VW Touareg 2 Running Gear Axles Steering Eng

Service
Workshop Manual
Touareg 2010 ➤
Touareg 2015 ➤
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.
Touareg 2010 ➤ , Touareg 2015 ➤
Running gear, axles, steering - Edition 01.2018
Contents
00 - Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1 Checklist for evaluating running gear of accident vehicles . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2 General information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
40 - Front suspension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
1 Evaluating accident vehicles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
2 Lifting front axle in unladen state . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
3 Overview - front axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
4 Assembly overview: subframe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
4.1 Repairing thread in longitudinal member . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
4.2 Fixing subframe in position, vehicles with V6 engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
4.3 Fixing subframe in position, vehicles with V8 engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
4.4 Removing and installing subframe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
4.5 Repairing subframe, bonded rubber bushes in direction of travel at front for V6 engines . . 22
4.6 Repairing subframe, bonded rubber bushes in direction of travel at front for V8 engines . . 28
4.7 Repairing subframe, bonded rubber bushes in direction of travel at rear for V6 engines . . 34
4.8 Repairing subframe, bonded rubber bushes in direction of travel at rear for V8 engines . . 38
5 Assembly overview - front wheel suspension, lower suspension link, upper suspension link
........................................................................ 44
5.1 Removing and installing upper suspension link, vehicles with steel spring struts . . . . . . . . 46
5.2 Removing and installing upper suspension link, vehicles with air spring struts . . . . . . . . . . 48
5.3 Repairing upper suspension link . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
5.4 Checking swivel joint . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
5.5 Removing and installing lower suspension link . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
5.6 Repairing lower suspension link - pressing in and out bonded rubber bushes (camber adjuster
screw connection) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
5.7 Repairing lower suspension link - pressing in and out bonded rubber bushes (caster adjuster
screw connection) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
5.8 Repairing lower suspension link - pressing in and out bonded rubber bushes (spring strut
connection) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
5.9 Removing and installing wheel bearing housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
6 Assembly overview - wheel bearing, 17 running gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
6.1 Removing and installing wheel bearing for 17" running gear . . . . . . . . . . . . . . . . . . . . . . . . 70
7 Assembly overview - wheel bearing, 18" running gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
7.1 Removing and installing wheel bearing unit for 18"/19" running gear . . . . . . . . . . . . . . . . 77
7.2 Repairing wheel bearing unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
8 Assembly overview: anti-roll bar . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
8.1 Removing and installing anti-roll bar . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
8.2 Removing and installing coupling rod . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
8.3 Removing and installing bush for anti-roll bar . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
9 Assembly overview - front steel spring strut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
9.1 Assignment of spacers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
9.2 Installation position of spacers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
9.3 Removing and installing steel spring strut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
9.4 Repairing front steel spring strut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
10 Front air spring strut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
10.1 Instructions for repairing air spring struts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
10.2 Air spring strut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
10.3 Pressure retention valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
10.4 Gaskets and seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108
10.5 Nuts and bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108
10.6 Front air spring strut components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108
Contents i
10.7 Assembly overview - front air spring strut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110

10.8 Removing and installing air spring strut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
10.9 Repairing front air spring strut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
10.10 Removing and installing pressure retention valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123
11 Assembly overview: drive shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126
11.1 Loosening and tightening 12-point nut securing drive shaft . . . . . . . . . . . . . . . . . . . . . . . . 127
11.2 Removing and installing drive shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128
11.3 Dismantling and assembling drive shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134
11.4 Checking outer joint . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139
42 - Rear suspension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141

2 Raising rear axle in unladen state . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 142
3 Overview - rear axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144
4 Assembly overview - subframe, stone-chip protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . 146
4.1 Repairing thread in rear longitudinal member . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147
4.2 Fixing position of subframe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 148
4.3 Removing and installing subframe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149
4.4 Repairing subframe, bonded rubber bushes in direction of travel at front . . . . . . . . . . . . . . 153
4.5 Repairing subframe, bonded rubber bushes in direction of travel at rear . . . . . . . . . . . . . . 157
5 Assembly overview - suspension link, track rod . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 163
5.1 Removing and installing front upper transverse link . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 165
5.2 Removing and installing upper rear transverse link . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 168
5.3 Removing and installing track rod . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 171
5.4 Removing and installing lower transverse link . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 174
6 Assembly overview: wheel bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 179
6.1 Removing and installing wheel bearing housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 181
6.2 Repairing wheel bearing housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 190
6.3 Removing and installing wheel bearing unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 194
6.4 Repairing wheel bearing unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 200
7 Assembly overview - rear suspension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 204
8 Assembly overview: anti-roll bar . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 206
8.1 Removing and installing anti-roll bar . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 207
8.2 Removing and installing anti-roll bar bush . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 208
8.3 Removing and installing coupling rod . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 210
9 Assembly overview - steel spring strut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 215
9.1 Assignment of spacers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 216
9.2 Installation position of spacers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 217
9.3 Removing and installing steel spring strut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 217
9.4 Repairing rear steel spring strut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 220
10 Rear air spring damper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 226
10.1 Instructions for repairing air spring struts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 226
10.2 Air spring strut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 226
10.3 Pressure retention valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 226
10.4 Gaskets and seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 227
10.5 Nuts and bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 227
10.6 Rear air spring strut components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 227
10.7 Assembly overview - rear air spring strut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 229
10.8 Removing and installing air spring strut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 229
10.9 Replacing bellows for air spring strut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 233
10.10 Repairing rear air spring strut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 235
10.11 Removing and installing pressure retention valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 243
11 Assembly overview: drive shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 246
11.1 Loosening and tightening 12-point nut securing drive shaft . . . . . . . . . . . . . . . . . . . . . . . . 246
ii Contents
11.2 Removing and installing drive shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 248

11.3 Dismantling and assembling drive shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 255
43 - Self-levelling suspension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 258

2 Jacking mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 259
3 Fault finding, air spring strut and self-levelling suspension . . . . . . . . . . . . . . . . . . . . . . . . 260
4 Self-levelling suspension components and fitting locations . . . . . . . . . . . . . . . . . . . . . . . . 263
4.1 Removing and installing adaptive suspension control unit J197 . . . . . . . . . . . . . . . . . . . . 265
4.2 Removing and installing front left and right body acceleration senders G341/G342 . . . . . . 265
4.3 Assembly overview - front left/right vehicle level senders G78/G289 . . . . . . . . . . . . . . . . 266
4.4 Removing and installing front left/right vehicle level sender G78/G289 . . . . . . . . . . . . . . 267
4.5 Assembly overview - rear left/right vehicle level senders G76/G77 . . . . . . . . . . . . . . . . . . 268
4.6 Removing and installing rear left/right vehicle level sender G76/G77 . . . . . . . . . . . . . . . . 269
4.7 Removing and installing accumulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 270
4.8 Filling the accumulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 271
4.9 Repairing air line . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 271
5 Assembly overview - compressor with adaptive suspension valve block NX7 . . . . . . . . . . 274
5.1 Removing and installing compressor without adaptive suspension valve block NX7 . . . . 275
5.2 Removing and installing compressor with adaptive suspension valve block NX7 . . . . . . 277
5.3 Removing and installing adaptive suspension valve block NX7 . . . . . . . . . . . . . . . . . . . . 281
44 - Wheels, tyres, vehicle geometry . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 284

2 Specified torques for wheel bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 285
3 Vehicle alignment check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 286
3.1 General information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 286
3.2 Conditions for testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 288
3.3 Test preparations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 288
3.4 Wheel alignment specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 289
3.5 Overview - wheel alignment procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 290
3.6 Adjusting camber at front wheels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 291
3.7 Adjusting camber on rear axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 292
3.8 Adjusting toe at rear axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 293
3.9 Adjusting caster on front axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 294
3.10 Adjusting front axle toe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 295
4 Vehicle data sticker . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 297
5 Adaptive Cruise Control (ACC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 298
5.1 General information on Adaptive Cruise Control (ACC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 299
5.2 Adjusting the automatic distance regulation sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 300
6 Lane departure warning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 306
6.1 General information about lane departure warning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 306
6.2 Calibrating the lane departure warning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 306
48 - Steering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 314
2 Assembly overview - airbag and steering wheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 315
2.1 Removing and installing airbag and steering wheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 315
3 Assembly overview: steering column, left-hand drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . 318
3.1 Removing and installing steering column, left-hand drive vehicle . . . . . . . . . . . . . . . . . . . . 319
3.2 Basic setting for steering angle sensor G85 steering angle sender must be checked after the
following repair work: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 326
3.3 Checking steering column for damage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 326
3.4 Removing and installing electronic steering column lock control unit J764 . . . . . . . . . . . . 326
Contents iii
3.5 Removing and installing control unit for electrically adjustable steering column J866 . . . . 328
4 Assembly overview: steering column, right-hand drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . 330
4.1 Removing and installing steering column, right-hand drive vehicle . . . . . . . . . . . . . . . . . . 331
4.2 Basic setting for steering angle sensor G85 steering angle sender must be checked after the
following repair work: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 338
4.3 Checking steering column for damage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 338
4.4 Removing and installing electronic steering column lock control unit J764 . . . . . . . . . . . . 338
4.5 Removing and installing control unit for electrically adjustable steering column J866 . . . . 340
5 Assembly overview: power steering, left-hand drive vehicle . . . . . . . . . . . . . . . . . . . . . . . . 342
5.1 Removing and installing power-assisted steering rack, left-hand drive vehicle . . . . . . . . . . 343
6 Assembly overview: power steering, right-hand drive vehicle . . . . . . . . . . . . . . . . . . . . . . 348
6.1 Removing and installing power steering rack, right-hand drive vehicle . . . . . . . . . . . . . . . . 349
7 Repairing power steering rack . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 353
7.1 Assembly overview: power steering rack, left-hand drive vehicle . . . . . . . . . . . . . . . . . . . . 353
7.2 Removing and installing track rod . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 354
7.3 Removing and installing track rod ball joint . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 356
7.4 Removing and installing bellows . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 358
8 Vane pump, 6-cylinder petrol engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 360
8.1 Checking vane pump delivery pressure, 6-cylinder petrol engine . . . . . . . . . . . . . . . . . . . . 360
8.2 Assembly overview: vane pump, 6-cylinder petrol engine . . . . . . . . . . . . . . . . . . . . . . . . . . 362
8.3 Removing and installing vane pump, 6-cylinder petrol engine . . . . . . . . . . . . . . . . . . . . . . 363
9 Vane pump, 6-cylinder diesel engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 367
9.1 Checking vane pump delivery pressure, 6-cylinder diesel engine . . . . . . . . . . . . . . . . . . . . 367
9.2 Assembly overview - vane pump, 6-cylinder diesel engine . . . . . . . . . . . . . . . . . . . . . . . . 370
9.3 Removing and installing vane pump, 6-cylinder diesel engine . . . . . . . . . . . . . . . . . . . . . . 372
10 Vane pump, 8-cylinder petrol and diesel engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 376
10.1 Checking vane pump delivery pressure, 8-cylinder petrol and diesel engine . . . . . . . . . . 376
10.2 Assembly overview: vane pump, 8-cylinder petrol and diesel engine . . . . . . . . . . . . . . . . 382
10.3 Removing and installing vane pump, 8-cylinder petrol and diesel engine . . . . . . . . . . . . . . 384
11 Assembly overview: hydraulic lines, 6-cylinder petrol engine . . . . . . . . . . . . . . . . . . . . . . 388
12 Assembly overview - hydraulic lines, 6-cylinder diesel engine . . . . . . . . . . . . . . . . . . . . . . 389
13 Assembly overview - hydraulic lines, 8-cylinder diesel engine . . . . . . . . . . . . . . . . . . . . . . 390
14 Removing and installing oil cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 391
15 Motor/pump unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 394
15.1 Assembly overview - motor/pump unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 394
15.2 Removing and installing motor/pump unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 395
16 Bleeding steering system and checking for leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 398
16.1 Bleeding steering system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 398
16.2 Check steering system for leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 398
iv Contents
00 – Technical data
1 Checklist for evaluating running gear
of accident vehicles
(VRL011248; Edition 01.2018)
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 ⇒ Wheels, tyres, wheel
alignment; Rep. gr. 44
♦ Check tyres for cuts and impact damage in the tread and on
the flanks ⇒ Wheels, tyres, wheel alignment; Rep. gr. 44
♦ Check tyre pressure; see tyre pressure sticker in fuel tank flap
or ⇒ Maintenance ; Booklet ; Checking tyres: Condition, wear
pattern, inflation pressure, tread depth
If rim of wheel and/or tyre is damaged, renew tyre. This also ap‐
plies if the circumstances of the accident and the damage to the
vehicle indicate possible damage which is not visible.
A further factor in the decision is the age of the tyre. Tyres should
not be older than 6 years.
If in doubt, the following always applies:
• Whenever a safety risk cannot be excluded, the tyre(s) must
be renewed.
1. Checklist for evaluating running gear of accident vehicles 1

Complete vehicle
Check other vehicle systems as well, for example:
♦ 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 like, for example, ABS/EDL; airbags;
electronically regulated suspension systems; electromechanical
or electrohydraulic steering and other driver assist systems must
be read with the Vehicle diagnosis, testing and information sys‐
tem - VAS 5051B- for possible stored fault messages. If faults are
saved in the event memories of the systems mentioned above,
repair them according to instructions in workshop manuals in EL‐
SA. Following repairs, read event memories of the affected sys‐
tems again to ensure that complete function has been restored.
2 Rep. gr.00 - Technical data

2 General information
Information concerning wheels, tyres and snow chains can be
found in “Wheel and Tyre Guide” ⇒ Wheels, tyres, wheel align‐
ment; Rep. gr. 44 .
2. General information 3
40 – Front suspension
1 Evaluating accident vehicles
A check list for evaluating running gear of accident vehicles can
be found under ⇒ page 1 .
4 Rep. gr.40 - Front suspension

2 Lifting front axle in unladen state
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.
2. Lifting front axle in unladen state 5

To simulate this position on the lifting platform, raise the respec‐

tive wheel suspension with the engine and gearbox jack - V.A.G
1383 A- and support - T10149- .
Before the 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

Steel spring strut 1BA/1BE 478 ± 10 mm
Steel spring strut 1BB 488 ± 10 mm
Air spring strut 1BK/1BY 475 ± 10 mm
Air spring strut 2MA 450 ± 10 mm
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. Which PR. No. refers to which running gear can be found
here ⇒ page 297 .
– Raise wheel bearing housing using engine and gearbox jack
- V.A.G 1383 A- until dimension -a- is attained.
WARNING
♦ Never raise or lower the vehicle while the engine and

gearbox jack is positioned beneath 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 Overview - front axle
Note
♦ It is not permitted to weld or straighten load-bearing or wheel-guiding components of the suspension.

♦ Always renew self-locking nuts.
♦ 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 .
I - Assembly overview: sub‐

frame ⇒ page 9
II - Assembly overview - front
wheel suspension, lower sus‐
pension link, upper suspen‐
sion link ⇒ page 44
III - Assembly overview - wheel
bearing, 17" running gear
⇒ page 69
IV - Assembly overview - wheel
bearing, 18" running gear
⇒ page 75
3. Overview - front axle 7

V - Assembly overview: anti-

roll bar ⇒ page 85
IV - Assembly overview - front
steel spring strut ⇒ page 95
V - Front air spring strut
⇒ page 107 .

4 Assembly overview: subframe
Note

state) ⇒ page 5 .
1 - Front final drive

❑ Removing and installing
⇒ Transfer box and final
drive; Rep. gr. 39 ; Re‐
moving and installing
front final drive .
2 - Nut
❑ 90 Nm + 90°
❑ Renew after each re‐
moval
3 - Bolt
moval
4 - Subframe
❑ Fixing in position for ve‐
hicles with V6 engines
⇒ page 11 .
❑ Fixing in position for ve‐
hicles with V8 engines
⇒ page 12 .
⇒ page 14
❑ Repairing, bonded rub‐
ber bushes in direction
of travel at front for V6
engines ⇒ page 22
of travel at front for V8
engines ⇒ page 28
of travel at rear for V6
engines ⇒ page 34
ber bushes in direction of travel at rear for V8 engines ⇒ page 38
5 - Bonded rubber bush
❑ Removing and installing in direction of travel at front for V6 engines ⇒ page 22
❑ Removing and installing in direction of travel at front for V8 engines ⇒ page 28
❑ Removing and installing in direction of travel at rear for V6 engines ⇒ page 34
❑ Removing and installing in direction of travel at rear for V8 engines ⇒ page 38
4. Assembly overview: subframe 9

6 - Thrust washer
❑ Opening faces in direction opposite to travel direction
❑ Only V8-TDI
❑ Allocation ⇒ Electronic parts catalogue “ETKA”
7 - Bolt
❑ 120 Nm + 180°
❑ Renew after each removal
8 - Eccentric washer
❑ Inner hole with lug
9 - Nut
❑ 170 Nm
10 - Lower suspension link
❑ Removing and installing ⇒ page 53
❑ Tapered pin must be free of oil and grease.
❑ If necessary, clean with a dry cloth but do not use cleaning solutions.
11 - Eccentric bolt
❑ If loosened, wheel alignment must be performed
❑ Do not turn more than 90° in either direction (i.e. from minimum to maximum adjustment position).
12 - Bolt
❑ 90 Nm + 90°
13 - Nut
❑ 90 Nm + 90°
14 - Bolt
4.1 Repairing thread in longitudinal member

Repairing the thread in captive nuts in the longitudinal member is
possible only under certain conditions ⇒ Body Repairs; Rep. gr.
50 .
Volkswagen Technical Site: http://vwts.ru http://vwts.info

4.2 Fixing subframe in position, vehicles with V6 engines

equipment required
♦ Locating pins - T10300-

♦ Torque wrench - V.A.G 1331-
Perform the following steps:
– Remove noise insulation below engine and gearbox ⇒ Rep.
gr. 50 ; Assembly overview - noise insulation; noise insulation .

– Remove one of the rear bolts of the subframe -arrow-
– Screw in locating pins - T10300- -1-.
– Screw in locating pins - T10300- »by hand« as far as the

marking -B-.
– Now, tighten locating pins - T10300- to 30 Nm, counterholding
sleeve with open-jaw spanner on flats to prevent its turning.
– This must now be done for the second rear bolt of the sub‐
frame.
The position of the subframe is now fixed.
Remove locating devices - T10300- in reverse order.
Specified torques
Component Specified torque
Subframe to body 120 Nm + 180°
♦ Use new bolts
4.3 Fixing subframe in position, vehicles

with V8 engines
Special tools and workshop equipment required

♦ Counter-hold tool - T10172-
♦ Insert - T10172/10-

– Remove one of the rear bolts of the subframe -arrow-


– Tighten locating pins - T10463- to 30 Nm.
frame.
Locating pins - T10463- are removed in reverse order.
– Bolt on subframe using new bolts -1-.

Ensure shims -2- are installed in correct fitting location.
– Open side -arrow- of shim -2- points to rear (opposite to normal
direction of travel).
– When tightening bolt -arrow-, hold thrust washer -3- in position

with counter-hold tool - T10172- .
1- Counter-hold tool - T10172-
2- Insert - T10172/10-
3- Thrust washer
Specified torques
♦ Use new bolts
4.4 Removing and installing subframe


equipment required
♦ Hose clamps to 25 mm - 3094-

♦ Spring tensioner - VW 552-
♦ Bits XZN 12 - T10099-
♦ Ball joint puller - T10187-

♦ Scissor-type assembly platform - VAS 6131-
♦ Left subframe mounting - VAS 6131/6-1-

♦ Right subframe mounting - VAS 6131/6-2-
♦ Left running gear support - VAS 6131/6-3-
♦ Right running gear support - VAS 6131/6-4-
♦ Support (2 x) - VAS 6131/6-5-
♦ 2 bolts M14 x 1.5 x 90, for example Bolts - N 104 281 01-
Removing
Brief description:
The subframe is removed using the assembly platform. The front
securing points of engine carrier must be secured with shorter
bolts. Subframe is removed with steering rack, front final drive,
lower suspension links and wheel bearing housings. The air
spring struts/steel spring struts and the suspension links remain
on the vehicle.
Vehicles with air spring struts
– Activate car jacking mode ⇒ page 259 and place vehicle on
lifting platform.
Continued for all vehicles
– Loosen wheel bolts.
– Raise vehicle.
– Remove front wheels.
– Bleed air from air spring strut with Vehicle diagnosis, testing
and information system - VAS 5051B- .
– Detach suction hose from servo oil container -2-.
1- Hose clamp - 3094-

– Insert spring tensioner - VW 552- -1- into upper opening of

wheel housing and attach to top suspension link on both sides
of the vehicle.
– Slightly pretension suspension link so that the ball pivot of the
suspension link is not damaged.
– Remove upper bracket for brake line -1 - from wheel bearing

housing -arrow-.
– Pull connector -1- and cable out of the bracket -3-.

– Undo bolt -2- and remove lower bracket for brake line -3- from
wheel bearing housing.
– Slacken off nut of suspension link at top but do not remove yet.
Caution
To protect thread, leave nut screwed a few turns onto joint pin.
– Press out top suspension link

1- Ball joint puller - T10187-
– Detach brake hoses from brake lines in wheel housing.

– Detach return line.

– Release connector -1- at solenoid valve for Servotronic and

pull off. - N119- .
– Unbolt hydraulic line bracket -1-.

– Disconnect pressure and return lines -2- from steering rack.
– Disconnect all electrical lines from body to axle.
– Remove propshaft from front final drive and lift and tie in place
⇒ Transfer box and final drive; Rep. gr. 39 ; Final drive, dif‐
ferential .
– Remove bolts (if any) -arrows-.

– Remove heat shield -1- from steering rack -2-.
– Turn steering rack to full right lock.

– Unscrew and remove bolt -arrow- of universal joint -1-.

– Pull universal joint -1- off power-assisted steering rack -2-.
– Bolt supports onto scissor-type assembly platform - VAS

6131- as shown in the illustration.
1- Left subframe mounting - VAS 6131/6-1-
2- Right subframe mounting - VAS 6131/6-2-
3- Right running gear support - VAS 6131/6-4-
4- Left running gear support - VAS 6131/6-3-
5- Subframe mounting - VAS 6131/6-5-
– Support subframe with assembly platform.

1- Left running gear support - VAS 6131/6-3-
2- Left subframe mounting - VAS 6131/6-1-
3- Subframe mounting - VAS 6131/6-5-

– Remove bolt -1- for strut -2- from suspension link.
– Unbolt left and right coupling rods -1- from anti-roll bar.
– Fixing subframe in position, vehicles with V6 engines
⇒ page 11 .
– Fixing subframe in position, vehicles with V8 engines
⇒ page 12 .
– Remove front subframe bolts -1-.
– Lower subframe -1- by about 50 mm with help of scissor-type

assembly platform - VAS 6131- .
– Use two bolts M14 x 1.5 x 90, for example bolts - N 104 281
01- to secure engine carrier to body on left and right -2-.
– Carefully pull breather line off front final drive.
– Slowly lower subframe, all the time making sure there is suf‐
ficient clearance.
Installing
Install in reverse order. During this procedure, observe the fol‐
lowing:
Installing propshaft ⇒ Transfer box and final drive; Rep. gr. 39 ;
Final drive, differential .
– Bolt on subframe using new bolts.

– Fit universal joint -1- onto steering rack and tighten bolt
-arrow- to specified torque.
– Bolt heat shield (if there is one) -1- onto steering rack -2-
-arrows-.
– Remove hose clamp - 3094- -1- of return line on servo reser‐

voir -2-.
– Remove hose clamp - 3094- -1- of return line.
Note
♦ If the subframe is replaced, the suspension link must be con‐

verted.
♦ Check wheel alignment after completing the installation.
– Install front wheels and tighten ⇒ page 285 .

– Bleed brake system ⇒ Rep. gr. 47 ; Bleeding brake system .

