rod ball joint on left marked “D”
– Turn steering wheel to straight-ahead position.
– Thread new clamps and rubber boot onto track rod.

Polo 2014 ➤
– Screw track rod into track rod ball joint until dimension -a- is
attained.
Dimension -a- = 373 ± 1 mm
– Tighten track rod.

1- Open-end spanner attachment - V.A.G 1923-
– Lightly grease sealing surface between boot and track rod with
grease from repair kit.
– Push rubber boot -2- onto track rod -1-, making sure that boot
is correctly positioned.
– Secure spring-type clip on rubber boot using hose clip pliers -
V.A.G 1275- .
– Lightly grease sealing surface between boot and steering rack
housing with grease from repair kit.
– Push rubber boot onto steering rack housing as far as it will
go.
– Install new clamp -1- using locking pliers for Phaeton steering
rack - VAS 6199- .
– Tighten clamp so that its ear -arrow- is positioned as shown in
illustration.
– Install wheel and tighten.
– Check wheel alignment ⇒ page 172 .
– 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
♦ ⇒ “4.1 Removing and installing lower suspension link”,
page 45
♦ ⇒ “1.5 Specified torques for wheel bolts”, page 164

Polo 2014 ➤
3.5 Removing and installing track rod ball

joint
♦ Ball joint puller - T10187- Ball joint puller - 3287 A-
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.
1- Ball joint puller - T10187-
– Unscrew track rod ball joint from track rod.
Installing
lowing:

Polo 2014 ➤
– Make sure that correct track rod ball joint is installed on each
side.
I - Track rod ball joint on right marked “C”
II - Track rod ball joint on left marked “D”
– Screw track rod ball joint onto track rod as far as previously
applied mark and secure with lock nut.
– Insert track rod ball joint into wheel bearing housing.
– Bolt track rod ball joint with new nut.
– Check wheel alignment ⇒ page 167 .
Specified torques
3.6 Adjusting steering rack

Two mechanics are required to perform adjustment. Perform ad‐
justment with engine switched off.
– Raise vehicle on lifting platform.
– Wheels in straight-ahead position.
– If there is excessive play in the steering, a knocking noise will
be audible when the steering wheel is rocked back and forth
(about 30° either side of centre position).
– In this case, have the second mechanic carefully screw in the
adjusting screw -1- into the cover until the knocking noise can
no longer be heard inside the vehicle.
– Carry out road test. During this, ensure that the steering inde‐
pendently resets itself to the straight-ahead position after cor‐
nering, without catching.
– Secure adjusting screw -1- with three punch marks -arrows-.

Polo 2014 ➤
4 Sensors
⇒ “4.1 Removing and installing steering angle sender G85 ”, page
232
4.1 Removing and installing steering angle

sender - G85-
Note
♦ The steering angle sender - G85- is part of the steering column

electronics control unit J500.
♦ It cannot be renewed as an individual part.
♦ If the steering angle sender - G85- is defective, the steering
column must be renewed ⇒ page 198 .

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Service

Service Department. Technical Information

42 - Rear suspension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121

2 Axle beam . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127

43 - Self-levelling suspension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 155

44 - Wheels, tyres, vehicle geometry . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 159

5 Adaptive cruise control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 188

1.1 Checklist for evaluating running gear on

1. Evaluating accident vehicles 1

If in doubt, the following always applies:

2 Rep. gr.00 - Technical data

2.1 Safety measures when working on ve‐

All bolts and nuts must be fully tightened according to specifi‐

There is a risk of an accident through an automatic engine start

2.2 Safety precautions when working on

3.1 Steering rack

3.2 Gaskets and seals

3.3 Nuts and bolts

3.4 Repairing damaged threads in longitu‐

4 Rep. gr.00 - Technical data

3.5 Electrical components

3.6 Raising suspension to unladen position

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‐

6 Rep. gr.00 - Technical data

If the vehicle is not strapped down, there is a danger that the

Running gear 1) Ride height -a- in mm

♦ Do not raise or lower the vehicle while the engine and

– Tighten respective nuts and bolts.

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 axle on

8 Rep. gr.00 - Technical data

If the vehicle is not strapped down, there is a danger that the

Measuring dimension -a-

Running gear 1) Ride height -a- in mm

♦ Do not raise or lower the vehicle while the engine and

– Tighten respective nuts and bolts.

1.1 Overview - front axle

10 Rep. gr.40 - Front suspension

2.1 Assembly overview - subframe

♦ It is not permitted to weld or straighten load-bearing or

Volkswagen Technical Site: http://vwts.ru http://vwts.info 2. Subframe 11

Repairing thread in longitudinal member ⇒ page 4

Repairing thread in longitudinal member ⇒ page 4

12 Rep. gr.40 - Front suspension

2.2 Fixing position of subframe

Special tools and workshop

♦ Locating pins - T10096-

– Unbolt pendulum support bolts -1- from gearbox.

To fix position of subframe, successively screw in locating pins -

– Unscrew securing bolt -1- on one side of vehicle and remove

14 Rep. gr.40 - Front suspension

– If locating pins - T10096- cannot be inserted, sleeve in sub‐

– Only unscrew one locating pin at a time and replace it with a

2.3 Removing and installing subframe with‐

♦ Torque wrench - V.A.G 1332-

– Pull retaining rings for exhaust pipe from subframe.

16 Rep. gr.40 - Front suspension

– Open clips -arrows- of retainer on subframe.