Specified torques
Upper suspension link to wheel bearing housing 85 Nm
♦ Use new nuts.
Union joint of pressure and return lines at steering rack 32 Nm

Universal joint to steering rack 20 Nm + 90°
♦ Use new bolts.
Heat shield on steering rack/universal joint 9 Nm

♦ Use new bolts.
Coupling rod to anti-roll bar 110 Nm

♦ Use new nuts.
Air spring strut/steel spring strut to suspension link 150 Nm + 90°

♦ Use new bolts and nuts.
4.5 Repairing subframe, bonded rubber bushes in direction of travel at front for
V6 engines

equipment required
♦ Assembly tool - T10301-

♦ Hydraulic press - VAS 6178- and thrust piece - T10205/13-
♦ Foot pump - VAS 6179-
Removing
lifting platform.
ferential .


– Unbolt coupling rod bolted connections -1- on side on which

bonded rubber bush is to be replaced.
Vehicles with V6 TDI engine
Note
A damper is fitted on the right-hand side of vehicles with a V6 TDI

engine.
– Price cap -1- off damper -2- and remove securing bolt.
– Pull damper -2- off anti-roll bar clip.
– Remove bolts -arrows- for anti-roll bar clamp -1- from sub‐
frame on side on which bonded rubber bush is to be replaced.
– Remove anti-roll bar clamp -1-.

– Position engine and gearbox jack - V.A.G 1383 A- under sub‐
frame.

– Lower subframe -1-.

a - Max. 40 mm
Pressing out bonded rubber bush
– Fit support ring - T10301/8- -1- with narrow side -arrow- facing
subframe.
It must be easy to apply support ring - T10301/8- , and it must not
be canted.

– Fit tools as shown in illustration.

1- Press tool - T10301/5-
2- Support ring - T10301/8-
3- Tube - T10301/3-
4- Spacer - T10301/9-
5- Hydraulic press - VAS 6178- and thrust piece - T10205/13-
6- Nut - T10301/2-
7- Spindle - T10301/1-
Caution
♦ Before pressing out, position engine and gearbox jack -

V.A.G 1383 A- with universal support under cylinder as
cylinder may drop down at end of pressing-out process.
♦ Hold hydraulic press - VAS 6178- securely during press‐
ing-out process.
– Press out bonded rubber bush.

Installation position
One of the two arrows -1- must point in direction of travel.

Pressing in bonded rubber bush
– Fit thrust plate - T10301/10- -1- with open side facing sub‐
frame.
Caution
When pressing in bonded rubber bush, ensure that thrust plate

- T10301/10- is in the correct position to prevent damage to
subframe.


2- Bonded rubber bush
3- Thrust plate - T10301/10-
4- Spacer - T10301/11-
6- Nut - T10301/2-
7- Spindle - T10301/1-
– Press in bonded rubber bush until collar contacts sleeve of
subframe »without gaps«.
Installing
lowing:
-arrows-.
Specified torques
♦ Use new bolts.


Anti-roll bar to subframe 60 Nm
Anti-roll bar to coupling rod 110 Nm
♦ Use new bolts.
4.6 Repairing subframe, bonded rubber bushes in direction of travel at front for
V8 engines

equipment required


♦ Insert - T10172/10-
Removing
lifting platform.
ferential .


– Unbolt coupling rod bolted connections -1- on side on which

bonded rubber bush is to be replaced.
– Remove bolts -arrows- for anti-roll bar clamp -1- from sub‐
frame on side on which bonded rubber bush is to be replaced.
– Remove front subframe bolts -1- and shims -2-.

frame.


a - Max. 40 mm
– Fit support ring - T10301/14- -1- with narrow side -arrow- fac‐
ing subframe.
It must be easy to apply support ring - T10301/14- , and it must
not be canted.


3- Tube - T10301/13-
4- Spacer - T10301/9-
6- Nut - T10301/2-
7- Spindle - T10301/1-
Caution

ing-out process.

The lugs -arrows A- must align along longitudinal axis of vehicle.

The cut-outs -arrows A- must face in normal direction of travel.
– Fit thrust plate - T10301/15- -1- with open side facing sub‐
frame.
Caution
When pressing in bonded rubber bush, ensure that thrust plate

- T10301/15- is in the correct position to prevent damage to
subframe.


4- Spacer - T10301/11-
6- Nut - T10301/2-
7- Spindle - T10301/1-
Installing
lowing:


2- Insert - T10172/10-
3- Thrust washer

-arrows-.
Specified torques
♦ Use new bolts.

♦ Use new bolts.
4.7 Repairing subframe, bonded rubber bushes in direction of travel at rear for
V6 engines


equipment required

Removing
lifting platform.



– Remove rear subframe bolts -arrows-.
– Lower subframe -1- and wedge a piece of wood -2- between

floor and subframe.
a - Max. 40 mm


3- Tube - T10301/3-
5- Nut - T10301/2-
6- Spindle - T10301/1-
Caution

ing-out process.

One of the two arrows -1- must point in direction of travel.


5- Nut - T10301/2-
6- Spindle - T10301/1-
Installing
lowing:

-arrows-.
Specified torques
♦ Use new bolts.

♦ Use new bolts.
4.8 Repairing subframe, bonded rubber bushes in direction of travel at rear for
V8 engines


equipment required

♦ Insert - T10172/10-


Removing
lifting platform.

– Unscrew rear subframe bolts -arrow-, and detach thrust wash‐

ers -2-.

– Lower subframe -1- and wedge a piece of wood -2- between

floor and subframe.
a - Max. 40 mm

3- Tube - T10301/13-
5- Nut - T10301/2-
6- Spindle - T10301/1-
Caution

ing-out process.

The lugs -arrows A- must align along longitudinal axis of vehicle.

The cut-outs -arrows A- must face in normal direction of travel.


5- Nut - T10301/2-
6- Spindle - T10301/1-
Installing
lowing:


2- Insert - T10172/10-
3- Thrust washer

-arrows-.
Specified torques
♦ Use new bolts.

♦ Use new bolts.

5 Assembly overview - front wheel suspension, lower suspension link,

upper suspension link
Note

state) ⇒ page 5 .
1 - Nut
❑ 60 Nm
❑ Qty. 3
2 - Ring
3 - Body - front
4 - Bolts
❑ 50 Nm + 180°
moval
❑ Renewing ⇒ page 50
❑ Allocation ⇒ Electronic
parts catalogue “ETKA”
6 - Nut
❑ 50 Nm + 180°
moval
7 - Upper suspension link
❑ Removing and instal‐
ling, vehicles with steel
spring struts
⇒ page 46 .
❑ Removing and instal‐
ling, vehicles with air
spring struts
⇒ page 48 .
❑ Cone must be free of oil
and grease.
❑ If necessary, clean with
a dry cloth but do not
use cleaning solutions.
8 - Nut
❑ 85 Nm
9 - Wheel bearing housing
❑ Different versions for 17" and 18" running gears
❑ Tapered hole must be free of oil and grease.

10 - Nut
❑ Various versions
❑ Bear in mind different specified torques:
❑ 17" running gear (cast steel) 110 Nm
❑ 18" running gear (cast aluminium) 130 Nm
❑ Pressing in and out (suspension strut connection) ⇒ page 62 .
❑ Pressing in and out (camber adjusting screw connection) ⇒ page 56 .
13 - Lower suspension link
❑ Pressing in and out (caster adjusting screw connection) ⇒ page 59 .
15 - Nut
❑ 150 Nm + 90°
16 - Bolt
17 - Steel spring strut
18 - Nut
❑ 110 Nm
19 - Bolt
❑ 110 Nm
20 - Coupling rod
21 - Air spring strut
5. Assembly overview - front wheel suspension, lower suspension link, upper suspension link 45
5.1 Removing and installing upper suspension link, vehicles with steel spring
struts

equipment required
Removing
– Raise vehicle.
– Remove wheel.
– Remove wheel housing liner ⇒ General body repairs, exterior;
Rep. gr. 66 ; Exterior equipment; Wheel housing liner

Vehicles with dynamic headlight range control

– Pull pin -2- for front left/right vehicle level sender - G78/G289-
downwards and unclip coupling rod at top suspension link.
– Use wheel bolt to attach support - T10149- .
– Slacken off nut of suspension link at top but do not remove yet.
Caution
– Press out upper suspension link and unscrew nut.

– Remove bolts -arrows- and remove upper suspension link

-1-.
Installing
lowing:
– Tighten bolted connection between upper suspension link and

body when dimension -a- between suspension link and body
has been attained.
a - 118 mm
– Install front wheel and tighten ⇒ page 285 .
Specified torques
♦ Use new nuts.
Upper suspension link to body 50 Nm + turn 180° further

♦ Tighten bolts in unladen state ⇒ page 5
5.2 Removing and installing upper suspension link, vehicles with air spring
struts


equipment required
Removing
lifting platform.
– Raise vehicle.
– Remove wheel.
Rep. gr. 66 ; Exterior equipment, Wheel housing liner
– Remove air spring strut ⇒ page 111
– Remove bolts -arrows- and remove upper suspension link

-1-.
Installing
lowing:
– Tighten bolted connection between upper suspension link and

body when dimension -a- between suspension link and body
has been attained.
a - 118 mm
– Install air spring strut ⇒ page 111 .
– Install front wheel and tighten ⇒ page 285 .
Specified torques
♦ Use new nuts.
Upper suspension link to body 50 Nm + turn 180° further

♦ Tighten bolts in unladen state ⇒ page 5
5.3 Repairing upper suspension link


equipment required
♦ Assembly tool - 3301-

♦ Thrust plate - VW 401-
♦ Press tool - VW 412-
♦ Tube - VW 426-
Pressing out
– Remove upper suspension link, vehicles with steel spring
struts ⇒ page 46 .
– Remove upper suspension link, vehicles with air spring struts
⇒ page 48 .
– Mark the position of the bonded rubber bush with reference to

the slot -arrow- in relation to upper suspension link.

1- Press tool - VW 412-
2- Tube - 3301/4-
3- Upper suspension link
4- Tube - VW 426-
5- Pressure plate - VW 401-
Pressing in
– Moisten outer surface of bonded rubber bush with assembly
oil - G 294 421 A1- .
– Pressing in bonded rubber bush.

4- Tube - T10219/1- with the gap in side facing upwards to
suspension link
– Continue pushing inner core of the bonded rubber bush until

the lip -arrow- slips out of the suspension link.
2- Pin - T10219/2-
4- Tube - T10219/1- with the gap in side facing upwards to
suspension link
– Install upper suspension link, vehicles with steel spring struts
⇒ page 46 .
– Install upper suspension link, vehicles with air spring struts
⇒ page 48 .

5.4 Checking swivel joint

• The check must be carried out with the vehicle raised.
lifting platform.
Checking axial play
– Firmly pull wheel down in -direction of arrow- and press up
again.
Checking radial play

– Set wheels/steering to straight-ahead position.
– Grip wheel at top and bottom and wobble in
-direction of arrow-.
– Turn wheels/steering to left and repeat check.
– Turn wheels/steering to right and repeat check.
Note
♦ There should be no palpable or visible “play” during both tests.

♦ Take into account any existing wheel bearing play or “play” in
upper spring strut mounting.
♦ Other methods of checking are impermissible, as the swivel
joint may otherwise be damaged.
5.5 Removing and installing lower suspension link

equipment required

♦ Insert tool - T10188-
Removing
lifting platform.
– Raise vehicle.
– Remove wheel.


Rep. gr. 66 ; Exterior equipment; Wheel housing liner and
hook spring compressor - VW 552- -1- into upper opening of
wheel housing and to top suspension link on both sides of ve‐
hicle.
– Slacken off nut on tapered pin (but do not remove yet).
Caution
– Press out lower suspension link and unscrew nut.

– Remove bolted joint -1-.

– Lower the lower suspension link in -direction of arrow- and
thread out of wheel bearing housing.
Installing
lowing:
Bolted joint between suspension strut and lower suspension link
must be tightened in unladen position ⇒ page 5 .
– Install wheel and tighten bolts or nuts ⇒ page 285 .
– Do not tighten bolted joint between lower suspension link and
subframe until during wheel alignment.
– Perform wheel alignment ⇒ page 286 .
Specified torques
Lower suspension link to subframe 170 Nm
♦ Self-locking nut
♦ Use new bolts
Spring strut to lower suspension link 150 Nm + 90°

♦ Use new nuts and bolts
Lower suspension link at wheel bearing housing 18" run‐ 130 Nm

ning gear (cast aluminium)
♦ Use new bolts

ning gear (cast steel)
♦ Use new bolts
5.6 Repairing lower suspension link - pressing in and out bonded rubber bushes
(camber adjuster screw connection)


equipment required

Removing
lifting platform.
– Raise vehicle.


– Lower the lower suspension link in -direction of arrow-.
Pressing out
– Fit tools to lower suspension link as shown in illustration.

1- Nut - T10230/2-
3- Lower suspension link
4- Tube - T10230/5-
5- Pressure plate - T10230/7-
Caution

ing-out process.

Pressing in


1- Nut - T10230/2-
– Press bonded rubber bush in to stop.
In doing so, core of bonded rubber bush is pressed in further than
necessary by thrust piece - T10230/6- . This is necessary so that
outer lip of bonded rubber bush lies on suspension link. After re‐
leasing hydraulic press - VAS 6178- , core of bonded rubber bush
returns to its correct position.
Installing
lowing:
Specified torques
♦ Use new bolts

(caster adjuster screw connection)

equipment required

Removing
lifting platform.
– Raise vehicle.



– Lower the lower suspension link in -direction of arrow-.
Pressing out

3- Tube - T10230/9-
5- Press tool - T10230/15-
6- Spindle - T10230/1- and nut - T10230/2-
Caution

ing-out process.

Pressing in
– Align bonded rubber bush so that the cams -arrows- point

straight downwards.
The imaginary centreline should be at an angle α of 90° to the
bottom side of the suspension link.

5- Press tool - T10230/16-
6- Spindle - T10230/1- and nut - T10230/2-
– Pressing in bonded rubber bush.
Installing
lowing:
Specified torques
♦ Use new bolts

(spring strut connection)


equipment required

– Remove lower suspension link ⇒ page 53 .
Pressing out
1- Threaded spindle - T10230/1-
2- Nut - T10230/2-
3- Press tool - T10230/13-
4- Tube - T10230/5-
Pressing in

1- Threaded spindle - T10230/1-
2- Nut - T10230/2-
3- Press tool - T10230/13-
5- Tube - T10230/5-
– Press bonded rubber bush in flush.
– Use openings in tube - T10230/5- to observe pressing in proc‐
ess.
– Install lower suspension link ⇒ page 53 .
5.9 Removing and installing wheel bearing housing


equipment required
♦ Fitting tool - T10206-

♦ Adapter - T10103/1- and bolts - T10103/2-
♦ Ejector - T10520-
Removing
lifting platform.
– Loosen 12-point drive shaft nut at wheel hub ⇒ page 127 .
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 the 12-point nut by more than 90°
when vehicle is resting on 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 150 Nm.

– Raise vehicle.
– Remove wheel.
– Loosen nut on track rod ball joint but do not remove complete‐
ly.
Caution
– Push track rod off wheel bearing housing and remove nut.

housing -arrow-.
– Remove brake caliper and hang from body using wire ⇒ Brake
system; Rep. gr. 46 ; Repairing front brake .
– Remove ABS speed sensor ⇒ Brake systems; Rep. gr. 46 ;
Repairing front brake .
– Remove brake disc.
– Remove cover plate.

Caution

– Unscrew 12-point nut for drive shaft.
Before using pressure tool - T10520- ensure that thrust piece

-1- is inserted.
– Press out drive shaft.

1- Adapter - T10103/1-
2- Press tool - T10520-
– It is essential to follow specified sequence.

I - Tighten knurled nut -1- hand-tight.
II - Turn only bolt -2- using a spanner in order to press out drive
shaft with ejector - 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.
– When removing, make sure joints have adequate clearance.
Caution
– Press out lower suspension link.

– Unscrew nut and remove wheel bearing housing.
Installing
lowing:
– Pull drive shaft in.

1- Fitting tool - T10206-
– Tighten 12-point drive shaft nut at wheel hub ⇒ page 127 .
Specified torques
♦ Use new nuts.

ning gear (cast aluminium)
♦ Use new nuts.

ning gear (cast steel)
♦ Use new nuts.
Track rod ball joint to wheel bearing housing 90 Nm

♦ Use new nuts.
Drive shaft to wheel bearing 500 Nm

♦ Use new bolts
Cover plate on wheel bearing housing 17" running gear 20 Nm

Cover plate on wheel bearing housing 18" running gear 9 Nm
Top bracket for brake line on wheel bearing housing 9 Nm
Lower bracket for brake line on wheel bearing housing 20 Nm

6 Assembly overview - wheel bearing, 17 running gear
1 - Wheel bearing
⇒ page 70
2 - Retaining ring
❑ Ensure it is properly
seated
3 - Wheel hub
⇒ page 70
4 - Nut
❑ 500 Nm
❑ Self-locking
moval
5 - Track rod
❑ Tapered pin must be
free of oil and grease.
⇒ page 356
6 - Front speed sensor
7 - Bolt
❑ 8 Nm
8 - Bolt
❑ 20 Nm
❑ Qty. 3
9 - Cover plate
10 - Nut
❑ 90 Nm
12 - Drive shaft
❑ Before assembling, coat splines with assembly paste - G 052 109 A2- .
13 - Cable retainer
14 - Bolt
❑ 20 Nm
15 - Bolt
❑ 9 Nm
6. Assembly overview - wheel bearing, 17 running gear 69

16 - Bracket
6.1 Removing and installing wheel bearing for 17" running gear

equipment required

♦ Splitter - 3 - Kukko 15/3-


Removing
– Remove drive shaft ⇒ page 128 .
– Bolt upper suspension link to wheel bearing housing.
– Remove brake caliper and hang from body using wire ⇒ Brake
system; Rep. gr. 46 ; Repairing front brake .
– Remove brake disc and backplate.
– Remove speed sensor for ABS.
Pulling out wheel hub
– Fasten gripping pieces - T10205/1- -1- with wheel bolts -2- to
hub.
Wheel bolts -2- must not protrude from backs of gripping pieces
- T10205/1- -arrow-.


1- Spindle - T10205/8-1-
2- Nut - T10205/8-2-
4- Bell - T10205/2-
5- Gripping pieces - T10205/1-
7- Nut - T10205/8-2-
8- Spindle - T10205/8-1-
Caution

ing-out process.
– Hold appliance firmly and pull wheel hub out.

Pulling out wheel bearing
– Remove retaining ring.

Observe the following:
Shoulder of thrust plate - T10205/6- must face final drive.
1- Spindle - T10205/8-1-
2- Nut - T10205/8-2-
4- Support tube - T10205/5-
5- Support - T10205/4-
6- Thrust plate - T10356/4- - inscription B must point to the
wheel bearing
7- Nut - T10205/8-2-
8- Spindle - T10205/8-1-
– Hold appliance firmly and pull out wheel bearing.
Pulling bearing inner race off wheel hub

– Set up splitter behind inner bearing race.

Please note:
Fitting position: Chamfer on plates faces to inner bearing race.
1- Splitter - 3 - Kukko 15/3-
2- Bell - T10205/2-
4- Nut - T10205/8-2-
6- Nut - T10205/8-2-
7- Spindle - T10205/8-1-
WARNING
When pulling, hold appliance so that the inner bearing race

faces downwards (danger of accident due to inner bearing race
springing off).
– Pull hub off inner bearing race.

Pressing in wheel bearing
– Ensure that rubber-coated ABS sensor ring -arrow- faces final

drive.
If no rubber-coated ring is visible, check which of the two sides is
magnetic using, e.g. a paper clip. On installation, this must point
to the final drive.
– Fit tools as shown in illustration. Make sure the wheel bearing

is centred on the thrust piece - T10205/7- .
1- Spindle - T10205/8-1-
2- Nut - T10205/8-2-
4- Wheel bearing
6- Tube - 3259-
8- Nut - T10205/8-2-
– Press in wheel bearing to stop.
– Install retaining ring.
Press in wheel hub


1- Spindle - T10205/8-1-
2- Nut - T10205/8-2-
3- Hydraulic cylinder - VAS 6178- with thrust piece -
T10205/13- and thrust plate - T10205/4-
4- Wheel hub
6- Nut - T10205/8-2-
7- Spindle - T10205/8-1-
– Press in wheel hub to stop.
Installing
lowing:
– Install drive shaft ⇒ page 134 .
– Install brake disc and backplate.
– Install brake caliper ⇒ Brake systems; Rep. gr. 46 ; Repairing
front brake .
Specified torques
Splash plate to wheel bearing housing 20 Nm

7 Assembly overview - wheel bearing, 18" running gear
1 - Wheel bearing
wheel bearing unit
⇒ page 77
❑ Repairing wheel bear‐
ing unit ⇒ page 81 .
Caution
Avoidance
• of dirt and
seal damage when plac‐
ing on a surface/storing
away ⇒ page 76 .
2 - Wheel hub
wheel bearing unit
⇒ page 70
❑ Repairing wheel bear‐
ing unit ⇒ page 81 .
Caution
Avoidance
• of dirt and
away ⇒ page 76 .
3 - Nut
❑ 500 Nm
moval
4 - Track rod
a dry cloth but do not use cleaning solutions.
5 - Front speed sensor
6 - Bolt
❑ 8 Nm
7 - Cover plate
8 - Bolts
❑ 9 Nm
❑ Qty. 3
9 - Nut
❑ 90 Nm
7. Assembly overview - wheel bearing, 18" running gear 75

Caution
Avoidance
• of dirt and
away ⇒ page 76 .
11 - Drive shaft
12 - Bracket
13 - Bolt
❑ 20 Nm
14 - Bolt
❑ 9 Nm
15 - Bracket
Avoidance of dirt and seal damage when placing on a surface/

storing away
♦ Wheel bearing -1- must always face upwards.
♦ When placing wheel bearing unit on a surface, always make
sure the hub -2- faces downwards.
The same procedure applies to the wheel bearing without hub.

7.1 Removing and installing wheel bearing unit for 18"/19" running gear

equipment required
♦ Adapter - T10103/1- and bolts - T10103/2-

♦ Adapter - T10103/1-
♦ Socket 32 mm - T10209-

♦ Assembly pin - T10439-
Press tool - T10520-

Removing
lifting platform.
Caution


– Raise vehicle.
– Remove wheel.
– Unbolt brake caliper and push outwards using guide - T10439-
⇒ Brake systems; Rep. gr. 46 ; Repairing front brake .
– Remove brake disc.
– Remove speed sensor for ABS.


-1- is inserted.
– Press drive shaft out as far as possible.

1- Adapter - T10103/1-
3- Assembly pin - T10439-

Note
– Remove bolts -arrows- above drive shaft.

– Remove bolts -arrows- below drive shaft.
– Pull wheel bearing unit off drive shaft.

1- Adapter - T10103/1-
3- -T10439-
– Remove wheel bearing unit together with remover - T10520- .
Caution
• Avoidance of dirt and seal damage when placing on a sur‐

face/storing away.
Wheel bearing -1- must always face upwards.

– Always set wheel bearing unit on hub -2- when placing on a
surface.
Installing
lowing:
– Fit wheel bearing unit onto splines of the drive shaft.
– Hand-tighten bolts -arrows- below drive shaft.

– Hand-tighten bolts -arrows- above drive shaft.

– Tighten bolts for wheel bearing unit.

– Fit brake caliper and brake disc ⇒ Brake systems; Rep. gr.
46 ; Repairing rear brake .
Specified torques
Wheel bearing unit to wheel bearing housing 80 Nm +120°
♦ Use new bolts

♦ Use new bolts
7.2 Repairing wheel bearing unit


equipment required

♦ Splitter - Kukko 15/3 mit 17/3-
– Remove wheel bearing unit ⇒ page 77 .

Press wheel hub out of wheel bearing

– Use special tools as illustrated.
2- Sleeve - T10230/8-
4- Wheel bearing unit
– Press wheel hub out of wheel bearing.
Press bearing inner race off wheel hub

– Insert splitter between bearing inner race -1- and wheel hub
-2- and pretension with spindle.
Note
Use a standard commercially available splitter, e. g. 15/3 and 17/3

from KUKKO.

2- Sleeve - T10230/8-
4- Wheel hub
5- Inner bearing race
6- Kukko 15/3 with 17/3.
– Press bearing inner race off wheel hub.
Pressing wheel hub into wheel bearing
Caution

face/storing away.


surface.

3- Wheel hub
4- Ball bearing
Note
Machined surface of wheel bearing outer race faces downwards.
Caution
When placing on a surface or pressing in, make sure that there

is no dirt between thrust plate - VW 401- -5- and ball bearing
-4-.
– Press wheel hub into wheel bearing.

– Install wheel bearing unit ⇒ page 77 .

8 Assembly overview: anti-roll bar
1 - Shock absorbers
2 - Bolt
moval
3 - Coupling rod
⇒ page 88
4 - Nut
❑ 110 Nm
moval
5 - Nut
❑ 110 Nm
moval
6 - Bolt
moval
7 - Anti-roll bar
⇒ page 86
8 - Subframe
9 - Mountings
❑ In two sections on both
sides of the vehicle
❑ Are connected to each
other by means of latch‐
ing lugs
❑ Always replace the
complete mountings
⇒ page 91
10 - Clip
11 - Damper weight
❑ Only V6 TDI
12 - Bolt
❑ 60 Nm
❑ M10 x 105
❑ Only V6 TDI
13 - Cap
❑ Only V6 TDI
14 - Bolt
❑ 60 Nm
8. Assembly overview: anti-roll bar 85

❑ M10 x 62
❑ Qty. 4
❑ Qty 3, only V6 TDI
8.1 Removing and installing anti-roll bar


Removing
lifting platform.
Continued for both vehicles
– Unscrew and remove bolted joint -1- for coupling rod.
Note

engine.

– Remove bolts -arrows-.for anti-roll bar clamp -1- from sub‐

frame.
– Remove anti-roll bar.
Installing
lowing:
– Fit anti-roll bar clamp -1-.

– Hand-tighten bolts -arrows-.for anti-roll bar clamp -1- on sub‐
frame.

– Place damper -2- on anti-roll bar clamp and hand-tighten se‐

curing bolt.
– Tighten bolts for anti-roll bar clamp to specified torque.
– Fit cap -1- on damper -2-.
Specified torque
8.2 Removing and installing coupling rod


equipment required


Removing
lifting platform.
– Raise vehicle.
– Remove wheel.
– Unbolt drive shaft from final drive.
housing -arrow-.


– Support wheel bearing housing.

Caution

– Support wheel bearing housing with the support -
T10149- .and swing engine and gearbox jack - V.A.G 1383 A-
outwards.
– Undo and remove bolted joint -1-.
– Undo and remove bolted joint -1- and remove coupling rod.
Installing
lowing:
Specified torque

Coupling rod to spring strut 110 Nm
Drive shaft to front final drive 50 Nm + 90°
8.3 Removing and installing bush for anti-

roll bar
Volkswagen Technical Site: http://vwts.ru http://vwts.info


Removing
lifting platform.
Note

engine.


frame.
The two halves of the bush are locked into each other by means
of latching lugs.
– Carefully detach the two latching lugs -arrows- on the anti-roll
bar bush -1-.
Installing
lowing:
– Make sure bush halves -1- are correctly seated on hexagonal

positioning element -arrow- of the anti-roll bar.
– Press two halves of bush together carefully until the latches
audibly engage.
– Fit anti-roll bar clamp -1-.

– Hand-tighten bolts -arrows-.for anti-roll bar clamp -1- on sub‐
frame.

– Place damper -2- on anti-roll bar clamp and hand-tighten se‐

curing bolt.
– Tighten bolts for anti-roll bar clamp to specified torque.
– Fit cap -1- on damper -2-.
Specified torque

9 Assembly overview - front steel spring strut
1 - Sealing plug
2 - Nut
❑ 56 Nm
moval
3 - Bearing plate
⇒ page 101
❑ Renew only as com‐
plete unit
4 - Upper spring shim
⇒ page 101
❑ Note installation posi‐
tion ⇒ page 106
5 - Upper spring seat
⇒ page 101
tion ⇒ page 106
6 - Boot
⇒ page 101
tion ⇒ page 105
7 - Buffer stop
⇒ page 101
tion ⇒ page 105
8 - Buffer cap
9 - Coil spring
❑ Surface of coil must not be damaged.
❑ Observe colour coding ⇒ page 96
❑ Observe assignment of spacers ⇒ page 96
❑ Note installation position ⇒ page 106
10 - Lower spring seat
11 - Lower spring shim
12 - Spacer
9. Assembly overview - front steel spring strut 95

13 - Spring plate
14 - Shock absorbers
9.1 Assignment of spacers

To ensure an even height at front and rear axles, the coil springs
must be fitted with the correct number of spacers.
Number of spacers
Number of colour marking on coil springs Number of spacers to be used
None 0
1 x violet 1
2 x violet 2
Colour coding of coil springs

1- Colour coding for allocation of spacers
2- Colour coding for allocation of coil springs
3- Coil spring installation position

9.2 Installation position of spacers

– The positioning lugs of the spacers -2- must latch into the po‐
sitioning openings of the spring shim -1-.
– The spacers -2- must latch over the lugs -arrows- of the spring
plate -1-.
9.3 Removing and installing steel spring strut


equipment required

♦ Bits XZN 12 - T10099-


Removing
When dismantling and assembling, ensure that no indentations
are formed on the protective boot of the steel spring damper.
– Remove engine-compartment cover.
Remove right steel spring strut in the case of vehicles with diesel
engine
– Remove fuel filter above steel spring damper ⇒ Rep. gr. 20 .
Remove left steel spring strut in the case of vehicles with hybrid
drive
– Unclip lines -1- from retainers -arrows-.
– Remove nuts -arrows- and push bracket -1- to one side.

– Unscrew nuts -arrows- and remove ring -2-.

– Raise vehicle.
– Remove wheel.



housing -arrow-.



Caution

outwards.
– Remove bolt -1- for steel spring damper -2- from suspension
link.
– Push top suspension link upwards, compress steel spring
damper and take out.
Installing
Carry out installation in the reverse sequence, noting the follow‐
ing:
Specified torques
Steel spring strut to body 60 Nm
Steel spring strut to lower suspension link 150 Nm + 90°

♦ Use new nuts.

Coupling rod to air spring strut 110 Nm
9.4 Repairing front steel spring strut


equipment required
♦ Insert tool - 3165-

♦ Tube - VW 420-
♦ Shock absorber tool set - T10001-
♦ Suspension strut clamp - V.A.G 1752-
♦ Spring compressor - V.A.G 1752/1-
♦ Spring retainer - V.A.G 1752/5-
♦ Strut support clamp - V.A.G 1752/20-
♦ Kukko 45-2
♦ Commercially available ratchet handle
– Remove steel spring strut ⇒ page 97

Dismantling steel spring strut

– Clamp steel spring strut.
1- Strut support clamp - V.A.G 1752/20-
– Ensure that coil spring is correctly seated in -arrow- in tool.

1- Spring compressor - V.A.G 1752/1-
2- Spring retainer - V.A.G 1752/4-
– Remove sealing plug ⇒ Item 1 (page 95) .

1- Commercially available ratchet handle
2- Hexagon bit, long reach - T10001/8-
7- Ratchet wrench - T10001/11-
– Tension coil spring until upper strut mounting is free.
WARNING
First compress spring far enough to ensure that upper strut

mounting is free.
– Unscrew hexagon nut from piston rod.

– Remove individual parts of steel spring strut.


1- Kukko 45-2
– Pull buffer cap off shock absorber.
– Force spring plate off shock absorber.
Assembling steel spring strut
ing:
– Drive spring plate onto shock absorber.

1- Tube - VW 420-
2- Hexagon bit, long reach - 3165-
– Push buffer cap onto shock absorber.


– Fit lower spring plate -1- correctly into lower spring shim -2-.
Note
The markings of the lower spring plate and the lower spring shim
must be in line with each other.
– Push stop buffer -1- into bellows -2- until it engages -arrows-.
– Fit bellows onto shock absorber.
– Engage bellows -1- in locking lugs -arrow- of buffer cap -2-.

– The end of the lower coil of the spring -1- must lie against the
stop -arrow- of the lower spring plate -2-.
– The end of the upper coil of the spring -1- must lie against the
stop -arrow- of the upper spring plate -2-.
– Fit upper spring shim -2- correctly onto upper spring plate
-1-.
Note
The markings of the upper spring plate and the upper spring shim
– Push bellows into strut mounting until it engages.

– Tighten new hexagon nut on piston rod.
– Relieve tension on spring compressor - VAS 6046- and re‐
move from coil spring.
– Install steel spring strut ⇒ page 97
Specified torque
Nut for steel spring strut 56 Nm
♦ Use new bolts

10 Front air spring strut
10.1 Instructions for repairing air spring struts

As of mileage of 200,000 km, renewing the air springs on both
sides is recommended in the event that one air spring is dam‐
aged.
In the case of leaking shock absorbers, the complete air spring
strut must be renewed, as the shock absorber oil may damage
the bellows ⇒ Item 6 (page 109) .
When depressurised, the air spring must not be twisted. This may
cause damage to the bellows inside the air spring due to kinking
or creasing!
To ensure perfect and successful air spring strut repair, the great‐
est care and cleanliness as well as the use of good and proper
tools are essential. Also note the basic rules on safety when per‐
forming repair procedures.
A number of general notes on the individual repair procedures,
which can otherwise be found in the relevant sections of the man‐
ual, are summarised here. These apply to repairing air spring
struts.
The structure and functioning of the air suspension system are
described in the ⇒ Self-study programme No. 469 ; Touareg
2011 running gear and all-wheel concept .
10.2 Air spring strut

– Before loosening the installed air line, check whether the air
spring still has approx. 3 bar residual pressure.
– To do this, press bead of air spring with your thumb. The bead
must offer perceptible resistance.
– If no great resistance is detectable, the air spring is not pres‐
surised.
– The vehicle can be driven up to 100 km with a unpressurised
air spring.
– The air spring must be replaced together with the pressure
retention valve if the vehicle has been driven for more than
100 km with a unpressurised air spring.
♦ Thoroughly clean all unions and the adjacent areas before
disconnecting.
♦ 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 lubricants specified by their part numbers.
♦ If repair work cannot be performed immediately, cover new
parts which have been removed from their packing.
10.3 Pressure retention valve

The pressure retention valve is maintenance-free and may be re‐
placed only if a leak is detected.
The pressure retention valve can be replaced only with the vehicle
on a lifting platform. It must be possible to turn the vehicle's
wheels freely.
10. Front air spring strut 107

Note
The pressure retention valve is open when the air line has been
screwed into the air spring strut. If the air line has been unscrewed
from the air spring strut, the pressure retention valve is closed.
10.4 Gaskets and seals

♦ Always renew sealing rings.
♦ Replace bellows if defective.
♦ After removing gaskets, check contact surface on housings for
burrs and damage.
10.5 Nuts and bolts

♦ Loosen and tighten securing bolts and nuts for covers and
housings diagonally.
♦ Specified torques given are for unoiled nuts, bolts and screws.
10.6 Front air spring strut components

The following components are part of the air springs.
♦ Cover ⇒ Item 4 (page 109)
♦ External guide ⇒ Item 5 (page 109)
♦ Bellows ⇒ Item 6 (page 109)
♦ Air spring plunger ⇒ Item 7 (page 109)
Note
These components are firmly connected to each other and cannot be disassembled.

1 - Mountings
2 - Seal
❑ Always renew
3 - Pressure retention valve
4 - Cover
❑ Firmly connected to
⇒ Item 5 (page 109) ,
⇒ Item 6 (page 109)
and
⇒ Item 7 (page 109) as
part of the air spring.
❑ Cannot be removed or
disassembled individu‐
ally.
5 - External guide
⇒ Item 4 (page 109) ,
and
ally.
6 - Bellows
⇒ Item 4 (page 109) ,
⇒ Item 5 (page 109) and
ally.
7 - Air spring plunger
❑ Firmly connected to ⇒ Item 4 (page 109) , ⇒ Item 5 (page 109) and ⇒ Item 6 (page 109) as part of the
air spring.
❑ Cannot be removed or disassembled individually.
8 - Boot
9 - Retention element
❑ Always renew
10 - Seal
❑ Always renew

10.7 Assembly overview - front air spring strut
1 - Grommet
2 - Bolt
❑ 9 Nm
❑ Qty. 4
3 - Cover
4 - Nut
❑ 70 Nm
moval
5 - Mountings
❑ 12 Nm
❑ Observe important
notes on removal and
installation ⇒ page 124
⇒ page 123
7 - Air spring
❑ Observe instructions for
repairing air spring
struts ⇒ page 107
❑ As of mileage of
200,000 km, renewing
the air springs on both
sides is recommended
in the event that one air
spring is damaged.
❑ With integrated pump
stop
❑ Always renew
9 - Boot
10 - Seal
❑ Always renew
❑ with a thin coat of lithium grease - G 052 150 A2-
11 - Seal
❑ Always renew
❑ Observe instructions for repairing air spring struts ⇒ page 107

10.8 Removing and installing air spring strut

equipment required

♦ 14 mm bits - T10099/1-


Removing
are formed on the protective boot of the air spring strut.
– Remove engine-compartment cover
Remove right air spring strut in the case of vehicles with diesel
engine
– Remove fuel filter above air spring strut ⇒ Rep. gr. 20
Remove left air spring strut in the case of vehicles with hybrid
drive
– Unclip lines -1- from retainers -arrows-.
– Remove nuts -arrows-.
lifting platform.
– Disconnect connector -1-.
– Unscrew nuts -arrows- and remove ring -2-.
– Raise vehicle.
– Remove wheel.
– Hook upper suspension link to body using spring tensioner -

VW 552- -1- and preload slightly.

– Unbolt air line from pressure retention valve -1- and seal both
connections.

housing -arrow-.



Caution

outwards.
– Remove bolt -1- for air spring strut -2- from suspension link.
– Push top suspension link upwards, compress air spring strut
and take out.
Installing
ing:

The air line has 2 markings.

Insert air line until the front marking -arrow A- is completely cov‐
ered by the union nut.
It must only be possible to see the second marking -arrow B- on
the air line.
– Fill air spring strut with the Vehicle diagnosis, testing and in‐
formation system - VAS 5051B- .
Specified torques
Air spring strut to body 60 Nm
Air spring strut to lower suspension link 150 Nm + 90°

♦ Use new nuts.

Coupling rod to air spring strut 110 Nm
10.9 Repairing front air spring strut
Note
Observe instructions for repairing air spring struts ⇒ page 107


equipment required
♦ Socket, 21 mm - 3186-
♦ Release tool set - VAS 1978/35-

♦ Spring retainer - V.A.G 1752/3A-

♦ Removal wedge - 3409-

Note
♦ Check whether the air spring still has approx. 3 bar residual
pressure.
♦ To do this, press bead of air spring with your thumb. The bead
♦ If no great resistance is detectable, the air spring is unpres‐
surised.
Dismantling air spring strut
– Clamp air spring strut by the anti-roll bar mounting in a vice

with protective jaws.
A - Aluminium protective jaws
Caution
Take care not to damage mounting.
– Knock cable lugs out of connector of air spring strut using set
of releasing tools - VAS 1978/35- .

– Unscrew bolts -2- and remove cover -3-.

– Push cable through grommet -1-.
– Unscrew nut from mount by counterholding it by the hexagonal

piece -3-.
2- Socket AF 21 - 3186-
– Remove mounting from shock absorber.
– Push bellows downwards.

– Press air spring plunger -1- off from shock absorber using
spring compressor - V.A.G 1752/1- .
Note
To avoid damage, a rubber mat -6- or similar must be inserted

between spring retainer inserts - V.A.G 1752/7- -5- and air spring
plunger.
1- Air spring plunger

2- External guide
4- Spring retainer - V.A.G 1752/3A-
6- Rubber mat or similar
Caution
♦ Insert protection, e.g. rubber, between spring retainer in‐

serts - V.A.G 1752/7- and air spring plunger.
♦ Insert protection, e.g. rubber, between spring retainers -
V.A.G 1752/3A- and shock absorber.
♦ Ensure that the plunger -1- does not slip down and out of
the external guide -2-.
Note
If the air spring is to be reused and the plunger has slipped out of
the external guide, it must be pushed in again by forming an even
fold all around the bellows -arrows-.

– Pull bellows -1- off shock absorber -arrow-.
Assembling air spring strut

– If the shock absorber has not been replaced, the sealing rings
-arrows- on the piston rod and the shock absorber tube must
be replaced.
– Clean contact surface with a lint-free cloth.
Note
Even slight soiling leads to air spring strut leakages.
– Lightly grease the seal with lithium grease - G 052 150 A2- .
– Push retention element onto shock absorber tube.
– Fit bellows -1- onto shock absorber.

– Ensure groove of bellows latches into place on shock absorber
-arrow-.

Note
– Extend shock absorber line, e.g. with a cable in order to take

it through the air spring.
– Push bellows downwards.
– Make sure that bump stop -1- is correctly seated in cover -2-
-arrow-.
The large diameter of the bump stop -1- must be seated so that
it is held clamped in the cover -2-.
– Fit mounting and secure with a new bolt, counterholding by the

hexagonal piece -3-.
2- Socket AF 21 - 3186-

– Align air spring so that pressure retention valve -1- is located

precisely on the air spring strut's imaginary symmetry axis
-arrow-.
– The pressure retention valve -1- must face towards the hole
for coupling rod -2-.
Note
During alignment, only turn by the plunger ⇒ Item 7 (page 109) in

order to avoid damaging the bellows ⇒ Item 6 (page 109) inside
the air spring.
– Fit cover -3- and secure with bolts -2-.

Vehicles with grommet that is not glued in.
– Insert grommet -1- in cover -3-.
Continued for both versions
– Push cable through grommet.
– Insert cable lug into connector housing.
– Install air spring strut ⇒ page 111 , but do not yet install air line.
– Raise air spring strut using engine and gearbox jack - V.A.G
1383 A- until plunger -1- lies on retention element -arrow-.

– Use removal wedge - 3409- to push retention element into

plunger.
1- Removal wedge - 3409-
– Continue to raise air spring strut using engine and gearbox

jack - V.A.G 1383 A- until welded ring on shock absorber tube
has disappeared approx. 3 mm into retention plunger
-arrow-.
– When lowering (rebound), hold pressure retention valve open
by opening valve tappet, e.g. with a 5 mm hexagon wrench,
so that air can flow in.
Note
This prevents the bellows from wrinkling.
– Push bellows onto air spring.

the air line.
Specified torques
Bearing to shock absorber 70 Nm
♦ Use new nuts.
Cover on air spring 9 Nm
10.10 Removing and installing pressure reten‐

tion valve

Note
♦ The pressure retention valve is maintenance-free and may be

replaced only if a leak is detected.
♦ When the air spring strut is removed, no further preliminary
work is required to renew the pressure retention valve.
WARNING
♦ The pressure retention valve can be replaced only with the

vehicle on a lifting platform. It must be possible to turn the
vehicle's wheels freely.
♦ The pressure retention valve may also come loose when
loosening the air line.
♦ If the vehicle is not raised using a lifting platform, the ve‐
hicle immediately lowers on the side at which the pressure
retention valve is loosened. There is an acute risk of injury,
as arms may become trapped.
♦ The vehicle must remain on the lifting platform until a new
pressure retention valve has been installed and the air
spring strut has been refilled.

Removing
This procedure applies to renewing a pressure retention valve
with the air spring strut installed.
– Activate jacking mode ⇒ page 259 .
– Place vehicle onto lifting platform and raise until wheels can
be freely rotated.
– Clean the area where pressure retention valve is located.

– Unscrew air line from pressure retention valve -1-.

– Unscrew pressure retention valve from air spring strut.
Installing
lowing:

the air line.
– Fill air spring strut using vehicle diagnostic, testing and infor‐
mation system - VAS 5051- .
Specified torques
Pressure retention valve to air spring strut 12 Nm
Air line to pressure retention valve 4 Nm

11 Assembly overview: drive shaft
1 - Nut
❑ 500 Nm
moval
2 - Outer constant velocity joint
plete unit
❑ Checking ⇒ page 139
⇒ page 136
3 - Retaining ring
moval
❑ Insert in groove in shaft
4 - Clip
moval
❑ Tightening ⇒ page 138
5 - Boot
❑ Check for splits and
chafing
❑ Material: Hytrel (poly‐
ester elastomer)
6 - Clip
moval
7 - Drive shaft
8 - Multi-point socket head bolt
❑ 50 Nm and 90°
9 - Locking plate
10 - Clip
11 - Boot
❑ Check for splits and chafing
❑ Material: Hytrel (polyester elastomer)
12 - Clip
13 - Inner constant velocity joint
❑ Renew only as complete unit

14 - Retaining ring
15 - Cover
11.1 Loosening and tightening 12-point nut

securing drive shaft
♦ Socket 32 mm - T10209-
Caution

11. Assembly overview: drive shaft 127


Loosen 12-point nut
– Loosen 12-point nut when vehicle is still standing on its
wheels.
– Loosen with socket 32 mm - T10209- only by a maximum of
90°, otherwise the wheel bearing will be damaged.
– Activate car jacking mode and place vehicle on lifting platform
⇒ page 259
– Raise vehicle so that wheels are off the ground.
– Have second mechanic apply brakes.
– Unscrew 12-point nut -arrow-.
Screw on twelve-point nut
– Replace hexagonal nut.
– Pre-tighten 12-point nut to 150 Nm.
– Lower vehicle onto its wheels.
– Tighten to 500 Nm.
11.2 Removing and installing drive shaft


equipment required

♦ Adapter - T10103/1-
♦ Bits XZN 12 - T10099-

♦ 32 mm bits - T10209-
Removing
lifting platform.

Caution


– Raise vehicle.
– Remove wheel.
– Insert spring tensioner - VW 552- -1- into upper opening of
wheel housing and attach to top suspension link on both sides
of the vehicle.
ly.
Caution


housing -arrow-.


-1- is inserted.
– Press out drive shaft.

1- Adapter - T10103/1-
– When removing, make sure joints have adequate clearance.


Note
– Attach support - T10149- with a wheel bolt.
Caution



– Pull bolt out of lower suspension link.
– Lower wheel bearing housing until drive shaft can be removed.
– Remove drive shaft.
Installing
lowing:
– Guide outer joint into wheel hub splines as far as possible.
– Pull drive shaft in to stop using fitting tool - T10206- .

– Remove fitting tool - T10206- .
Specified torques
♦ Use new nuts.

♦ Use new nuts.


♦ Use new nuts.

11.3 Dismantling and assembling drive shaft


equipment required
♦ Thrust piece - VW 454-

♦ Press tool - VW 408 A-
♦ Clamp tensioner - V.A.G 1682-
♦ Snap ring pliers - VW 161 A-


♦ Multi-purpose tool - VW 771-
♦ Puller - T10382-
Removing outer constant velocity joint
– Clamp drive shaft in vice using jaw protectors.
– Remove clamps.
– 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- .

– Pull constant velocity joint off drive shaft.

1- Puller plate - T10382/1-
2- Spindles - T10382/2-
Check outer joint ⇒ page 139
Driving on outer constant velocity joint
– Install new retaining ring.
– If necessary, push new joint boot onto drive shaft.
– Press half of the total amount of grease from repair kit into the
joint body.
– Distribute remaining grease from repair kit in the protective
boot of the joint.
– Knock onto shaft with plastic hammer until retaining ring en‐
gages.
Removing inner constant velocity joint
– Remove clamps.
– First, remove outer constant velocity joint ⇒ page 136 .
– Pull protective boot off inner joint.
– Drive off cover for inner joint.

Remove retaining ring using circlip pliers - VW 161 A- .
– Press inner joint off drive shaft as illustrated. Hold drive shaft
whilst doing this.
Inner joint cannot be dismantled for checking.
Pressing on inner constant velocity joint

– Press inner joint onto drive shaft as illustrated.

– Install new circlip onto drive shaft with circlip pliers - VW 161
A- .
joint body.
boot of the joint.
– Fit new cover on inner joint.
Tightening clamp on larger diameter

– Position clamp tensioner - V.A.G 1682- as shown in diagram.
Ensure jaws of tensioner lie in corners -arrows B- of ear on O-
type clip.
– Tighten clip 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 with setting range of 5 … 50 Nm (e.g. tor‐
que wrench - V.A.G 1331- ).
♦ Ensure that the spindle thread -A- moves smoothly. Lubricate
with MOS2 grease if necessary.
♦ If the thread is tight (e.g. due to dirt), the required clamping
force for the clip will not be attained although the correct torque
is applied.

Tightening clip on small diameter

type clip.
cant pliers).
Note

1682- .
♦ Use torque wrench -C- with setting range 5 … 50 Nm (e.g.
torque wrench - V.A.G 1331- ).
is applied.
11.4 Checking outer joint

The joint has to be dismantled to renew the grease or to check
the running surfaces of the balls 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.
– Take out cage with hub.

– Swing segment of hub into 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. Too much circumferential backlash in the joint
becomes noticeable during load change jolts; in such cases, the
joint must be renewed. Smoothing and traces of wear of the balls
are no reason to change the joint.
Installing
– Pack half of total grease quantity (60 g) into joint body.
– Fit cage with hub into joint body.
– Note large chamfer on inner diameter of ball hub and large
inner diameter on ball cage; these must point to drive shaft on
installation.
– Press in opposing balls one after the other; the original position
of the hub relative to the cage and joint body must be restored.
– Distribute remaining grease in boot.

42 – Rear suspension
1. Evaluating accident vehicles 141

2 Raising rear axle in unladen state

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.
142 Rep. gr.42 - Rear suspension

To simulate this position on the lifting platform, raise the respec‐

tive wheel suspension with the engine and gearbox jack - V.A.G
1383 A- and support - T10149- .
Before the 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.
– 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

Steel spring strut 1BA/1BE 486 ± 10 mm
Steel spring strut 1BB 502 ± 10 mm
Air spring strut 1BK/1BY 483 ± 10 mm
Air spring strut 2MA 458 ± 10 mm
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. Which PR. No. refers to which running gear can be found
here ⇒ page 297 .
– Raise wheel bearing housing using engine and gearbox jack
- V.A.G 1383 A- until dimension -a- is attained.
WARNING
♦ Never raise or lower the vehicle while the engine and

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

– Pull engine and gearbox jack - V.A.G 1383 A- out from under
vehicle.
– Detach support - T10149- .
2. Raising rear axle in unladen state 143

3 Overview - rear axle
Note

state) ⇒ page 142 .
I - Assembly overview - sub‐

frame, stone-chip protection
⇒ page 146
II - Assembly overview: sus‐
pension link, track rod
⇒ page 163
III - Assembly overview: wheel
bearing ⇒ page 179
IV - Assembly overview: rear
suspension ⇒ page 204

V - Assembly overview: anti-

roll bar ⇒ page 206
VI - Assembly overview - steel
spring strut ⇒ page 215
VII - Rear air spring damper
⇒ page 226
3. Overview - rear axle 145

4 Assembly overview - subframe, stone-chip protection
Note

1 - Bolt
❑ 90 Nm + 90°
❑ Qty. 2
moval
2 - Rear final drive
3 - Nut
❑ Qty. 2
moval
4 - Subframe
❑ Fixing position
⇒ page 148
⇒ page 149
of travel at front
⇒ page 153
of travel at rear
⇒ page 157
front bonded rubber
bush ⇒ page 153
rear bonded rubber
bush ⇒ page 157
6 - Bolt
❑ 1 Nm
parts catalogue “ETKA” Volkswagen Technical Site: http://vwts.ru http://vwts.info
7 - Bolt
❑ 120 Nm + 180°
8 - Stone deflector

9 - Bolt
10 - Stone deflector
11 - Spreader rivet
13 - Spreader rivet
14 - Nut
❑ 90 Nm + 90°
15 - Bolt
4.1 Repairing thread in rear longitudinal

member
Repairing the thread in captive nuts in the rear longitudinal mem‐
ber is possible under certain conditions ⇒ Body Repairs; Rep. gr.
50 .
4. Assembly overview - subframe, stone-chip protection 147

4.2 Fixing position of subframe

equipment required

♦ Engine and gearbox jack - V.A.G 1383 A- or
– Position engine and gearbox jack - V.A.G 1383 A- with nec‐
essary supports under subframe.

– Remove one of the front bolts of the subframe -arrow-
– Screw in locating pins - T10300- »by hand« as far as the

marking -A-.
– Now, tighten locating pins - T10300- to 30 Nm, counterholding
sleeve with open-jaw spanner on flats to prevent its turning.
frame.
Remove locating devices - T10300- in reverse order.
Specified torque
♦ Use new bolts
4.3 Removing and installing subframe


equipment required

♦ Brake pedal depressor - V.A.G 1869/2-
♦ Support (2x) - VAS 6131/6-5-
♦ Support (2x) - VAS 6131/6-7-
Removing
Brief description:
The subframe is removed using the assembly platform. Subframe
is removed together with rear final drive, lower suspension links
and wheel bearing housings. The air/steel spring struts remain on
vehicle.
lifting platform.
– Apply brake pedal depressor - V.A.G 1869/2- .

– Raise vehicle.
– Remove rear wheels.
– Remove rear part of exhaust system ⇒ Rep. gr. 26 ; Removing
and installing parts of exhaust system .
– Remove propshaft from rear final drive and lift and tie in place
⇒ Rep. gr. 39 ; Final drives, differential .
– Separate brake lines.
– Disconnect all electrical lines from body to axle.
– Undo bolted connection -arrow- between air spring strut -1-
and coupling rod at wheel bearing housing.
– Remove bolt.
Vehicles with steel spring struts

– Undo bolted connection -arrow- between steel spring strut
-1- and coupling rod at wheel bearing housing.
– Insert wooden beam between subframe -1- and upper rear

transverse link -2-.
– Press axle down with wooden beam.
– Remove bolt.

– Bolt supports - VAS 6131/6-7- and -VAS 6131/6-5- onto scis‐

sor-type lifting platform - VAS 6131- .
– Support subframe with assembly platform - VAS 6131- .

– Fix position of subframe ⇒ page 148 .
– Unscrew rear bolts for subframe -arrow- on both sides of ve‐

hicle.
– Slowly lower the subframe with scissor-type assembly plat‐
form - VAS 6131- .
Installing
lowing:
– Install subframe using bolts originally removed. These bolts
must be renewed following wheel alignment.
– Tighten the old bolts to the specified torque but without angled
torque wrench.
– Check wheel alignment after completing the installation
⇒ page 286 .
– Bleed brake system ⇒ Rep. gr. 47 ; Bleeding brake system .
– Install wheels and tighten bolts or nuts ⇒ page 285 .
Specified torques
Air/steel spring strut with coupling rod to wheel bearing 90 Nm + 90°
housing
♦ Tighten bolted connection in unladen state
⇒ page 142 .


♦ Use new bolts.
4.4 Repairing subframe, bonded rubber

bushes in direction of travel at front
– Before replacing a defective bonded rubber bush, check the
other bonded rubber bushes.
If cracks or other damage is visible, they must be replaced.

equipment required

♦ Countersupport - KUKKO 22-2- -4-
♦ Internal puller - KUKKO 21/4- -1-
♦ Splitter - KUKKO 15-2- -3-



Removing
lifting platform.
– Secure exhaust system to subframe using tensioning strap -
T10038- -1- as shown in figure.
– Release rear part of exhaust system ⇒ Rep. gr. 26 ; Removing
and installing parts of exhaust system .

– Remove bolt.



– Remove bolt.
frame.

frame.

a - Max. 40 mm

– Prise off cover -1- for example with a screwdriver -arrow-.


3- Tube - T10301/3-
5- Nut - T10301/2-
6- Spindle - T10301/1-
Chamfer on outer circumference of support ring - T10301/4- must
face subframe.
Caution

ing-out process.
Holes -1- must face direction of normal travel.

The cut-outs -arrow- must be at right angles to direction of normal
travel.


5- Nut - T10301/2-
6- Spindle - T10301/1-
Installing
lowing:
Specified torque
♦ Use new bolts
Exhaust system to body ⇒ Rep. gr. 26 ; Removing and installing parts of

exhaust system
4.5 Repairing subframe, bonded rubber

bushes in direction of travel at rear
– Before replacing a defective bonded rubber bush, check the
other bonded rubber bushes.
If cracks or other damage is visible, they must be replaced.


equipment required

♦ Countersupport - KUKKO 22-2- -4-
♦ Internal puller - KUKKO 21/4- -1-
♦ Splitter - KUKKO 15-2- -3-


Removing
lifting platform.
– Raise vehicle.
– Remove bolt.



– Remove bolt.
frame.

frame.

a - Max. 40 mm
– Prise off cover -1- for example with a screwdriver -arrow-.



3- Tube - T10301/3-
5- Nut - T10301/2-
6- Spindle - T10301/1-
Chamfer on outer circumference of support ring - T10301/4- must
face subframe.
Caution

ing-out process.
Holes -1- must face direction of normal travel.

The cut-outs -arrow- must be at right angles to direction of normal
travel.

5- Nut - T10301/2-
6- Spindle - T10301/1-
Installing
lowing:

Specified torque
♦ Use new bolts
Exhaust system to body ⇒ Rep. gr. 26 ; Removing and installing parts of

exhaust system

5 Assembly overview - suspension link, track rod
Note

1 - Subframe
⇒ page 149
3 - Track rod
⇒ page 171
4 - Eccentric bolt
❑ If loosened, wheel align‐
ment must be per‐
formed
❑ Do not turn more than
90° in either direction
(i.e. from minimum to
maximum adjustment
position).
5 - Nut
❑ 170 Nm
moval
❑ Always tighten bolted
connection in unladen
state ⇒ page 142 .
6 - Bolt
❑ 150 Nm + 90°
moval
❑ Always tighten bolted
connection in unladen
state ⇒ page 142 .
7 - Bolt
8 - Nut
❑ 90 Nm + 90°
❑ Always tighten bolted connection in unladen state ⇒ page 142 .
9 - Nut
5. Assembly overview - suspension link, track rod 163

10 - Upper rear transverse link

12 - Nut
13 - Bolt
❑ 150 Nm + 90°
14 - Bolt
❑ 150 Nm + 90°
15 - Nut
16 - Front upper transverse link
17 - Nut
❑ 90 Nm + 90°
18 - Bolt
20 - Spreader rivet
21 - Bolt
22 - Lower transverse link
23 - Nut
❑ 150 Nm + 90°
24 - Eccentric bolt
❑ If loosened, wheel alignment must be performed
❑ Do not turn more than 90° in either direction (i.e. from minimum to maximum adjustment position).
26 - Nut
❑ 170 Nm

27 - Bolt
❑ 150 Nm + 90°
28 - Nut
5.1 Removing and installing front upper transverse link

equipment required


Removing
– Raise vehicle.
– Remove wheel.

– Remove bolt.
⇒ page 259 .
– Bleed air from rear air spring struts with the Vehicle diagnosis,
testing and information system - VAS 5051B- .
– Raise vehicle.
– Remove wheel.
– Unscrew coupling rod -1- bolted connection -arrow- from rear

vehicle level sender on front of upper transverse link.
– Unscrew coupling rod -1- bolted connection -arrow- from rear
vehicle level sender on transverse link.
– Remove bolted joint -2- of cable bracket.
– Remove stone deflector strip -3- if there is one.
– Attach support - T10149- with a wheel bolt -A-.


– Unscrew bolted joints -arrows- of upper front transverse link

-1-.
– Remove bolts.
– Remove upper front transverse link -1-.
Installing
lowing:
– Insert upper front transverse link into vehicle and hand-tighten
bolts.

– Insert bolt -arrow- between steel spring strut -1- and coupling
rod at wheel bearing housing.
– Hand-tighten bolt.
The steel spring strut may only be bolted to wheel bearing housing
with coupling rod only when distance “a” has been attained
⇒ page 5 .
– Tighten bolt of steel spring strut.
The transverse link may be bolted on only when size “a” has been
attained ⇒ page 5 .
– Tighten front upper transverse link on subframe and wheel
bearing housing.
– Fill rear air spring strut with the Vehicle diagnosis, testing and
information system - VAS 5051B- .
Specified torque
Upper front transverse link to wheel bearing housing 150 Nm + 90°
⇒ page 142 .
♦ Apply tightening torque by means of bolt


Upper front transverse link to subframe 90 Nm + 90°
⇒ page 142 .
Front coupling rod of rear vehicle level sender to upper front 8 Nm

transverse link
Cable bracket to front upper transverse link 8 Nm
Steel spring strut with coupling rod to wheel bearing hous‐ 90 Nm + 90°
ing
⇒ page 142 .
5.2 Removing and installing upper rear transverse link

equipment required


Removing
– Raise vehicle.
– Remove wheel.

– Remove bolt.
⇒ page 259 .
– Raise vehicle.
– Remove wheel.


– Unscrew bolted joint -arrow- of upper front transverse link -1-

at wheel bearing housing.
– Remove bolt.
– Unscrew bolted joint -arrow- of upper rear transverse link -1-

at wheel bearing housing and subframe.
– Remove bolts.
– Remove upper rear transverse link -1-.
Installing
lowing:
– Insert upper rear transverse link into vehicle and hand-tighten
bolts.
– Hand-tighten bolt for upper front transverse link at wheel bear‐
ing housing.


– Insert bolt -arrow- between spring strut -1- and coupling rod at
⇒ page 5 .
The transverse links may be bolted on only when size “a” has
been attained ⇒ page 5 .
– Tighten transverse links at subframe and wheel bearing hous‐
ing.
Specified torque
Upper rear transverse link to wheel bearing housing 150 Nm + 90°
⇒ page 142 .
Upper rear transverse link to subframe 90 Nm + 90°

⇒ page 142 .

⇒ page 142 .
ing
⇒ page 142 .
5.3 Removing and installing track rod


equipment required
Removing
– Raise vehicle.
– Remove wheel.


– Remove bolt.
⇒ page 259 .
– Raise vehicle.
– Remove wheel.

– Unscrew and remove bolted connection -arrows- of track rod

-1-.
– Remove bolts.
– Remove track rod -1-.
Installing
lowing:
– Insert track rod into vehicle and hand-tighten bolts.


⇒ page 5 .
The track rod may be bolted only when distance “a” has been
– Tighten track rod at subframe and wheel bearing housing.
Specified torque
Track rod to wheel bearing housing 150 Nm + 90°
⇒ page 142 .
Track rod to subframe 170 Nm

♦ Use new bolts
⇒ page 142 .
ing
⇒ page 142 .
5.4 Removing and installing lower transverse link


equipment required
Removing
– Raise vehicle.
– Remove wheel.


– Remove bolt.
⇒ page 259 .
– Raise vehicle.
– Remove wheel.

– Unscrew bolted joint -arrow- of lower transverse link -1- at

– Remove bolt.
– Unscrew bolted joints -arrows- of lower transverse link -1- at

subframe.
– Remove bolts.
– Push transverse link inwards towards subframe.
– Swivel from transverse link at wheel bearing housing down‐
wards.
– Remove transverse link -1- from subframe.
Installing
lowing:
– Insert transverse link into vehicle and hand-tighten bolts.


⇒ page 5 .
The track rod may be bolted only when distance “a” has been
– Tighten transverse link at subframe and wheel bearing hous‐
ing.
Specified torque
Transverse link to wheel bearing housing 150 Nm + 90°
⇒ page 142 .
Transverse link to subframe at front 150 Nm + 90°

⇒ page 142 .
Transverse link at subframe at rear to eccentric bolt 170 Nm

♦ Use new bolts
⇒ page 142 .


ing
⇒ page 142 .

6 Assembly overview: wheel bearing
Note

1 - Wheel bearing
⇒ page 194
Caution
Avoidance
• of dirt and
away ⇒ page 180 .
2 - Wheel hub
⇒ page 200
Caution
Avoidance
• of dirt and
away ⇒ page 180 .
3 - Nut
❑ 500 Nm
moval
4 - Bolt
❑ 8 Nm
❑ Qty. 4
5 - Brake carrier plate
⇒ Brake system; Rep.
gr. 46
Caution
Avoidance
• of dirt and
away ⇒ page 180 .
6. Assembly overview: wheel bearing 179

7 - Drive shaft
8 - Rear speed sensor
9 - Bolt
❑ 8 Nm
10 - Bolts
❑ 80 Nm + 120°
❑ Qty. 4
11 - Cable retainer
12 - Bolt
❑ 10 Nm

storing away

6.1 Removing and installing wheel bearing housing

equipment required

♦ Adapter - T10103/1-
♦ Socket 32 mm - T10209-


equipment required

Removing

Caution


– Raise vehicle.
– Remove wheel.

– Remove bolt.
⇒ page 259 .
– Remove wheel.
– Remove brake calliper and brake disc ⇒ Brake systems; Rep.
gr. 46 ; Repairing rear brake .
– Attach brake calliper to body so that weight of brake calliper
does not bend or damage brake hose or brake pipe.
– Remove parking brake ⇒ Brake systems; Rep. gr. 46 ; Re‐
pairing rear brake .

– Release and pull off connector -1- at parking brake motor of

electromechanical parking brake.
– Release and pull off connector -1- from rear speed sensor .
– Remove rear speed sensor -1-. To do this, unscrew bolt

-arrow-.
– Unscrew bolt -arrow- and remove retainer -1- with cables.


-1- is inserted.
– Turn wheel hub until one of the wheel bolt holes is at the bot‐
tom.
1- Adapter - T10103/1-
3- Support - T10149-
4- Engine and gearbox jack - V.A.G 1383 A-
– Loosen bolted joint -arrow- of upper front transverse link -1- at

– Remove bolt.

– Loosen bolted joint -arrow- of upper rear transverse link -1- at

– Remove bolt.
– Loosen bolt -arrow- of track rod -1- at wheel bearing housing.

– Remove bolt.

and coupling rod -2- at wheel bearing housing -3-.
– Remove bolt.

– Loosen bolted joint -arrow- of lower transverse link -1- at wheel
bearing housing.
– Remove bolt.

– Pull wheel bearing housing off drive shaft.

1- Adapter - T10103/1-

Note
– Remove wheel bearing housing together with parking brake

motor of electromechanical parking brake and brake carrier.
If the wheel bearing housing is to be replaced, the following must
be done:
– Clamp wheel bearing housing in vice using protective jaw cov‐

ers.
– Unscrew bolts -arrows-.
– Remove wheel bearing unit-1- from wheel bearing housing.
Caution

face/storing away ⇒ page 180 .


storing away
– Unscrew bolts -1- and remove cover plate -2-.

– Remove parking brake motor of electromechanical parking
brake ⇒ Brake systems; Rep. gr. 46 ; Removing and installing
parking brake motor .
Installing
Note
♦ If the wheel bearing housing has been renewed, the sequence

of installation must be complied with.
♦ Install parking brake motor of electromechanical parking
brake.
♦ Fit cover plate.
♦ Install wheel bearing unit.

lowing:
– Install wheel bearing housing with help of support -
T10149- .and engine and gearbox jack - V.A.G 1383 A- .
– Guide outer joint into wheel hub splines of wheel hub as far as
possible.
– Hand-tighten bolted connections at wheel bearing housing.
– Remove support - T10149- from wheel bearing housing.


– Hand-tighten bolted connection.

The wheel bearing housing may be bolted on only when distance
“a” has been attained ⇒ page 5 .
– Tighten bolted connections at wheel bearing housing.
– Install parking brake ⇒ Brake systems; Rep. gr. 46 ; Repairing
rear brake .
– Install rear speed sensor -1-.

– Tighten bolt -arrow-.
– Tighten 12-point nut for drive shaft at wheel hub
⇒ page 246 .
Specified torque
⇒ page 142 .
Spring strut with coupling rod to wheel bearing housing 90 Nm + 90°

⇒ page 142 .


⇒ page 142 .
Tighten bolt for cable bracket on wheel bearing hous‐ 10 Nm

ing
Lower transverse link to wheel bearing housing 150 Nm + 90°
⇒ page 142 .
Drive shaft to hub 500 Nm

♦ Use new bolts
Bolt for rear speed sensor 8 Nm

Bolts for brake carrier plate 8 Nm
Bolts for parking brake motor of electromechanical 20 Nm + 60°
parking brake.
♦ Use new bolts
Bolts for wheel bearings 80 Nm + 120°

♦ Use new bolts

⇒ page 142 .
6.2 Repairing wheel bearing housing


equipment required


WARNING
On vehicles with disconnectable anti-roll bars, the disconnect‐

able anti-roll bars must be engaged before beginning work.
Disengaged anti-roll bars otherwise pose a risk of injury due to
unintentional engagement.
– Remove wheel.
– Remove bolt -1- and remove lower suspension link -2- from
– Insert a piece of wood between suspension link -arrow- and

WARNING
Without the piece of wood inserted, there is a risk of injury if

the lower suspension link slips back to its original position.

– Install tools to wheel bearing housing as shown in illustration.

1- Nut - T10230/2-
2- Press tool - T10230/13-
4- Tube - T10230/5-
6- Tube - T10230/3-
Caution
Before pressing out, position engine and gearbox jack - V.A.G

1383 A- with universal support under cylinder; cylinder may
drop down at end of pressing-out process.

– Install tools and bonded rubber bush to wheel bearing housing

as shown in illustration.
1- Nut - T10230/2-
2- Press tool - T10230/13-
6- Tube - T10230/3-
– Press in the bonded rubber bush to stop.
In doing so, core of bonded rubber bush is pressed in further than
necessary by thrust piece - T10230/6- -arrow-. This is necessary
so that outer lip of bonded rubber bush lies on suspension link.
After releasing hydraulic press - VAS 6178- , core of bonded rub‐
ber bush returns to its correct position.
– Remove wood from between wheel bearing housing and lower
suspension link.
– Press wheel bearing housing in -direction of arrow-.
WARNING
Be careful to press only on wheel bearing housing. The joint

between the suspension link and the wheel bearing housing
presents a risk of injury!
Suspension link will now engage in wheel bearing housing.

Continue installation in reverse order of removal.

Specified torques
Suspension link to wheel bearing housing 150 Nm + 90°
♦ Tighten in unladen state.
Wheel to wheel hub 180 Nm
6.3 Removing and installing wheel bearing unit

equipment required
♦ Adapter - T10103/1-
♦ Socket 32 mm - T10209-


Removing
Caution


– Raise vehicle.
– Remove wheel.


– Remove bolt.
⇒ page 259 .
– Remove wheel.
– Remove brake calliper and brake disc ⇒ Brake systems; Rep.
gr. 46 ; Repairing rear brake .
– Attach brake calliper to body so that weight of brake calliper
does not bend or damage brake hose or brake pipe.
– Remove coupling rod ⇒ page 210



-1- is inserted.

1- Adapter - T10103/1-

Note
– Press drive shaft out of wheel bearing housing as far as stop.
– Remove bolts -arrows- above drive shaft.

– Remove bolts -arrows- below drive shaft.
– Pull wheel bearing unit off drive shaft.

1- Adapter - T10103/1-
– Remove wheel bearing unit together with remover - T10520- .
Caution

face/storing away.

surface.
Installing
lowing:
– Hand-tighten bolts -arrows- below drive shaft.

– Hand-tighten bolts -arrows- above drive shaft.

– Tighten bolts for wheel bearing unit.

– Install coupling rod.

The coupling rod may be bolted on only when distance “a” has
– Tighten coupling rod.
Specified torque


♦ Use new bolts
⇒ page 142 .

⇒ page 142 .

ing
Bolts for wheel bearing unit 80 Nm +120°
♦ Use new bolts
Drive shaft to hub 500 Nm

♦ Use new bolts
6.4 Repairing wheel bearing unit

equipment required


♦ Splitter - Kukko 15/3 mit 17/3-
– Remove wheel bearing unit ⇒ page 194 .
Press wheel hub out of wheel bearing
2- Sleeve - T10230/8-
4- Wheel bearing unit
– Press wheel hub out of wheel bearing.
Press bearing inner race off wheel hub

– Insert splitter between bearing inner race -1- and wheel hub
-2- and pretension with spindle.
Note
Use a standard commercially available splitter, e. g. 15/3 and 17/3

from KUKKO.


2- Sleeve - T10230/8-
4- Wheel hub
5- Inner bearing race
6- Kukko 15/3 with 17/3.
– Press bearing inner race off wheel hub.
Pressing wheel hub into wheel bearing
Caution

face/storing away.

surface.


3- Wheel hub
4- Ball bearing
Note
Machined surface of wheel bearing outer race faces downwards.
Caution
When placing on a surface or pressing in, make sure that there

is no dirt between thrust plate - VW 401- -5- and ball bearing
-4-.
– Press wheel hub into wheel bearing.

– Install wheel bearing unit ⇒ page 194 .

7 Assembly overview - rear suspension
Note

-Arrow A- direction of travel
1 - Body
2 - Bolt
❑ M10 x 1.5 x 115
❑ 50 Nm + 180°
moval
❑ Observe tightening se‐
quence for steel spring
struts
♦ Tightening sequence on left
⇒ page 219 .
♦ Tightening sequence on
right ⇒ page 220 .
❑ Observe tightening se‐
quence for air spring
struts
♦ Tightening sequence on left
⇒ page 233 .
♦ Tightening sequence on
right ⇒ page 233 .
3 - Bolt
❑ M10 x 1.5 x 160
❑ 50 Nm + 180°
moval
4 - Steel spring strut
⇒ page 217
❑ Repairing ⇒ page 220
5 - Bolt
moval
7 - Coupling rod

8 - Nut
❑ 90 Nm + 90°
9 - Air spring strut
❑ Repairing ⇒ page 235
7. Assembly overview - rear suspension 205

8 Assembly overview: anti-roll bar
1 - Subframe
2 - Coupling rod on right
❑ connects anti-roll bar to
shock absorber/wheel
bearing housing
⇒ page 210
3 - Nut
❑ 100 Nm
❑ Self-locking
moval
❑ When tightening, coun‐
terhold on multi-point
socket of bolt
❑ Tighten in unladen state
⇒ page 142 .
4 - Bolt
❑ 50 Nm
❑ Tighten evenly
moval
❑ Tighten in unladen state
⇒ page 142 .
5 - Clip
❑ As of model year 2015
an additional bracket for
the tyre pressure moni‐
tor control unit - J502- is
bolted to the clamp on
vehicles with tyre pres‐
sure monitoring system ⇒ page 207 .
6 - Mountings
❑ In two sections on both sides of the vehicle
❑ Are connected to each other by means of latching lugs
❑ Always replace the complete mounting
7 - Anti-roll bar
8 - Coupling rod on left
❑ connects anti-roll bar to shock absorber/wheel bearing housing

Bracket -1- for tyre pressure monitor control unit, as of model year
2015


Removing
⇒ page 5 .
– Raise vehicle.
– Remove wheel.
frame.
– Remove anti-roll bar clamp.

– Remove nut -1- and pull coupling rod -3- out of anti-roll bar
-2-.
– Remove anti-roll bar.
Installing
lowing:
– Insert anti-roll bar -2- into vehicle.

– Insert coupling rod -3- in anti-roll bar -2- and hand-tighten nut
-1-.
– Hand-tighten bolts -arrows-.for anti-roll bar clamp -1- uniformly

on subframe.
The anti-roll bar may be bolted on only when distance “a” has
– Tighten anti-roll bar clamp on subframe uniformly.
– Secure coupling rod to anti-roll bar.
Specified torque
♦ Use new bolts
⇒ page 142 .

♦ Use new bolts
⇒ page 142 .

bush


Removing
⇒ page 5 .
frame.
– Remove anti-roll bar clamp.
The two halves of the bush are locked into each other by means
of latching lugs.
– Carefully detach the two latching lugs -arrows- on the anti-roll
bar bush -1-.
Installing
– Make sure bush halves -1- are correctly seated on hexagonal

positioning element -arrow- of the anti-roll bar.
– Press two halves of bush together carefully until the latches
audibly engage.

– Hand-tighten bolts -arrows-.for anti-roll bar clamp -1- uniformly

on subframe.
The anti-roll bar may be bolted on only when distance “a” has
– Tighten anti-roll bar clamp on subframe uniformly.
Specified torque
♦ Use new bolts
⇒ page 142 .
8.3 Removing and installing coupling rod


equipment required
Removing
– Raise vehicle.
– Remove wheel.


– Remove bolt.
⇒ page 5 .
– Raise vehicle.
– Remove wheel.

– Release and pull off plug-in connection -1- at electromechan‐

ical parking brake.


– Remove bolt.
– Remove nut -1- and pull coupling rod -3- out of anti-roll bar
-2-.
T10149- .and push engine and gearbox jack - V.A.G 1383 A-
upwards.
– Take out coupling rod.
Installing

lowing:
– Insert coupling rod -3- in anti-roll bar -2- and hand-tighten nut
-1-.


– Insert bolt -arrows- between steel spring strut -1- and coupling
rod -2- at wheel bearing housing -3-.

– Insert bolt -arrow- between air spring strut -1- and coupling rod
The coupling rod may be bolted on only when distance “a” has
– Tighten coupling rod.
Specified torque

♦ Use new bolts
⇒ page 142 .
Coupling rod spring strut to wheel bearing housing 90 Nm + 90°

⇒ page 142 .

ing

9 Assembly overview - steel spring strut
Note

1 - Nut
❑ 26 Nm
moval
2 - Support bearing cover
⇒ page 220
3 - Nut
❑ 56 Nm
moval
4 - Support mounting
⇒ page 220
5 - Strut mount
⇒ page 220
6 - Upper spring shim
tion ⇒ page 225
7 - Upper spring seat
tion ⇒ page 225
8 - Boot
⇒ page 220
tion ⇒ page 224
9 - Buffer stop
⇒ page 220
10 - Coil spring
❑ Surface of coil must not be damaged.
❑ Observe colour coding ⇒ page 216
9. Assembly overview - steel spring strut 215

11 - Lower spring seat

12 - Lower spring shim
13 - Spacer
14 - Buffer cap
15 - Spring plate
9.1 Assignment of spacers

To ensure an even height at front and rear axles, the coil springs
must be fitted with the correct number of spacers.
Number of spacers
Number of colour marking on coil springs Number of spacers to be used
None 0
1 x violet 1
2 x violet 2
Colour coding of coil springs

1- Colour coding for allocation of spacers
2- Colour coding for allocation of coil springs
3- Coil spring installation position

9.2 Installation position of spacers

– The positioning lugs of the spacers -2- must latch into the po‐
sitioning openings of the spring shim -1-.
– The spacers -2- must latch over the lugs -arrows- of the spring
plate -1-.
9.3 Removing and installing steel spring

strut

Removing
– Remove floor of luggage compartment⇒ General body re‐
pairs, interior; Rep. gr. 70 ; Luggage compartment panelling .
– Remove mounting plate for floor of luggage compartment⇒
General body repairs, interior; Rep. gr. 70 ; Luggage com‐
partment panelling .

– Remove plugs above bolted connections of steel spring strut.

– Unscrew and remove bolted connections -arrows- of steel
spring strut.


– Remove bolt.
– Remove steel spring strut.
Installing
lowing:
– Insert steel spring strut with guide bolts -arrows A- into upper
holes -arrows B- in body.

– Hand-tighten bolts -arrows- at strut support.

– Insert steel spring strut -1- in wheel bearing housing.
The steel spring strut may be bolted on only when distance “a”
has been attained ⇒ page 5 .
Observe tightening sequence on left

– Tighten bolts -1- to -4- to 50 Nm in sequence shown.
– Then tighten bolts -1- to -4- 180° further in sequence shown.

Observe tightening sequence on right

– Tighten bolts on lower steel spring damper.
Specified torque
Steel spring strut to body 50 Nm + 120°
♦ Use new bolts
⇒ page 142 .
♦ Observe tightening sequence on left ⇒ page 219
♦ Observe tightening sequence on right ⇒ page 220
ing
⇒ page 142 .
9.4 Repairing rear steel spring strut


equipment required
♦ Insert tool - 3165-

♦ Tube - VW 420-
♦ Suspension strut clamp - V.A.G 1752-
♦ Kukko 45-2
♦ Commercially available ratchet handle
– Remove steel spring strut ⇒ page 217

Dismantling steel spring strut

– Clamp steel spring strut.

– Remove bearing cover.

7- Ratchet wrench - T10001/11-
– Tension coil spring until upper strut mounting is free.
WARNING
First compress spring far enough to ensure that upper strut

mounting is free.
– Unscrew hexagon nut from piston rod.

– Remove individual parts of steel spring strut.


1- Kukko 45-2
– Pull buffer cap off shock absorber.
– Force spring plate off shock absorber.
Assembling steel spring strut
lowing:
– Drive spring plate onto shock absorber.

1- Tube - VW 420-
2- Hexagon bit, long reach - 3165-
– Push buffer cap onto shock absorber.


– Insert lower spring plate -1- correctly into spring shim -2-.
Note
The markings of the lower spring plate and the lower spring shim
– Push stop buffer -1- into bellows -2- until it engages -arrows-.
– Fit bellows onto shock absorber.
– Engage bellows -1- with locking lugs -arrows- of buffer cap

-2-.

– The end of the lower coil of the spring -1- must lie against the
stop -arrow- of the lower spring plate -2-.
– The end of the upper coil of the spring -1- must lie against the
stop -arrow- of the upper spring plate -2-.
– Fit upper spring shim -2- correctly onto upper spring plate
-1-.
The markings of the upper spring plate and the upper spring shim
– Push bellows into strut mounting until it engages.
– Tighten new hexagon nut on piston rod.
– Relieve tension on spring compressor - VAS 6046- and re‐
move from coil spring.
– Install steel spring strut ⇒ page 217
Specified torque
Nut for steel spring strut 56 Nm
♦ Use new bolts
Nuts for support bearing cover 26 Nm

♦ Use new nuts

10 Rear air spring damper
10.1 Instructions for repairing air spring struts

As of mileage of 200,000 km, renewing the air springs on both
sides is recommended in the event that one air spring is dam‐
aged.
In the case of leaking shock absorbers, the complete air spring
strut must be renewed, as the shock absorber oil may damage
the bellows ⇒ Item 6 (page 109) .
When depressurised, the air spring must not be twisted. This may
cause damage to the bellows inside the air spring due to kinking
or creasing!
To ensure perfect and successful air spring strut repair, the great‐
est care and cleanliness as well as the use of good and proper
tools are essential. Also note the basic rules on safety when per‐
forming repair procedures.
A series of generally valid instructions for individual repairs are
summarised here. These apply to repairing air spring struts.
The structure and functioning of the air suspension system are
described in the ⇒ Self-study programme No. 469 ; Touareg
2011 running gear and all-wheel concept .
10.2 Air spring strut

– Before loosening the installed air line, check whether the air
spring still has approx. 3 bar residual pressure.
– To do this, press bead of air spring with your thumb. The bead
– If no great resistance is detectable, the air spring is not pres‐
surised.
– The vehicle can be driven up to 100 km with a unpressurised
air spring.
– The air spring must be replaced together with the pressure
retention valve if the vehicle has been driven for more than
100 km with a unpressurised air spring.
♦ Thoroughly clean all unions and the adjacent areas before
disconnecting.
♦ 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 lubricants specified by their part numbers.
♦ If repair work cannot be performed immediately, cover new
parts which have been removed from their packing.
10.3 Pressure retention valve

wheels freely.

Note
♦ The pressure retention valve is open when the air line has
been screwed into the air spring strut.
♦ If the air line has been unscrewed from the air spring strut, the
pressure retention valve is closed.
10.4 Gaskets and seals

♦ Renew seals.
♦ Replace bellows if defective.
♦ After removing gaskets, check contact surface on housings for
burrs and damage.
10.5 Nuts and bolts

♦ Loosen and tighten bolts and securing nuts for covers and
housings diagonally.
♦ Specified torques given are for unoiled nuts, bolts and screws.
10.6 Rear air spring strut components

The following components are part of the air springs.
♦ Cover ⇒ Item 4 (page 228)
♦ External guide ⇒ Item 5 (page 228)
♦ Bellows ⇒ Item 6 (page 228)
♦ Air spring plunger ⇒ Item 7 (page 228)
Note
These components are firmly connected to each other and cannot be disassembled.
10. Rear air spring damper 227

1 - Mountings
2 - Seal
❑ Always renew
4 - Cover
⇒ Item 5 (page 228) ,
and
ally.
5 - External guide
⇒ Item 4 (page 228) ,
and
ally.
6 - Bellows
⇒ Item 4 (page 228) ,
⇒ Item 5 (page 228) and
ally.
7 - Air spring plunger
❑ Firmly connected to ⇒ Item 4 (page 228) , ⇒ Item 5 (page 228) and ⇒ Item 6 (page 228) as part of the
air spring.
❑ Cannot be removed or disassembled individually.
8 - Boot
❑ Always renew
10 - Seal
❑ Always renew

10.7 Assembly overview - rear air spring strut
1 - Bolt
❑ 27 Nm
❑ Qty. 4
2 - Cover
3 - Nut
❑ 70 Nm
moval
4 - Mountings
❑ 12 Nm
❑ Observe important
notes on removal and
installation ⇒ page 244
⇒ page 243
6 - Air spring
❑ Observe instructions for
repairing air spring
struts ⇒ page 226
❑ As of mileage of
200,000 km, renewing
the air springs on both
sides is recommended
in the event that one air
spring is damaged.
❑ With integrated pump
stop
❑ Always renew
8 - Boot
❑ Replace when air spring
strut is in mounted position ⇒ page 233
9 - Seal
❑ Always renew
10 - Seal
❑ Always renew
11 - Wiring guide
❑ Observe instructions for repairing air spring struts ⇒ page 226
10.8 Removing and installing air spring strut



Removing
⇒ page 259 .
– Raise vehicle.
– Remove wheel.
are formed on the protective boot of the air spring strut.
– Remove luggage compartment floor ⇒ Rep. gr. 70 .
– Remove mounting plate for luggage compartment floor ⇒
Rep. gr. 70 .
– Remove plugs above bolted connections of air spring strut.
– Unscrew and remove bolted connections -arrows- of air spring
strut.
– Unscrew union nut -1- of air line from air spring strut and seal
both connections.

– Release connector -1- for valve for shock-absorption adjust‐

ment and pull off .

– Remove bolt.
– Remove steel spring strut.
Installing
lowing:
– Insert air spring strut with guide bolts -arrows A- into upper
holes -arrows B- in body.
– Hand-tighten bolts -arrows- at strut support.

The rear air line is sheathed in a shrink-fit hose.

– Insert air line until end of shrink-fit hose -2- is touching union
nut -1-.
It must be ensured that the end of the shrink-fit hose is not more
than 2 mm away from union nut.
– Bolt air line with union nut -1- on air spring strut.
– Plug in connector -1- for valve for shock-absorption adjust‐

ment .
– Insert bolt -arrow- between air spring strut -1- and coupling rod
Note
If the holes of the wheel bearing housing and air spring strut for
inserting the bolt are not in line with each other, the air spring strut
must be re-aligned. To do this, loosen the bellows and hold the
spring plunger in position. Now, turn the shock absorber opposite
the spring plunger until the holes are in line. When doing this,
make sure the spring plunger is not twisted. Follow installation
instructions ⇒ page 241 .
The air spring strut may be bolted on only when distance “a” has

Observe tightening sequence on left

Observe tightening sequence on right

– Tighten bolts at air spring strut.
Specified torque
Air spring strut to body 50 Nm + 120°
♦ Use new bolts
⇒ page 142 .
♦ Tightening sequence on left ⇒ page 233 .
♦ Tightening sequence on right ⇒ page 233 .
Air spring strut with coupling rod to wheel bearing housing 90 Nm + 90°
⇒ page 142 .
10.9 Replacing bellows for air spring strut



– Remove wheel.
– Unscrew air spring strut -1- from wheel bearing housing
-arrow-.
– Pull bellows off air spring.
– Swivel air spring strut inwards and remove bellows -1- be‐
tween wheel bearing housing and air spring strut -arrow-.
– Check bellows -1- for damage.

Surface must be regular and even.

Installing
lowing:
Caution
When new bellows is being installed, make sure it is not dam‐

aged.
When installing bellows -1-, bear in mind the narrow gap between
wheel bearing housing and air spring strut -arrow-.
– Ensure groove of bellows latches into place on shock absorb‐
er.
Specified torques
Air spring strut to wheel bearing housing 90 Nm + 90°
10.10 Repairing rear air spring strut
Note
Observe instructions for repairing air spring struts ⇒ page 226 .


equipment required
♦ Socket, 21 mm - 3186-
♦ Guide pins - T10093-
♦ Spring retainer - V.A.G 1752/3A-
♦ Release tool set - VAS 1978/35-

♦ Removal wedge - 3409-

Note
♦ Check whether the air spring still has approx. 3 bar residual
pressure.
♦ To do this, press bead of air spring with your thumb. The bead
♦ If no great resistance is detectable, the air spring is not pres‐
surised.
Dismantling air spring strut

– Pull bellows off shock absorber downwards and remove.
– Clamp suspension strut support clamp - V.A.G 1752/20- -1- in

a vice.
– Clamp air spring strut in support clamp for spring struts - V.A.G
1752/20- -1-.
– Knock cable lugs out of connector of air spring strut using set
of releasing tools - VAS 1978/35- .
– Unclip cable conduit -3-.

– Remove grommet -arrow- from cover -2-.

– Unscrew bolts -1- and remove cover -2-.
– Push cable through grommet.
– Unscrew nut from mount by counterholding it by the hexagonal

piece -3-.
2- Socket AF 21 - 3186-
– Remove mounting from shock absorber.

– Insert guide pins - T10093- -1- into air spring strut bearing.
Note
♦ Guide pins - T10093- serve to counter-hold spring retainers -

V.A.G 1752/3A- -2-.
♦ To avoid damage, a rubber mat -6- or similar must be inserted
between spring retainer inserts - V.A.G 1752/7- -5- and air
spring plunger.
– Press air spring plunger -1- off from shock absorber using
spring compressor - V.A.G 1752/1- .
1- Guide pin - T10093-
2- Spring retainer - V.A.G 1752/3A-
3- Suspension strut clamping block - V.A.G 1752/20-
4- Air spring plunger
6- Rubber mat or similar
7- External guide
Caution
♦ Insert protection, e.g. rubber, between spring retainer in‐

serts - V.A.G 1752/7- and air spring plunger.
♦ Insert protection, e.g. rubber, between spring retainers -
V.A.G 1752/3A- and shock absorber.
♦ Ensure that the plunger -4- does not slip down and out of
the external guide -7-.
Note

Assembling air spring strut

– If the shock absorber has not been replaced, the sealing rings
-arrows- on the piston rod and the shock absorber tube must
be replaced.
– Clean contact surface with a lint-free cloth.
Note
Even slight soiling leads to air spring strut leakages.
– Lightly grease the seal with lithium grease - G 052 150 A2- .
– Push retention element onto shock absorber tube.
Note
– Extend shock absorber line, e.g. with a cable, in order to take

it through the air spring.
– Make sure that bump stop -1- is correctly seated in cover -2-
-arrow-.
The large diameter of the bump stop -1- must be seated so that
it is held clamped in the cover -2-.

– Fit mounting and secure with a new bolt, counterholding by the

hexagonal piece -3-.
2- Socket AF 21 - 3186-
– Insert cable lug into connector housing.
– Fit cable conduit -3- again and clip in place.
– Fit cover -2- and secure with bolts -1-.

– Insert grommets -arrows- in cover -2-.
– Align air spring so that pressure retention valve -1- is located

slightly to the side of the air spring strut's imaginary axis of
symmetry -arrow- (approx. 10° off-centre).
Note
During alignment, only turn by the plunger ⇒ Item 7 (page 228) in

order to avoid damaging the bellows ⇒ Item 6 (page 228) inside
the air spring.
– Install air spring strut ⇒ page 229 , but do not yet install air line.

– Raise air spring strut using engine and gearbox jack - V.A.G
1383 A- until plunger -1- lies on retention element -arrow-.
– Use removal wedge - 3409- to push retention element into

plunger.
1- Removal wedge - 3409-
– Continue to raise air spring strut using engine and gearbox

jack - V.A.G 1383 A- until welded ring on shock absorber tube
has disappeared approx. 3 mm into retention plunger
-arrow-.
– When lowering (rebound), hold pressure retention valve open
by opening valve tappet, e.g. with a 5 mm hexagon wrench,
so that air can flow in.
Note
This prevents the bellows from wrinkling.
– Push bellows onto air spring.

– Pull bellows over shock absorber so that the groove of bellows
latches into place.


nut -1-.
– Bolt air line with union nut -1- on air spring strut.
Specified torques
Bearing to shock absorber 70 Nm
♦ Use new nuts.
Cover on air spring 27 Nm
10.11 Removing and installing pressure reten‐

tion valve

wheels freely.
When the air spring strut is removed, no further preliminary work
is required to renew the pressure retention valve.

Note
♦
♦ The pressure retention valve is open when the air line has
been screwed into the air spring strut. If the air line has been
unscrewed from the air spring strut, the pressure retention
valve is closed.
Note
WARNING
♦ The vehicle must stand on a lifting platform so that the

pressure retention valve can be replaced. It must be pos‐
sible to turn the vehicle's wheels freely.
♦ If the vehicle is not raised using a lifting platform, the ve‐
hicle immediately lowers on the side at which the pressure
retention valve is loosened. There is an acute risk of injury,
as arms may become trapped.
♦ The vehicle must remain on the lifting platform until a new
pressure retention valve has been installed and the air
spring strut has been refilled.

Removing
This procedure applies to renewing a pressure retention valve
with the air spring strut installed.
– Place vehicle onto lifting platform and raise until wheels can
be freely rotated.
– Bleed air from air spring strut with ⇒ Vehicle diagnostic tester.
– Clean the area where pressure retention valve is located.
– Unscrew air line from pressure retention valve -1-.
– Unscrew pressure retention valve from air spring strut.
Installing
lowing:


nut -1-.
– Inflate air spring strut with ⇒ Vehicle diagnostic tester.
Specified torques
Pressure retention valve to air spring strut 12 Nm

11 Assembly overview: drive shaft
1 - Nut
❑ 500 Nm
moval
2 - Outer constant velocity joint
plete unit
⇒ page 255
3 - Clip
moval
4 - Boot
❑ Check for splits and
chafing
❑ Material: Hytrel (poly‐
ester elastomer)
5 - Clip
moval
6 - Retaining ring
moval
7 - Drive shaft
8 - Boot
❑ Check for splits and chafing
❑ Material: Hytrel (polyester elastomer)
9 - Inner constant velocity joint
❑ Removing ⇒ page 255
10 - Retaining ring
❑ Insert into groove in inner constant velocity joint
11.1 Loosening and tightening 12-point nut

securing drive shaft

♦ Socket 32 mm - T10209-
Caution


Loosen 12-point nut
– Loosen 12-point nut when vehicle is still standing on its
wheels.
– Loosen with socket 32 mm - T10209- only by a maximum of
90°, otherwise the wheel bearing will be damaged.
⇒ page 5 .
– Raise vehicle so that wheels are off the ground.

– Unscrew 12-point nut -arrow-.

Screw on twelve-point nut
– Replace hexagonal nut.
– Pre-tighten 12-point nut to 150 Nm.
– Lower vehicle onto its wheels.
– Tighten to 500 Nm.
11.2 Removing and installing drive shaft

equipment required

♦ Adapter - T10103/1-

♦ 32 mm bits - T10209-
Removing

Caution


– Raise vehicle.
– Remove wheel.

– Remove bolt.
⇒ page 5 .
– Raise vehicle.
– Remove wheel.
– Turn wheel hub until one of the wheel bolt holes is at the bot‐
tom.


-1- is inserted.

1- Adapter - T10103/1-
– Support wheel upright.
– Unscrew bolted connection of upper rear transverse link -1-

from wheel bearing housing.
– Unscrew track rod -3- from wheel bearing housing.
– Undo and remove bolted connection -4- between air spring
strut and coupling rod at wheel bearing housing.

– Loosen bolted joint -1- for upper front transverse link at wheel
bearing housing.
– Loosen bolt -2- for lower transverse link and remove.
– Unscrew and remove bolted connection -arrow- of cable

bracket -1-.
– Release connector -2- from cable bracket.
– Release connectors -2- and pull off.
– Put wiring harness together with cable bracket to one side.
– Swivel wheel bearing housing upwards using engine and

gearbox jack - V.A.G 1383 A- .
2- Adapter - T10103/1-
– Press drive shaft out of inner splined union using remover -
T10520- .


Note
– When doing this, make sure there is enough room for the ar‐
ticulations by swivelling the wheel bearing housing further
upwards.
– Swivel outer joint out of wheel hub.
– Secure drive shaft to prevent it from falling.
– Remove drive shaft -1- from gearbox flange -3- using a plastic-
coated assembly lever -2-.
– Remove drive shaft.
Installing
lowing:
– Before assembling, coat splines of outer joint with assembly
paste - G 052 109 A2- .
Remove any paint residues and/or corrosion on thread and
splines of outer joint.
– Fit new retaining ring into groove of inner constant velocity
joint.
– Mesh outer and inner splines of joint body and gearbox.
– Push drive shaft into joint body as far as the stop.
– Now push joint body onto inner splines of gearbox with a
»sudden, hard push«.
Note
Never use a hammer or other driving tools.
– Check that the joint body is securely seated by pulling the joint
body against the resistance of retaining ring.
Caution
For this check, pull only on joint body and not on drive shaft.
– Guide outer joint into wheel hub splines as far as possible.


– Remove tools from wheel bearing housing.

1- Adapter - T10103/1-

– Hand-tighten bolted connections at wheel bearing housing.


The wheel bearing housing may be bolted on only when distance
“a” has been attained ⇒ page 5 .
– Tighten bolted connections at wheel bearing housing.
Specified torque
⇒ page 142 .

⇒ page 142 .

⇒ page 142 .

⇒ page 142 .
Tighten bolt for cable bracket on wheel bearing housing 10 Nm

Lower transverse link to wheel bearing housing 150 Nm + 90°
⇒ page 142 .
Drive shaft to hub 500Nm

♦ Use new bolts
11.3 Dismantling and assembling drive shaft


♦ Clamp tensioner - V.A.G 1682-

Dismantling
Force off constant velocity joint on outside and inside
– Clamp drive shaft in vice using jaw protectors.
– Remove clamps.
– Fold back boot of joint.
– Drive constant velocity joint off drive shaft using drift -A-.
The drift must be positioned exactly on the star of the constant
velocity joint.
Force-fit constant velocity joint on outside and inside
– Install new retaining ring.
joint body.
boot of the joint.
– Knock onto shaft with plastic hammer until retaining ring en‐
gages.

Tightening clamp on larger diameter

type clip.
– Tighten clamp by turning spindle with a torque wrench (do not
cant tool).
Note

1682- .
♦ Use torque wrench with setting range of 5 … 50 Nm (e.g. tor‐
que wrench - V.A.G 1331- ).
is applied.
Tightening clip on small diameter

type clip.
cant pliers).
Note

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

43 – Self-levelling suspension
258 Rep. gr.43 - Self-levelling suspension

2 Jacking mode
Caution
♦ Jacking mode must be activated before raising vehicle

with vehicle jack or lifting platform etc.
♦ The jacking mode switches off regulation of the air sus‐
pension. As a result, corrective regulation of the air springs
is prevented when the vehicle is lifted.
♦ In order to reduce the risk of injury, the jacking mode must
be activated every time the vehicle is lifted.
♦ The jacking mode is automatically deactivated at speeds
in excess of 5 km/h.
Switching on
– Switch on electric parking brake.
– Switch on ignition.
– Press LOCK button in centre console for 5 seconds.
The vehicle jacking mode is displayed in the instrument cluster
display and the LOCK button warning lamp flashes.
– Switch off ignition.
Switching off
– Press LOCK button until warning lamp in button goes out.

– Switch off ignition.
Note
The jacking mode is automatically deactivated at speeds in ex‐

cess of 5 km/h.
2. Jacking mode 259

3 Fault finding, air spring strut and self-levelling suspension

Symptom Fault detection Possible causes Rectifying fault
Leakage at air spring strut Repairing air spring strut
Front ⇒ page 115
Rear ⇒ page 235
»Slow« pressure loss Observe the level over a Leakage in air lines Repairing air lines
Vehicle stands at an an‐ long period and use com‐ ⇒ page 271
gle after a long time mercially available leak de‐
tector spray to find the leak
⇒ page 261
Leakage at pressure reten‐ Replace pressure reten‐
tion valve tion valve
Front ⇒ page 123
Rear ⇒ page 243
Vehicle stands at an an‐ Carry out Guided Fault Vehicle level sender defec‐ Renew vehicle level
gle Finding with vehicle diag‐ tive sender
Leakage excluded nostic, testing and informa‐ Linkage or holder of vehicle front ⇒ page 267
tion system - VAS 5051B- level sender bent rear ⇒ page 269
Vehicle level is too high, 1) Check whether the vehi‐ Vehicle has touched
cannot be moved lower cle has sufficient ground ground
clearance
2) Check air line and line Air line blocked, kinked or Check whether the air
routing frozen line has been inserted
deeply enough into the
pressure retention valve
Repair kinked air lines
⇒ page 271
Use compressed air to
blow clear air lines
blocked by dirt or ice
3) Carry out Guided Fault Release valve or air spring
Finding with vehicle diag‐ valves do not function
nostic, testing and informa‐
tion system - VAS 5051B-
Vehicle is standing low 4) Carry out Guided Fault Onboard supply for relay,
and cannot be moved up Finding with vehicle diag‐ connectors, wiring harness
or only very slowly nostic, testing and informa‐ and fuses
tion system - VAS 5051B-
5) Check for leaks in accu‐ Pressure receiver defec‐ Renew the accumulator
mulator with commercially tive/leaking ⇒ page 270
available leak detector Air line or connections to Repair air line
spray. pressure receiver defec‐ ⇒ page 271
tive/leaking
6) Carry out Guided Fault Release valve defective/ Renew valve block for
Finding with vehicle diag‐ leaking/open adaptive suspension -
nostic, testing and informa‐ NX7-
tion system - VAS 5051B- ⇒ page 281
Changeover valve defec‐ Replace compressor
tive/leaking/open ⇒ page 277
7) Check for leaks in com‐ Compressor is leaking Renew compressor
pressor with commercially ⇒ page 277
available leak detector
spray.
8) Check for leaks in air Air line, connections, pres‐ Repair air suspension
spring strut with commer‐ sure retention valve or air
cially available leak detec‐ spring leaking
tor spray.

Symptom Fault detection Possible causes Rectifying fault

9) First, check points 5 - 8. Compressor defective Replace compressor
If no defects are detected, ⇒ page 277
the compressor is defec‐
tive.
»Rapid« pressure loss Vehicle level uneven, air Defect on the air spring Repair air spring strut
can be heard escaping from Front ⇒ page 115
the defective air spring Rear ⇒ page 235
when an attempt is made to Air line torn off Repairing air lines
move to another level ⇒ page 271
Installation position of air line at front

It must be ensured that only the second marking -arrow B- on the
air line can be seen.
Installation position of air line at rear

nut -1-.
Carry out the following test under these conditions:
• The vehicle must be cold and must not be moved during the
test
• The room temperature should be between 10 - 30 °C and
should also fluctuate as little as possible
• The vehicle must be on a flat surface
– Start engine.
– Use rotary knob for level adjustment to move vehicle to high
level and then the normal level

– Switch off engine.
3. Fault finding, air spring strut and self-levelling suspension 261

– Measure and make a note of the standing height of the vehicle

at all 4 wheels.
– After 2 hours, measure the standing height again, make a note
of it and compare the measurement -a- with the first meas‐
urement.
If the vehicle is on a slant, there is a leak at the wheel suspension
which has the largest difference between the first and the second
measurement.
– Use commercially available leakage spray to check the affec‐
ted air spring strut and the corresponding air line in this se‐
quence:
♦ Connections of the air line
♦ Pressure retention valve
♦ Check air spring strut.
If no deviation can be determined after 2 hours, the measurement
must be repeated after 24 hours. A deviation of up to 4 mm is
permissible after 24 hours.

4 Self-levelling suspension components and fitting locations
1 - Adaptive suspension con‐

trol unit - J197-
❑ Location: in luggage
compartment behind
right side wall trim
❑ Can be checked using
“Guided Fault Finding”
function of vehicle diag‐
nostic, testing and infor‐
mation system - VAS
5051B- .
⇒ page 265
2 - Rear left air spring strut
❑ With rear left shock ab‐
sorber damper adjust‐
ment valve - N338- .
❑ The rear left shock-ab‐
sorber damper adjust‐
ment valve - N338- can
be checked using “gui‐
ded fault finding” with
the vehicle diagnosis
system, testing and in‐
formation system - VAS
5051B- .
⇒ page 229
3 - Rear left vehicle level send‐
er - G76-
❑ Location: on rear sub‐
frame
❑ Can be checked using
“Guided Fault Finding”
function of vehicle diag‐
nostic, testing and infor‐
mation system - VAS
5051B- .
❑ If the rear left vehicle level sender - G76- is removed and installed, the adaptive suspension system must
be reset with the vehicle diagnosis system, testing and information system - VAS 5051B-
4 - Adaptive suspension control unit - E281-
❑ Located in centre console
❑ Switch on jacking mode ⇒ page 259 .
5 - Pressure accumulator
❑ Location: front left on underbody
❑ Charging ⇒ page 271
6 - Front left body acceleration sender - G341-
❑ Location: on top left of wheel housing
❑ Can be checked using “Guided Fault Finding” function of vehicle diagnostic, testing and information
system - VAS 5051B- .
4. Self-levelling suspension components and fitting locations 263

7 - Front left air spring strut

❑ With front left shock absorber damper adjustment valve - N336- .
❑ The front left shock-absorber damper adjustment valve - N336- can be checked using “guided fault find‐
ing” with the vehicle diagnosis system, testing and information system - VAS 5051B- .
8 - Front left vehicle level sender - G78-
❑ Location: in front left wheel housing and on upper suspension link
❑ If the front left vehicle level sender - G78- is removed and installed, the adaptive suspension system
must be reset with the vehicle diagnosis system, testing and information system - VAS 5051B-
9 - Front right vehicle level sender - G289-
❑ Location: in front right wheel housing and on upper suspension link
❑ If the front right vehicle level sender - G289- is removed and installed, the adaptive suspension system
10 - Front right air spring strut
❑ With front right shock absorber damper adjustment valve - N337-
❑ The front right shock-absorber damper adjustment valve - N337- can be checked using “guided fault
finding” with the vehicle diagnosis system, testing and information system - VAS 5051B- .
11 - Front right body acceleration sender - G342-
❑ Location: on top right of wheel housing
12 - Compressor with adaptive suspension valve block - NX7- .
system - VAS 5051 -
❑ Removing and installing without valve block for adaptive suspension - NX7- ⇒ page 275
❑ Removing and installing with valve block for adaptive suspension - NX7- ⇒ page 277
❑ Removing and installing adaptive suspension valve block - NX7- ⇒ page 281
❑ Not designed to be repaired.
❑ Location: front right on underbody
❑ With adaptive suspension compressor motor - V66- .
❑ With adaptive suspension pressure sender - G291- .
13 - Rear right vehicle level sender - G77-
❑ Location: on rear subframe
❑ If the rear right vehicle level sender - G77- is removed and installed, the adaptive suspension system
14 - Rear right air spring strut
❑ With rear right shock absorber damper adjustment valve - N339- .
❑ The rear right shock-absorber damper adjustment valve - N339- can be checked using “guided fault
finding” with the vehicle diagnosis system, testing and information system - VAS 5051B- .

4.1 Removing and installing adaptive sus‐

pension control unit - J197-
Fitting location:
The adaptive suspension control unit - J197- is installed behind
the right side wall trim in the luggage compartment.
Removing
– Remove side luggage compartment trim ⇒ General body re‐
pairs, interior; Rep. gr. 70 ; Luggage compartment trim; Re‐
moving and installing side luggage compartment trim .
– Release connectors -1- and pull them off adapted suspension
control unit - J197- -2-.
– Unscrew nuts -arrows- and remove adaptive suspension con‐
trol unit 2 - J197- -2-.
Installing
lowing:
If the adaptive suspension control unit - J197- has been replaced,
it must be coded with the vehicle diagnosis system, testing and
Specified torques
Adaptive suspension control unit - J197- to bracket. 6 Nm
4.2 Removing and installing front left and

right body acceleration senders - G341/
G342-

Fitting location:
The front left/right body acceleration senders - G341/G342- are
installed on top of the respective wheel housing.
Removing
– Release connectors -1- and pull off.
– Unscrew bolt -2- and remove front left and right body acceler‐
ation senders - G341/G342- -3-.
Installing
Install in reverse order.
Specified torques
Front left and right body acceleration senders - G341/ 8 Nm
G342- to wheel housing
4.3 Assembly overview - front left/right vehicle level senders - G78/G289-
Note
The front left/right vehicle level sender - G78/G289- is only available as a replacement part complete with
coupling rod and upper and lower retaining plates.

1 - Upper suspension link

2 - Wheel housing
3 - Bolt
❑ 9 Nm
4 - Front left/right vehicle level
sender - G78/G289-
❑ Complete with attach‐
ments
⇒ page 267
❑ If the front left/right vehi‐
cle level sender - G78/
G289- is removed and
installed, the adaptive
suspension system
must be reset with the
vehicle diagnosis sys‐
tem, testing and infor‐
mation system - VAS
5051B-
❑ After replacement, re-
adjust the headlights
with the vehicle diagno‐
sis system, testing and
information system -
VAS 5051B-
5 - Assembly pin
4.4 Removing and installing front left/right

vehicle level sender - G78/G289-

Removing
lifting platform.

– Pull connector -1- off front left/right vehicle level sender - G78/
G289- .
– Pull pin -2- downwards and unclip coupling rod on top of sus‐
pension link.
– Undo bolt -3- and remove front left/right vehicle level sender -
G78/G289- .
Installing
lowing:
– Reset adaptive suspension with the vehicle diagnosis system,
Specified torques
Vehicle level sender to wheel housing 9 Nm
4.5 Assembly overview - rear left/right vehicle level senders - G76/G77-
Note
The rear left/right vehicle level sender - G76/G77- is only available as a replacement part complete with coupling
rod.

1 - Nut
❑ 8 Nm
2 - Upper link (front)
3 - Bolt
❑ 5 Nm
4 - Rear left/right vehicle level
sender - G76/G77-
❑ Complete with attach‐
ments
⇒ page 269
❑ If the front left vehicle
level sender - G78- is re‐
moved and installed,
basic setting of the
adaptive suspension
system must be per‐
formed using the vehicle
diagnostic, testing and
VAS 5051B-
❑ After replacement, re-
adjust the headlights
with the vehicle diagno‐
sis system, testing and
VAS 5051B-
Basic setting of headlights ⇒
“Guided Fault Finding” func‐
tion of vehicle diagnostic, test‐
ing and information system
VAS 5051
5 - Subframe
4.6 Removing and installing rear left/right

vehicle level sender - G76/G77-

Removing
lifting platform.

– Pull connector -1- off rear left/right vehicle level sender - G76/
G77- .
– Unscrew nut -2-.
– Undo bolts -3- and remove front left/right vehicle level sender
- G78/G289- .
Installing
lowing:
– Reset adaptive suspension with the vehicle diagnosis system,
Specified torques
Vehicle level sender to subframe 5 Nm
Coupling rod to front upper suspension link 8 Nm
4.7 Removing and installing accumulator

Fitting location:
The accumulator is mounted on the underbody on left hand side
at front.
Removing
– Remove air from accumulator with the vehicle diagnosis sys‐
tem, testing and information system - VAS 5051B- .
lifting platform.
– Remove underbody panelling on left ⇒ General Body Repairs
- Exterior; Rep. gr. 50 ; Underbody panelling

– Screw air line off -1-.

– Undo bolt -2- and pull accumulator -3- off retaining bolts
-arrows-.
Installing
lowing:
– Fill accumulator using the vehicle diagnostic, testing and in‐
formation system - VAS 5051B- ⇒ page 271 .
Specified torques
Accumulator to body 20 Nm
4.8 Filling the accumulator

The accumulator is filled with the vehicle diagnosis system, test‐
ing and information system - VAS 5051B- .
There are two ways of filling the accumulator with the vehicle di‐
agnosis system, testing and information system - VAS 5051B- .
♦ Filling by means of the compressor
♦ Filling with nitrogen
– When filling with nitrogen, secure the tools to accumulator as
shown in illustration.
1- Adapter - T10157-
2- Nitrogen charging set for air suspension struts - VAS 6629-
4.9 Repairing air line


♦ Cutting pliers - VAS 6228-
Defective air lines need not be renewed completely. Partial re‐

newal of an air line is possible using a connector.
Allocation of connectors for air lines ⇒ Electronic Parts Catalogue
“ETKA” .
Note
♦ The repair point must be an area protected from spray water,

for example in the interior or between wheel housing liner and
wheel housing.
♦ The connector must be secured to the body or a wiring guide
using cable ties.
♦ Select straight line sections for the repair.

– Clean area of connection and respective separating point.
– Use cutting pliers - VAS 6228- to cut off air line (right-angled
cut) on vehicle at separating point.
– Unscrew connection piece and remove air pipe.
– Mark -arrows- ends of air line in vehicle and new line section
with a waterproof marker.
The marks at 17 mm and 22 mm are for checking after repair work
has been completed.
– Route new air line along route of original securing points.
Fit new line connectors.
Note
The connection pieces in the plug-in connectors are already tight‐

ened to specified torque. The air pipes only need to be pushed
in.
– Remove transport protection cap.

– Push the old air pipe through the sealing rings -1-.
– Then, applying a little pressure, push the air line through the
cutting ring -2- and into the line connectors as far as it will go.
Note
The air lines have been pushed in far enough when the first colour
marking -arrow A- is no longer visible and the second colour
marking -arrow B- remains visible.
– Repeat the steps with the new air line.

5 Assembly overview - compressor with adaptive suspension valve

block - NX7-
1 - Air line
❑ 4 Nm
❑ Between adaptive sus‐
pension valve block -
NX7- and compressor
❑ Clean line joint before
loosening.
❑ Air escapes when joint
is loosened.
❑ Protect threaded joint
from soiling.
2 - Compressor
without valve block for
adaptive suspension -
NX7- ⇒ page 275
with valve block for
adaptive suspension -
NX7- ⇒ page 277
❑ Cannot be repaired
3 - Bolt
❑ 5 Nm
4 - Cushioning element
5 - Adaptive suspension valve
block - NX7-
⇒ page 281
❑ Connection assignment
of the air lines
⇒ page 275
6 - Bracket
❑ For adaptive suspen‐
sion valve block - NX7-
7 - Bolt
❑ 5 Nm
8 - Air line
❑ 4 Nm
❑ Clean line connection before loosening.
❑ Air escapes when joint is loosened.
❑ Protect threaded joint from soiling.
9 - Bolt
❑ 5 Nm
10 - Nut
❑ 6 Nm
11 - Bracket
❑ For compressor and adaptive suspension valve block - NX7-

12 - Bracket
❑ For compressor
13 - Rubber mounting
14 - Bracket
❑ For compressor
15 - Bolt
❑ 5 Nm
18 - Intake manifold
19 - Air line
❑ 4 Nm
❑ Between adaptive suspension valve block - NX7- and compressor
❑ Clean line joint before loosening.
❑ Air escapes when joint is loosened.
❑ Protect threaded joint from soiling.
Terminal assignment of the air lines

1- Black, drainage line
2- Blue, internal air line between adaptive suspension valve
block - NX7- and compressor
3- Yellow, air line to rear right air spring strut
4- Violet, air line to front left air spring strut
5- Red, air line to rear left air spring strut
6- Green, air line to front right air spring strut
7- Black, air line from compressor to accumulator
5.1 Removing and installing compressor

without adaptive suspension valve block
- NX7-
5. Assembly overview - compressor with adaptive suspension valve block NX7 275

Removing
– Remove air from accumulator using vehicle diagnostic, testing
lifting platform.
– Remove underbody panelling on right ⇒ General Body Re‐
pairs - Exterior; Rep. gr. 50 ; Underbody panelling
– Remove clip -arrow- and detach intake line -1-.
– Unclip and unplug connectors -1- and -2- between compressor

and body.
– Remove air lines -1- and -2- from compressor.

– Remove cable ties -arrows-.

– Unscrew nuts -1- for compressor.
– Unscrew bolts -arrows- and swivel compressor with bracket

-1- downwards and secure.
– Low compressor with bracket at front until compressor can be
removed.
Caution
♦ Make absolutely sure that the adaptive suspension valve

block - NX7- is taken as small a distance as possible away
from the underbody.
♦ In addition, it must be ensured that the air lines are never
kinked or stretched.
Installing
lowing:
Specified torques
Air lines to compressor 4 Nm
Bracket to body 20 Nm
Compressor to bracket 6 Nm
5.2 Removing and installing compressor

with adaptive suspension valve block -
NX7-

Removing
lifting platform.
– Clean area around pressure retention valve at air spring struts
at front.
– Unscrew air lines from pressure retention valves of air spring
struts at front -1-.
at rear.

struts at rear -1-.

– Remove clip -arrow- and detach intake line -1-.
– Unclip and unplug connectors -1- and -2- between compressor

and body.
– Separate connector -3- from adaptive suspension valve block
- NX7- .
– Unscrew air lines -2- from compressor.
Note
The air line -1- remains installed.
– Unscrew air lines -1- to -5- from adaptive suspension valve

block - NX7- .
– Unscrew bolts -arrows- and remove compressor together with

adaptive suspension valve block - NX7- -1-.
Installing
lowing:
Installation position of air line at front

the air line.
lowing:
Installation position of air line at rear

nut -1-.
Terminal assignment for air lines at adaptive suspension valve

block - NX7- .
Specified torques
Air lines to adaptive suspension valve block - NX7- and 4 Nm
compressor


5.3 Removing and installing adaptive sus‐

pension valve block - NX7-

Removing
lifting platform.
at front.
struts at front -1-.
at rear.

struts at rear -1-.
– Separate connector -1- from adaptive suspension valve block

- NX7- .
– Unscrew air lines -1- to -6- from adaptive suspension valve

block - NX7- .
– Unscrew bolts -arrows-, lower compressor together with adap‐

tive suspension valve block - NX7- -1- approx. 10 cm and then
secure.
– Undo bolts -arrows- and remove adaptive suspension valve

block - NX7- .
Installing
lowing:

Before the air line is installed, it must be ensured that only the
second marking -arrow- on the air line can be seen.
The distance -a- from the end of the air line to the cutting ring
-1- must be between a minimum of 4 mm and a maximum of 6
mm.
Terminal assignment for air lines at adaptive suspension valve

block - NX7- :
Specified torques
Air lines to adaptive suspension valve block - NX7- 4 Nm
Valve block for adaptive suspension - NX7- 7 Nm
44 – Wheels, tyres, vehicle geometry

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

2 Specified torques for wheel bolts

Wheel bolt to wheel hub for all vehicles
Specified torque: 180 Nm
– Before fitting wheel, protect wheel centring seat against cor‐
rosion ⇒ Wheels and Tyres Guide - General Information; Rep.
gr. 44 ; Wheel change; Protecting wheel centring seat against
corrosion .
♦ Fitting anti-theft wheel bolts using adapter set for wheel bolts
⇒ Wheels and Tyres Guide - General Information; Rep. gr.
44 ; Wheel bolts; Adapter sets for anti-theft wheel bolts .
2. Specified torques for wheel bolts 285

3 Vehicle alignment check

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

proved wheel alignment computer
3.1 General information

Wheel alignment must be performed only using VW/AUDI ap‐
proved wheel alignment equipment!
Whenever wheels are aligned, both the front and rear axle must
be measured.
Otherwise, the steering rack may not be centred!
– Carry alignment out with the wheel alignment computer.
All information needed for alignment is stored on the wheel align‐
ment computer.
Current data »updates« are located in VW ServiceNet:

⇒ VW ServiceNet; Systems; Wheel alignment computer soft‐

ware; Beissbarth
ware; Hunter
ware; Corghi
ware; 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.
Wheel alignment is necessary if:

♦ The vehicle does not handle properly.
♦ Vehicle has been involved in an accident and components
have been renewed.
♦ Axle components are removed or renewed.
♦ Tyres wear on one side.
Components have been renewed
Front axle component was Alignment necessary Rear axle component re‐ Alignment necessary
renewed. newed
yes no yes no
Lower suspension link X Lower suspension link X
Bonded rubber bush X Front upper suspension link X
for suspension link
Wheel bearing housing X Rear upper suspension link X
Track rod/track rod ball joint X Track rod X
Steering rack X Wheel bearing housing X
Subframe X1) Subframe X2)
Spring strut/air spring strut X Spring strut/air spring strut X
Anti-roll bar X Anti-roll bar X
1)Prerequisite: the position of the subframe was fixed before the
part was removed ⇒ page 11 .
Components removed and installed

Front axle component re‐ Alignment necessary Rear axle component re‐ Alignment necessary
moved and reinstalled moved and reinstalled
yes no yes no
Lower suspension link X Lower suspension link X
Bonded rubber bush X Front upper suspension link X
for suspension link
Wheel bearing housing X Rear upper suspension link X
3. Vehicle alignment check 287

Front axle component re‐ Alignment necessary Rear axle component re‐ Alignment necessary
moved and reinstalled moved and reinstalled
yes no yes no
Track rod/track rod ball X Track rod X
joint
Steering rack X Wheel bearing housing X
Subframe X3) Subframe X4)
Spring strut/air spring strut X Spring strut/air spring strut X
Anti-roll bar X Anti-roll bar X
3.2 Conditions for testing

• Check suspension, wheel bearing, steering and steering link‐
age for excessive play and damage.
• Tread depth difference of no more than 2 mm on one axle.
• Tyres inflated to correct pressure.
• Vehicle unladen.
• Fuel tank must be full.
• Spare wheel and vehicle tools are stowed in correct locations.
• The fluid reservoir for the windscreen/headlight washer sys‐
tem 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 units and com‐
puters can lose their calibration over a period of time.
Wheel alignment platforms and alignment units 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


The existing lateral runout of the wheel must be compensated for.

Otherwise, the result of the measurement will be incorrect.
If runout compensation is not performed, it is not possible to adjust
toe-in correctly!
Please follow the instructions of the manufacturer of the wheel
alignment equipment.
– Carry out wheel runout compensation.
– Apply brake pedal depressor - V.A.G 1869/2- .
– Use brake pedal depressor to depress brake pedal.
3.4 Wheel alignment specifications

These specifications apply to all engines.
♦ Explanations regarding PR. numbers ⇒ page 297
The ride height shown in the table refers to dimension -a-.
Front axle Steel spring strut Air spring strut

PR numbers 1BA/1BE 1BB 1BK/1BY 2MA
Toe-in per wheel (individual toe) +5' ± 2.5' +5' ± 2.5' +5' ± 2.5' +5' ± 2.5'
Maximum permissible differ‐ max. 5' max. 5' max. 5' max. 5'
ence between sides
Camber (in straight-ahead posi‐ -15' ± 20' -15' ± 20' -15' ± 20' -15' ± 20'
tion)
ence between sides
Castor angle +8° 35' +10'/-30' +8° 26' +10'/-30' +8° 38' +10'/-30' +9° 5' +10'/-30'
Maximum permissible differ‐ max. 30′ max. 30′ max. 30′ max. 30′
ence between sides
Ride height 478 ± 10 mm 488 ± 10 mm 475 ± 10 mm 450 ± 10 mm

Rear axle Steel spring strut Air spring strut

PR numbers 1BA/1BE 1BB 1BK/1BY 2MA
Toe-in per wheel (individual toe) +10' ± 5' +10' ± 5' +10' ± 5' +10' ± 5'
ence between sides
Camber -1° 20' ± 20' -1° 20' ± 20' -1° 20' ± 20' -1° 20' ± 20'
ence between sides
Ride height 486 ± 10 mm 502 ± 10 mm 483 ± 10 mm 458 ± 10 mm
3.5 Overview - wheel alignment procedure

Always adhere to the following procedure!
– Observe instructions for your wheel alignment device.
Alignment procedure
Start → Carry out wheel runout com‐ → Bounce springs.

pensation.
↓
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 Adjusting ⇒ page 291
↓ ↓
↓ ← ← ← ← ←
↓
Check rear axle camber → Is actual value within toler‐ → no
ance?
↓ ↓
↓ ↓
↓ ← ← ← ← ←
↓
Check rear axle toe → Is actual value within toler‐ → no
ance?
↓ ↓

↓ ↓
↓ ← ← ← ← ←
↓
Check front axle caster → Is actual value within toler‐ → no
ance?
↓ ↓
↓ ↓
↓ ← ← ← ← ←
↓
Check front axle toe → Is actual value within toler‐ → no
ance?
↓ ↓
End ← yes Adjusting ⇒ page 295
↑ ↓
↑ ← ← ← ← ←
1) If steering wheel is not centred, it must be straightened after
wheel alignment is finished. Then perform basic settings for steer‐
ing angle sensor - G85- using vehicle diagnosis, testing and
3.6 Adjusting camber at front wheels



– Undo nut -1- and adjust camber by turning the eccentric bolt
-1-.
– Tighten nut for camber adjusting bolt.

1- Insert - T10188-
2- Torque wrench - V.A.G 1332-
Specified torques
Bolt Specified torque
“camber adjusting bolt”
♦ Use new bolts
3.7 Adjusting camber on rear axle



– Undo nut -1- and adjust camber by turning the eccentric bolt
-2-.
– Tighten nut -1-.
Specified torques
“camber adjusting bolt”
♦ Use new bolts
3.8 Adjusting toe at rear axle


– Undo nut -1- and adjust toe by turning the eccentric bolt -2-.
– Tighten nut -1-.

Specified torques
Track rod to subframe 170 Nm
“to adjusting bolt”
♦ Use new bolts
♦ Tighten threaded connections only when vehicle is in
the normal running position ⇒ page 142
3.9 Adjusting caster on front axle


– Undo nut -1- and adjust caster by turning the eccentric bolt
-2-.

– Tighten nut for caster adjusting bolt.

1- Insert - T10188-
Specified torques
“caster adjusting bolt”
♦ Use new bolts
3.10 Adjusting front axle toe

♦ Insert tool, 24 mm - V.A.G 1332/11-

– Undo lock nut -1- while counterholding on track rod ball joint.
– Pull spring-type clip off boot.
– Adjust toe by turning left and/or right track rod.
To to this, it is possible to position an open jaw spanner on hex‐
agonal profile of track rod.
After turning track rods, ensure that boots are not twisted.
Twisted boots wear out quickly.
– Tighten lock nut -1- with tool insert 24 mm - V.A.G 1332/11-
while counterholding on flats of track rod ball joint.
– Check toe values again.
It is possible that the value will change slightly when lock nut is
tightened.
However, if the measured toe value lies within the tolerance, the
adjustment is correct.
– Fit spring-type clip to boot.
Specified torques
Track rod ball joint to track rod 70 Nm

4 Vehicle data sticker

Explanation of “PR numbers” on vehicle data sticker
Various types of running gear are installed depending on engine
and equipment level. These are identified by the PR numbers.
The PR numbers are critical in determining the wheel alignment
specifications.
The running gear version fitted in the vehicle is indicated on the
vehicle data sticker by the PR number for the front axle.
The vehicle data sticker can be found in the spare wheel well and
in the service booklet.
Example of a vehicle data sticker
In this example, the vehicle is equipped with the 1BA running gear
-arrow-.
4. Vehicle data sticker 297

5 Adaptive Cruise Control (ACC)

5.1 General information on Adaptive Cruise

Control (ACC)
Detailed information on the Adaptive Cruise Control (ACC) sys‐
tem can be found in ⇒ Self-study programme No. 449 ; Touareg
2011 .
The Adaptive Cruise Control (ACC) system has 2 sensors for au‐
tomatic distance regulation , Distance regulation control unit -
J428- “master” and distance regulation control unit 2 - J850-
“slave”. The distance regulation sensor and the distance
regulation control unit are installed together in a single housing.
The entire unit has to be replaced if the sensor or the control unit
are defective.
The distance regulation control unit - J428- “master” is installed
on the right of the vehicle in the bumper support at the front.
Control unit 2 for adaptive cruise control - J850- “slave” is installed
on left side of vehicle in front bumper.
In the following, the sensor/control unit combination is referred to
as the “sensor”.
If the sensor is soiled, functional faults can occur. Clean sensor.
It must be ensured that the radar sensors and ultrasonic sensors
are not covered by stickers, paint or similar because this can im‐
pair proper functioning of the Adaptive Cruise Control (ACC)
system.
Impacts or damage to bumper cover, wheel arch and underbody
can adversely affect the sensors. As a result, proper functioning
of the Adaptive Cruise Control (ACC) can be impaired.
Before adjusting the adaptive cruise control (ACC) system, check
both sensors as well as their brackets and securing elements for
damage, external influence and secure seating. Repair any dam‐
aged parts if necessary. The front bumper cover is also to be
checked for damage, cracks and secure seating and any dam‐
aged parts are to be repaired.
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 distance regulation control unit - J428- “master” and/or
distance regulation control unit 2 - J850- “slave” has been re‐
moved/installed.
♦ The front bumper support has been removed and installed.
♦ The front bumper support has been loosened or moved.
♦ The misalignment angle is greater than -0.8° to +0.8°.
♦ The vehicle has been brought into the service position.
5. Adaptive Cruise Control (ACC) 299

5.2 Adjusting the automatic distance regu‐

lation sensor
♦ Adjusting tool - VAS 6190/2-
♦ ACC setting device - VAS 6430- or setting device, basic kit -

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

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

make sure there is sufficient space between the vehicle and
the ACC setting device - VAS 6430- . The distance between
the ACC setting device - VAS 6430- and the VW emblem 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.
♦ The ACC reflector mirror of the ACC setting device - VAS
6430- and ACC reflector mirror - VAS 6430/3- may not come
into contact during installation.
♦ If the position of the ACC reflector mirror - VAS 6430/3- on the
alignment beam is changed, the setting of the ACC setting
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.
The adjustment procedure described here is based on ACC set‐
ting 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
reflector mirror - VAS 6430/3- fitted in the middle and the
VW emblem on radiator grille
2- Fit ACC reflector mirror - VAS 6430/3- on right next to ver‐
tical slide block (see in direction of travel)
3- Set distance regulation control unit - J428- “master”
4- Move ACC reflector mirror to opposite side of alignment
beam
5- Check and, if necessary, correct position of spirit levels and
alignment beam
6- Set distance regulation control unit 2 - J850- “slave”.
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
– Click button for ACC setting with dual radar in wheel alignment
computer.
– Note testing preconditions for wheel alignment ⇒ page 288 .
Vehicles with air suspension
– Move vehicle to normal level.
– Drive car onto wheel alignment platform.
– Connect battery charger ⇒ Electrical system; general infor‐
mation; Rep. gr. 27 .
– Connect vehicle diagnosis, testing and information system -
VAS 5051 B- to the car. (Route diagnostic cable through open
window.)
Note
During the setting procedure, make sure that all the car doors
remain closed and that the car's outside lighting is switched off.
– Move front wheels to straight-ahead position.

– Mount quick-release clamps on rear wheels.
– Fit measurement transducers to rear wheels.
– Carry out wheel run-out compensation at rear wheels.
Setting with or without preceding wheel alignment
– Remove cover for fog lamp -1- on left and right ⇒ Rep. gr.
63 .
– Remove dirt, if there is any, from the sensor lens.

– Position ACC setting device - VAS 6430- in the middle and

parallel at a distance -a- from the ACC reflector mirror - VAS
6430/3- fitted in the middle to the VW emblem in the radiator
grille.
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

– Fit measurement transducers of front wheels -1- an - VAS
6430- .
– Remove mirror fitted in middle and mount it again on the far

right-hand side next to the vertical slide block.
– 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- 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 mirror -4- on side of alignment beam until the laser

beam hits the sensor lens in the middle.
– Set the same individual toe values of the front axle by means
of fine adjusting screw -5-.
• The difference between the two individual toe values must be
smaller than or equal to 6'.

– Level spirit levels -2- of the measurement transducer -1-.

– Now, use laser beam -3- am -VAS 6430/3- again to check
whether laser beam hits the sensor lens in the middle.
Note
♦ - VAS 6430- is correctly aligned if the laser beam still coincides

with the sensor lens at this stage, after the identical toe values
have been set.
♦ The alignment of - VAS 6430- must be repeated if the laser
beam does not coincide with the sensor lens.
– Go to vehicle diagnosis system, test and information system -

VAS 5051B- , click Go To and select the function “Function/
component selection”.
Selection on the VAS 505X for setting the distance regulation
control unit - J428- “Master”:
– On the screen, click the following buttons one after the other:
♦ Running gear (Rep. Gr. 01; 40 - 49)
♦ Proximity control
♦ Master
♦ 01 - Self-diagnosis compatible system
♦ 13 - Adaptive cruise control I J428
♦ 13 - Adaptive cruise control, functions
♦ 13 - Adjusting adaptive cruise control unit J428
Follow instructions on screen to adjust the control unit.
Designation of adjusting screws of distance regulation control unit

- J428- “Master”
1- Adjuster screw
2- Adjuster screw
3- Must not be rotated - serves only as point of rotation

The procedure for setting distance regulation control unit 2 - J850-

“Slave” is analogous to that of distance regulation control unit -
J428- “Master”.
Move ACC reflector mirror - VAS 6430/3- -1- to opposite side of
alignment beam.
Selection on the VAS 505X for setting distance regulation control
unit 2 - J850- “Slave”:
– On the screen, click the following buttons one after the other:
♦ Running gear (Rep. Gr. 01; 40 - 49)
♦ Proximity control
♦ Slave
♦ 01 - Self-diagnosis compatible system
♦ 8B - Adaptive cruise control 2 I J850
♦ BB - Adaptive cruise control, functions
♦ BB - Adjusting control unit 2 for adaptive cruise
control J850
Follow instructions on screen to adjust the control unit.
Designation of adjusting screws of distance regulation control unit

2 - J850-
1- Adjuster screw
2- Adjuster screw
3- Must not be rotated - serves only as point of rotation
WARNING
The ACC setting is not accepted until “Actuating element di‐

agnosis completed” is shown in the vehicle diagnosis system,
test and information system - VAS 5051B- .

6 Lane departure warning
6.1 General information about lane depar‐

ture warning
Detailed information on the lane departure warning is provided in
⇒ Self-study programme No. 449 ; Touareg 2011
Note
The following situations can cause the camera function to be im‐

paired by sustained poor visibility of the lane marker lines:
♦ The field of view of the camera is contaminated or iced over.

In this case, clean the affected area.
♦ The field of view of the camera is fogged over.
♦ The condition of the carriageway means that no lane marker
lines can be detected clearly (e.g. road covered with snow, at
roadwork's).
The camera’s viewing window must be cleaned manually if there
is heavy soiling on the inside of the windscreen in the field of view
of the camera. To do this, the control unit and lens hood must be
removed and the windscreen cleaned using cleaning solution.
Removing the control unit and lens cover ⇒ Rep. gr. 94 .
Correct calibration is a basic precondition for the lane departure
warning to function without faults.
The following circumstances make it necessary to recalibrate the
lane departure warning:
♦ Entry “no or incorrect basic setting / adaptation” is stored in
event memory.
♦ Camera control unit - J852- has been renewed.
♦ Windscreen has been renewed or removed.
♦ Rear axle toe has been adjusted.
♦ Modifications having an effect on the body height have been
made to the car's running gear.
Note
♦ Before calibrating the lane departure warning, read out event

memory and rectify faults as necessary.
♦ The geometrical driving axis of the car must be measured in
order to calibrate the lane departure warning. It is used as a
reference position for the setting device - VAS 6430- .
♦ Calibration of the lane departure warning must only be per‐
formed only using VW/AUDI approved wheel alignment equip‐
ment!
♦ Calibration of the lane departure warning is only permitted us‐
ing the setting device - VAS 6430- !
6.2 Calibrating the lane departure warning


♦ Vehicle diagnosis, testing and information system - VAS 5051

B-
♦ Setting device - VAS 6430-
♦ Wheel alignment computer
Note
♦ The camera control unit - J852- must be correctly located in

the holder.
♦ The field of view of the camera must be clean and clear.
♦ Before driving the vehicle onto the wheel alignment platform,
make sure there is sufficient space between the midpoint of
the hub of the front wheels and the setting device - VAS 6430- .
♦ The distance between the setting device - VAS 6430- and the
centre point of the hub of the front wheels must be 1500 mm
± 25 mm.
♦ If the available space is not adequate, move the vehicle back‐
wards on the alignment platform as required.
♦ Before starting calibration, read out event memory and rectify
any faults.
– Note testing preconditions for wheel alignment ⇒ page 288 .

Vehicles with air suspension
– Move vehicle to normal level and activate car jacking mode
⇒ page 259
– Drive car onto wheel alignment platform.
– Connect battery charger ⇒ Electrical system; general infor‐
mation; Rep. gr. 27 .
– Connect vehicle diagnosis, testing and information system -
VAS 5051 B- to the car. (Route diagnostic cable through open
window.)
6. Lane departure warning 307

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

– Select calibration run for lane departure warning in wheel
alignment computer.
– Mount quick-release clamps on all four wheels.
– Mount measuring transducers on wheels.
– Perform wheel runout compensation on rear wheels.
– Bounce springs.
– Measure standing height at all four wheels and make a note
of it.
Note
♦ Setting device - VAS 6430- is not allowed to be moved on

alignment beam.
♦ Wheel alignment platform must be in the lowermost levelled
position for next work step.
– Align setting device - VAS 6430- at a right angle to lengthways

axis of car.
– Turn setting device - VAS 6430- upwards so that alignment

beam is parallel to middle of measurement transducers on
front wheels, in order to perform a correct measurement with
distance measuring unit -1-.
1- Distance measuring unit with tape measure and socket pin
– Position setting device - VAS 6430- at distance -a- of 1500 mm
± 25 mm from midpoint of hub of front wheels to beam of set‐
Caution
♦ Distance -a- of 1500 mm ± 25 mm must be measured on

both sides of vehicle and adjustment device - VAS 6430-
must then be aligned.
♦ Distance -a- must be same on both sides of car.
♦ To guarantee correct calibration, setting device - VAS
6430- must be at right angle to lengthways axis of car.

– Mount measurement transducer -1- of front wheels onto set‐

– Measure height value -a- between standing surface of setting

device - VAS 6430- and wheel support surface on wheel align‐
ment platform and enter value in wheel alignment computer.
– Unscrew clamping bolt -arrow-, place measuring bar -1- on

floor.
– Use crank -1- to set lane departure warning calibration panel

- VAS 6430/4- to nominal height -2- indicated by wheel align‐
ment computer and make a note.

When nominal height has been reached, measuring bar -1- must
be moved upwards slightly and secured with clamping screw
-arrow-.
– Use adjuster screw -1- to level spirit level -A-.
– Move setting device - VAS 6430- sideways -arrows B- until

display on wheel alignment computer is within tolerance.

– Screw down adjuster screws -2- and -3- slightly to secure set‐
ting device - VAS 6430- against rolling away.
– Turn fine adjuster screw -1- until display on wheel alignment

computer is within tolerance.
– Use adjuster screw -1- to level spirit level -A-.

– Use adjuster screws -2- and -3- to level spirit level -B-.
– Unscrew clamping bolt -arrow-, place measuring bar -1- on

floor.
– Check nominal height -2- again and correct if necessary.

When nominal height has been reached, measuring bar -1- must
be moved upwards slightly and secured with clamping screw
-arrow-.
Subsequent work is performed using vehicle diagnosis, testing
– On vehicle diagnosis, testing and information system - VAS
5051- , select “Guided fault finding” ⇒ Vehicle diagnostic test‐
er.
Body (Rep. Gr. 01;27;50...97)
Electrical system (Rep. Gr. (01, 27, 90…97)
01_Self-diagnosis compatible systems
85_control unit for camera- J852
85_control unit for camera- J852, functions
J852 - Calibration (Rep. Gr. 44
Follow instructions on screen to perform calibration.
Note
The next step in Guided fault finding is to measure the body

height.
– Enter the noted standing height.

48 – Steering
314 Rep. gr.48 - Steering

2 Assembly overview - airbag and steering wheel
1 - Steering column
⇒ page 319
2 - Steering wheel
⇒ page 315
❑ Different versions possi‐
ble. Refer to ⇒ Electron‐
ic parts catalogue
3 - Bolt
❑ 30 Nm + 90°
moval
2.1 Removing and installing airbag and

steering wheel
2. Assembly overview - airbag and steering wheel 315


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

the electrical system and removing the steering wheel:
♦ Earth strap must be disconnected from battery ⇒ 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!
– Move steering column to middle height position.

– Remove airbag module ⇒ General body repairs, interior; Rep.
gr. 69 ; Passenger protection .
– Turn wheels to straight-ahead position.
Note
The steering wheel must be removed/installed in the middle po‐

sition (wheels facing straight ahead).
Vehicles with heated steering wheel

– Release and pull off connector -1-.


– Remove bolt -1-.
– Mark position of steering wheel/steering column with a felt-
tipped pen.
– Pull steering wheel -2- off steering column.
Installing
lowing:
Make sure that the wheels are pointing straight ahead before fit‐
ting the steering wheel.
– When installing a steering wheel that has been removed,
make sure that the markings on the steering column and steer‐
ing wheel are in line.
– When installing a new steering wheel (without marking), the
steering wheel must be mounted in middle position (steering
wheel spoke must be horizontal and wheels in straight posi‐
tion).
– Install steering wheel.
– Installing airbag module ⇒ General body repairs, interior; Rep.
gr. 69 ; Passenger protection .
– Carry out road test.
– If the steering wheel is skewed, the steering wheel must be
removed again and fitted onto the splines of the steering col‐
umn.
Specified torque

Bolt for steering wheel 30 Nm + 90°
♦ Use new bolt
2. Assembly overview - airbag and steering wheel 317

3 Assembly overview: steering column, left-hand drive
Note

1 - Cross member
2 - Electronic steering column
lock control unit - J764-
⇒ page 326
3 - Bolt
❑ 5 Nm
4 - Steering column
❑ Different steering col‐
umn variants installed,
allocation ⇒ electronic
parts catalogue “ET‐
KA” .
⇒ page 319
❑ Check for damage
⇒ page 326
5 - Bolt
6 - Bolt
❑ 20 Nm
❑ Qty. 4
7 - Bolt
❑ 20 Nm + 90°
moval
8 - Nut
❑ 4 Nm
9 - Nut
❑ 20 Nm
moval
10 - Control unit for electrically adjustable steering column - J866-
11 - Bolt
❑ 5 Nm

3.1 Removing and installing steering col‐

umn, left-hand drive vehicle
WARNING
Before steering column is removed, the following must be

done:
Make a sketch of:
♦ The routing of the electrical wiring harnesses
♦ The fastenings of the electrical wiring harnesses
♦ The mounting locations of the cable ties
This especially applies to the wiring harness for the electronic
steering column lock control unit - J764- .
Before steering column is installed, the following must be done:
• The wiring harnesses must be routed and laid exactly as
before removal.
• The wiring harnesses must be secured exactly as before
removal.
• All cable ties that have been undone or cut open must be
fastened at the same places.
• Make sure that the wiring harness for the electronic steer‐
ing column lock control unit - J764- does not become
jammed or touch sharp edges when steering column is
adjusted.
3. Assembly overview: steering column, left-hand drive 319


Removing
Note
♦ Only the complete steering column is supplied as a replace‐

ment part. Repair is not possible.
♦ If the steering column is renewed, the electronic steering col‐
umn lock control unit - J764- has already been mounted on the
new steering column and does not have to be transferred.
♦ If an electrically adjustable steering column is renewed, the
control unit for electrically adjustable steering column - J866-
has already been mounted on the new steering column and
does not have to be transferred.

⇒ page 259 .
– Remove left front wheel.
– Remove noise insulation ⇒ General body repairs, front; Rep.
gr. 50 ; Noise insulation .
– Remove front left wheel housing liner ⇒ General body repairs,
exterior; Rep. gr. 66 ; Wheel housing liner
– Remove airbag and steering wheel ⇒ page 315 .
WARNING

– Remove steering column trim ⇒ General body repairs, interior;

Rep. gr. 68 ; Compartments, covers and trims .
– Remove switch module of steering column ⇒ Lights, lamps,
switches - exterior; Rep. gr. 94 ; Steering column switches .
– Remove footwell cover -1- on driver side ⇒ General body re‐
pairs, interior; Rep. gr. 68 ; Compartments, covers and trims .
– If installed, remove knee airbag ⇒ General body repairs, in‐
terior; Rep. gr. 69 .



WARNING
♦ There is a risk of injury from the exhaust system depend‐

ing on the engine.
– Unscrew nuts -arrows- from sealing boot -1-.
– Release cable bracket -arrow- from wiring harness -1- on

steering column -2-.
– Lay the wiring harness to one side.

Vehicles with electrically adjustable steering column

– Release connector -2- of wiring harness for the electrically ad‐
justable steering column -1- behind the dash panel insert and
pull off.
– Unscrew and remove bolts -arrows- of steering column -1-.
– Unscrew and remove bolted connection -arrows- between

steering column and frequency brace.
– Remove bolt, while supporting steering column -1- from below
with your hand.

– Detach connector -arrow- from electronic steering column lock

– Carefully lower steering column.
– Fold back floor covering in area of sealing boot in footwell on
driver's side.
– Remove steering column together with sealing boot from ve‐
hicle.
Installing
lowing:
WARNING

• Check steering column for damage ⇒ page 326 .
before removal.
removal.
• When installing steering column, all cable ties that were
removed or cut open when removing it must be re-attach‐
ed in the same positions.
adjusted.
– Insert steering column -1- into vehicle.

– Insert bolt -arrow- for frequency brace.
– Reconnect electrical connectors.
– Hand-tighten all bolts of steering column.

– Ensure sealing boot -1- is correctly seated in plenum chamber

bulkhead -2-.
– Hand-tighten nuts -arrows- for sealing boot uniformly.

– Tighten sealing boot -1-.
Note tightening sequence

– Tighten bolts -1- to -4- to specified torque in the sequence
shown.
– Tighten nut -5- to specified torque.
Note
The threaded hole for the bolt at universal joint must always be
cleaned (e.g. with a tap).

– Fit steering column -1- onto steering pinion of the power-as‐

sisted steering rack -2- as far as stop and tighten bolt
-arrow-.
– After installation of the steering column's circuit box, the steer‐
ing angle sensor - G85- must be calibrated ⇒ page 326 .
When steering column is renewed with electronic steering column
lock control unit - J764- , electronic steering column lock control
unit - J764- must be adapted.
Use the vehicle diagnosis system, testing and information system
- VAS 5051B- .
Body (Rep. Gr. 01;27;50;...97)
Body work (Rep. Gr. 01;50;...77)
05_access and start authorisation => J393
09_access and start authorisation, functions

When the electrically adjustable steering column is replaced to‐
gether with control unit for electrically adjustable steering column
- J866- , the control unit for electrically adjustable steering column
- J866- must be adapted.
- VAS 5051B- .
Body (Rep. Gr. 01;27;50;...97)
Electrical system (Rep. Gr. 01;27;90;...97)
09 Onboard power supply control unit J519
09 Functions of onboard power supply control unit
Coding control unit for electrically adjustable

steering column J866
Follow instructions on screen to perform adaption.

If the control unit for the electrically adjustable steering column -
J866- is renewed, basic setting must be carried out.
- VAS 5051B- .
Body (Rep.-Gr. 01;27;50;...97)
Basic settings for control unit for electrically ad-

justable steering column - J866
Follow instructions on screen to perform basic setting.

Specified torque


Universal joint to power-assisted steering rack 20 Nm + 90°
♦ Use new bolt
Steering column to cross member 20 Nm

Steering column to frequency brace 20 Nm
♦ Use new bolts
Heat shield to power-assisted steering rack 9 Nm

Sealing boot to plenum chamber bulkhead 4 Nm
3.2 Basic setting for steering angle sensor

G85 steering angle sender must be
checked after the following repair work:
♦ When vehicle steering angle sensor - G85- is removed or re‐
newed,
♦ After removal or renewal of steering column,
♦ After removal or renewal of steering rack,
♦ If steering wheel was repositioned.
Basic setting of steering angle sensor G85
- VAS 5051B- .
Body (Rep.-Gr. 01;27;50;...97)
16 Steering column electronics control unit J527
16 Functions of steering column electronics control

unit
16 Basic settings of steering column electronics con-

trol unit (Rep. Gr. 94)
3.3 Checking steering column for damage

Visual check
– Check all steering column parts for damage.
– Check sealing boot for damage and that rubber grommet for
correct seating.
Checking function
– Check that steering column turns smoothly and easily.
– Check whether steering column can be adjusted longitudinally
and vertically.
3.4 Removing and installing electronic

steering column lock control unit - J764-


Removing
– Remove steering column ⇒ page 319 .
– Unscrew screw -arrow-.
– Slightly raise electronic steering column lock control unit -
J764- -1- and lift it off steering column.
WARNING
• After removing the control units, make sure that no dirt or

foreign bodies enter the steering column.
Installing
lowing:
♦ If only the electronic steering column lock control unit - J764-
has been renewed, the previously installed securing bolt for
the control unit must be re-used.
♦ If the steering column has been renewed, the electronic steer‐
ing column lock control unit - J764- has already been fitted to
the new steering column.

– Insert electronic steering column lock control unit - J764- -1-

with lug into groove -arrow- of steering column.
– Tighten bolt.
Note
♦ If the same electronic steering column lock control unit - J764-

has been reinstalled, the electronic steering column lock con‐
trol unit - J764- need not be readapted.
♦ If the electronic steering column lock control unit - J764- has
been renewed, it must be readapted.
If electronic steering column lock control unit - J764- has been

renewed, the electronic steering column lock control unit - J764-
must be adapted.
- VAS 5051B- .
Body (Rep. Gr. 01;27;50;...97)
Specified torque

ELS control unit - J764- to steering column 5 Nm
3.5 Removing and installing control unit for

electrically adjustable steering column -
J866-

Removing


– Slightly raise control unit for electrically adjustable steering
column - J866- -2- and lift it off steering column.
Installing
lowing:
– Insert control unit for electrically adjustable steering column -

J866- -1- with lug into groove -arrow- of steering column.
– Tighten bolt.
If an electrically adjustable steering column is renewed, the con‐
trol unit for electrically adjustable steering column - J866- has
already been mounted on the new steering column and does not
have to be transferred.
If control unit for electrically adjustable steering column - J866-
has been renewed, the control unit for electrically adjustable
steering column - J866- must be adapted.
Use ⇒ Vehicle diagnostic tester.
Body (Rep.-Gr. 01;27;50;...97)


Body (Rep.-Gr. 01;27;50;...97)


Specified torque

Control unit for electrically adjustable steering column 5 Nm
- J866- to steering column

4 Assembly overview: steering column, right-hand drive
Note

1 - Cross member
2 - Bolt
❑ 5 Nm
3 - Control unit for electrically
adjustable steering column -
J866-
⇒ page 340
4 - Nut
❑ 4 Nm
5 - Nut
❑ 20 Nm
moval
6 - Bolt
❑ 20 Nm + 90°
moval
7 - Bolt
❑ 20 Nm
❑ Qty. 4
8 - Steering column
❑ Different steering col‐
umn variants installed,
allocation ⇒ electronic
parts catalogue “ET‐
KA” .
⇒ page 331
❑ Check for damage ⇒ page 338
9 - Bolt
10 - Electronic steering column lock control unit - J764-
11 - Bolt
❑ 5 Nm

4.1 Removing and installing steering col‐

umn, right-hand drive vehicle
WARNING
Before steering column is removed, the following must be

done:
Make a sketch of:
♦ The routing of the electrical wiring harnesses
♦ The fastenings of the electrical wiring harnesses
♦ The mounting locations of the cable ties
This especially applies to the wiring harness for the electronic
steering column lock control unit - J764- .
before removal.
removal.
• All cable ties that have been undone or cut open must be
fastened at the same places.
adjusted.
4. Assembly overview: steering column, right-hand drive 331


Removing
Note
♦ Only the complete steering column is supplied as a replace‐

ment part. Repair is not possible.
♦ If an electrically adjustable steering column is renewed, the
control unit for electrically adjustable steering column - J866-
has already been mounted on the new steering column and
does not have to be transferred.

⇒ page 259 .
– Turn wheels to straight-ahead position.
– Switch off ignition and remove ignition key.
– Remove front right wheel.
– Remove front right wheel housing liner ⇒ General body re‐
pairs, exterior; Rep. gr. 66 ; Wheel housing liner .
– Remove airbag and steering wheel ⇒ page 315 .
WARNING

– Remove steering column trim ⇒ General body repairs, interior;

Rep. gr. 68 ; Compartments, covers and trims .
– Remove switch module of steering column ⇒ Lights, lamps,
switches - exterior; Rep. gr. 94 ; Steering column switches .
– Remove footwell cover on driver side ⇒ General body repairs,
interior; Rep. gr. 68 ; Compartments, covers and trims .
– Remove right and left dash panel trim on driver side ⇒ General
body repairs, interior; Rep. gr. 68 ; Compartments, covers and
trims .


– Remove heat shield -1- from steering rack.

WARNING
♦ There is a risk of injury from the exhaust system depend‐

ing on the engine.
– Unscrew nuts -arrows- from sealing boot -1-.
– Release cable bracket -arrow- from wiring harness -1- on

steering column -2-.
– Lay the wiring harness to one side.


– Release connector -2- of wiring harness for the electrically ad‐
justable steering column -1- behind the dash panel insert and
pull off.
– Unscrew and remove bolts -arrows- of steering column -1-.
– Unscrew and remove bolted connection -arrows- between

steering column and frequency brace.
– Remove bolt, while supporting steering column -1- from below
with your hand.

– Detach connector -arrow- from electronic steering column lock

– Carefully lower steering column.
– Fold back floor covering in area of sealing boot in footwell on
driver's side.
– Remove steering column together with sealing boot from ve‐
hicle.
Installing
lowing:
WARNING

• Check steering column for damage ⇒ page 338 .
before removal.
removal.
• When installing steering column, all cable ties that were
removed or cut open when removing it must be re-attach‐
ed in the same positions.
adjusted.
– Insert steering column -1- into vehicle.

– Insert bolt -arrow- for frequency brace.
– Reconnect electrical connectors.
– Hand-tighten all bolts of steering column.

– Ensure sealing boot -1- is correctly seated in plenum chamber

bulkhead -2-.
– Hand-tighten nuts -arrows- for sealing boot uniformly.

– Tighten sealing boot -1-.
Note tightening sequence

– Tighten bolts -1- to -4- to specified torque in the sequence
shown.
– Tighten nut -5- to specified torque.
Note
The threaded hole for the bolt at universal joint must always be
cleaned (e.g. with a tap).

– Fit steering column -1- onto steering pinion of the power-as‐

sisted steering rack -2- as far as stop and tighten bolt
-arrow-.
– After installation of the steering column's circuit box, the steer‐
ing angle sensor - G85- must be calibrated ⇒ page 338 .
When steering column is renewed with electronic steering column
lock control unit - J764- , electronic steering column lock control
unit - J764- must be adapted.
- VAS 5051B- .
Body (Rep. Gr. 01;27;50;...97)

When the electrically adjustable steering column is replaced to‐
gether with control unit for electrically adjustable steering column
- J866- , the control unit for electrically adjustable steering column
- J866- must be adapted.
- VAS 5051B- .
Body (Rep. Gr. 01;27;50;...97)


- VAS 5051B- .
Body (Rep.-Gr. 01;27;50;...97)


Specified torque


Universal joint to power-assisted steering rack 20 Nm + 90°
♦ Use new bolt
Steering column to cross member 20 Nm

Steering column to frequency brace 20 Nm
♦ Use new bolts
Heat shield to power-assisted steering rack 9 Nm

Sealing boot to plenum chamber bulkhead 4 Nm
4.2 Basic setting for steering angle sensor

G85 steering angle sender must be
checked after the following repair work:
♦ When vehicle steering angle sensor - G85- is removed or re‐
newed,
♦ After removal or renewal of steering column,
♦ After removal or renewal of steering rack,
♦ If steering wheel was repositioned.
Basic setting of steering angle sensor G85
- VAS 5051B- .
Body (Rep.-Gr. 01;27;50;...97)

unit

4.3 Checking steering column for damage

Visual check
– Check all steering column parts for damage.
– Check sealing boot for damage and that rubber grommet for
correct seating.
Checking function
– Check that steering column turns smoothly and easily.
– Check whether steering column can be adjusted longitudinally
and vertically.
4.4 Removing and installing electronic

steering column lock control unit - J764-


Removing
– Slightly raise electronic steering column lock control unit -
J764- -1- and lift it off steering column.
WARNING
• After removing the control units, make sure that no dirt or

foreign bodies enter the steering column.
Installing
lowing:
♦ If only the electronic steering column lock control unit - J764-
has been renewed, the previously installed securing bolt for
the control unit must be re-used.
♦ If the steering column has been renewed, the electronic steer‐
ing column lock control unit - J764- has already been fitted to
the new steering column.

– Insert electronic steering column lock control unit - J764- -1-

with lug into groove -arrow- of steering column.
– Tighten bolt.
Note
♦ If the same electronic steering column lock control unit - J764-

has been reinstalled, the electronic steering column lock con‐
trol unit - J764- need not be readapted.
♦ If the electronic steering column lock control unit - J764- has
been renewed, it must be readapted.
If electronic steering column lock control unit - J764- has been

renewed, the electronic steering column lock control unit - J764-
must be adapted.
- VAS 5051B- .
Body (Rep. Gr. 01;27;50;...97)
Specified torque

ELS control unit - J764- to steering column 5 Nm
4.5 Removing and installing control unit for

electrically adjustable steering column -
J866-

Removing


– Slightly raise control unit for electrically adjustable steering
column - J866- -2- and lift it off steering column.
Installing
lowing:
– Insert control unit for electrically adjustable steering column -

J866- -1- with lug into groove -arrow- of steering column.
– Tighten bolt.
If an electrically adjustable steering column is renewed, the con‐
trol unit for electrically adjustable steering column - J866- has
already been mounted on the new steering column and does not
have to be transferred.
If control unit for electrically adjustable steering column - J866-
has been renewed, the control unit for electrically adjustable
steering column - J866- must be adapted.
Body (Rep.-Gr. 01;27;50;...97)


Body (Rep.-Gr. 01;27;50;...97)


Specified torque

Control unit for electrically adjustable steering column 5 Nm
- J866- to steering column

5 Assembly overview: power steering, left-hand drive vehicle
1 - Hexagon bolt
❑ 9 Nm
2 - Heat shield
3 - Power steering rack
⇒ page 343
❑ Tapered hole must be
❑ Various versions
5 - Self-locking nut
❑ 90 Nm
moval
6 - Subframe
7 - Hexagon bolt
moval
8 - Hexagon bolt
❑ 9 Nm
9 - Heat shield
10 - Nut
❑ 90 Nm + 90°
moval
11 - Hexagon bolt
❑ 9 Nm
12 - Servotronic solenoid valve - N119-
13 - Seal
❑ Renew
14 - Pressure line
15 - Return line
16 - Union nut
❑ 32 Nm

5.1 Removing and installing power-assisted steering rack, left-hand drive ve‐
hicle

equipment required
♦ Hose clamp - 3094-

Removing
⇒ page 259 .
– Raise vehicle.
– Remove wheels.
5. Assembly overview: power steering, left-hand drive vehicle 343

– Detach suction hose from servo oil container -2-.


ly.
Caution
– Push track rod ball joint off wheel bearing housing and remove
nut.
– Unbolt left track rod from steering rack.

1- Open-end spanner attachment - V.A.G 1923-



– Release connector -1- at solenoid valve for Servotronic and

pull off. - N119- .
– Unbolt hydraulic line bracket -1-.

– Disconnect pressure and return lines -2- from steering rack.

– Unscrew and remove bolted connection -arrow- of heat shield

-1-.
– Remove heat shield.
– Unscrew bolted connection -arrow- of steering rack.

– Push steering rack to right side of vehicle

-direction of arrow 1-.
– Swing steering rack down on left side.
– Then remove steering rack first to left side of vehicles and then
downwards -direction of arrow 2-.
Installing
lowing:
– Bleed steering system ⇒ page 398 .
– Check steering system for leaks ⇒ page 398 .
– Check hydraulic fluid level, and top up fluid if necessary
⇒ Maintenance ; Booklet 17.1 ; Power steering: Checking fluid
level .
⇒ page 286 .
– Carry out basic setting for steering angle sender - G85- .
- VAS 5051B- .
Body (Rep.-Gr. 01;27;50;...97)

unit

Specified torque
Union joint of pressure and return lines at steering rack 32 Nm
♦ Use new bolt
Heat shield to steering rack on right (if there is one) 9 Nm

Track rod to wheel bearing housing 90 Nm
♦ Use new bolts
Track rod to steering rack 100 Nm

Steering box to subframe 90 Nm + 90°
Bracket for hydraulic lines on steering rack 9 Nm

6 Assembly overview: power steering, right-hand drive vehicle
1 - Heat shield
2 - Hexagon bolt
❑ 10 Nm
moval
❑ Tapered hole must be
❑ 90 Nm
moval
⇒ page 349
7 - Subframe
8 - Hexagon bolt
❑ 90 Nm + turn 90° further
moval
9 - Heat shield
10 - Hexagon bolt
❑ 9 Nm
11 - Union nut
❑ 30 Nm
12 - Return line
13 - Pressure line
14 - Seal
❑ Always renew
15 - Servotronic solenoid valve - N119-

6.1 Removing and installing power steering rack, right-hand drive vehicle

equipment required

6. Assembly overview: power steering, right-hand drive vehicle 349


Removing
⇒ page 259 .
– Raise vehicle.
– Remove wheels.
– Clamp off pressure and return lines using hose clamps -
3094- .
– Unscrew bolts from steering rack -arrow-.
– Open retainer -1- and remove return line.
ly.
Caution
– Push track rod ball joint off wheel bearing housing and remove
nut.
– Remove bolts -1- from steering rack and remove heat shield.

– Disconnect pressure and return lines -1- from steering rack

and pull out downwards.
– If installed, disconnect connector -2- on Servotronic solenoid
valve - N119- .
– Unscrew bolts -arrows- and remove shield -1-.

– Unscrew bolt for universal joint and pull universal joint off
steering rack.
– Unbolt steering rack securing bolts -arrows- from subframe.
– Remove connecting bolts -1- to -3- for front final drive -A- on
subframe -B-.
– Insert support from trolley jack in engine and gearbox jack -
V.A.G 1383 A- .
– Lift front final drive with engine and gearbox jack - V.A.G 1383
A- .
6. Assembly overview: power steering, right-hand drive vehicle 351

– Unscrew rear bolts for subframe -arrow- on both sides of ve‐

hicle.
– Lower subframe as far as possible.
– Remove steering rack to right side of vehicle.
Installing
ing:
– Check level of hydraulic fluid and top up if necessary ⇒ Main‐
tenance ; Booklet ; Power steering: Checking fluid level .
⇒ page 286 .
– Carry out basic setting for steering angle sender - G85- .
- VAS 5051B- .
Body (Rep.-Gr. 01;27;50;...97)

unit

Specified torque
Pressure and return lines to steering rack 32 Nm
Clamps on steering rack 9 Nm
♦ Use new bolts.
Heat shield to steering rack 9 Nm

♦ Use new nuts.
Steering box to subframe 90 Nm + 90°

Front final drive to subframe 90 Nm + 90°


♦ Use new bolts.

7 Repairing power steering rack
7.1 Assembly overview: power steering rack, left-hand drive vehicle
1 - Right track rod ball joint

❑ Marked with an “R”
⇒ page 355
❑ Check that dust caps
are undamaged and
correctly seated.
⇒ page 356
2 - Hexagon nut
❑ 70 Nm
3 - Spring-type clip
4 - Boot
❑ Check for damage
❑ Do not twist when ad‐
justing track.
5 - Clip
moval
6 - Track rod
❑ 100 Nm
⇒ page 354
7 - Seal
❑ Also replace if boot re‐
moved ⇒ page 358
9 - Left track rod ball joint
❑ Marked with an “L” ⇒ page 355
❑ Check that dust caps are undamaged and correctly seated.
7. Repairing power steering rack 353

7.2 Removing and installing track rod

equipment required

♦ Open-end spanner attachment - V.A.G 1923-
♦ Locking pliers - VAS 6199-
Carry out the following work:
Removing
⇒ page 259 .
– Raise vehicle.
– Remove wheel.

ly.
Caution
– Clean outside of power steering rack in vicinity of boot.
– Open clamps -arrows- and push boot back.
– Unscrew track rod.

Installing
ing:
If the boot has been pulled off the steering rack, the sealing ring
⇒ Item 7 (page 353) on the steering rack must be replaced at the
same time.
– Make sure that correct track rod ball joint is installed on each
side.
I - Track rod ball joint on left marked with an “L”
II - Track rod ball joint on right marked with an “R”

– Tighten track rod.

– Check boots for wear (splits, tears) and check sealing surfaces
for soiling.
– Install boot and clamp.
Note
Only use original clamp.
Continue installation in reverse order of removal.

⇒ page 286 .
Specified torques
♦ Use new bolts
Track rod to steering rack 100 Nm
7.3 Removing and installing track rod ball

joint


Removing
⇒ page 259 .
– Raise vehicle.
– Remove wheel.
– Loosen nut -1-.
– Mark position of track rod ball joint on track rod.
ly.
Caution
– Unscrew track rod ball joint from track rod.
Installing
lowing:

– Make sure that correct track rod ball joint is installed on each
side.
I - Left track rod ball joint
II - Right track rod ball joint
– 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.
⇒ page 286 .
Specified torques
♦ Use new bolts
Track rod ball joint to track rod 70 Nm

♦ Use new bolts
7.4 Removing and installing bellows
Note
♦ If boot is defective, moisture and dirt will enter steering rack.

There must be a palpable film of grease in the area of the teeth
on the steering rack. If there is no film of grease, the steering
rack must be renewed.
♦ The steering rack must be renewed:
♦ In the event of corrosion.
♦ In the event of damage.
♦ In the event of excessive wear
♦ In the event of soiling on the steering rack.

Removing
⇒ page 259 .
– Turn steering wheel to straight-ahead position.
– Remove wheel.
– Clean outside of steering rack in vicinity of boot.

No dirt must be allowed to enter the steering rack through a de‐

fective rubber boot during this operation.
– Remove track rod ball joint ⇒ page 356 .
– Open hose clips -arrows-.
– Pull boot off steering rack housing and track rod.
Installing
Always renew sealing rings ⇒ Item 7 (page 353) on steering rack.
Before installation, steering rack must be coated with steering
rack grease - AOF 063 000 04- provided in repair set.
Caution
Never use any other grease.
To grease, turn steering to full lock on each side in succession.

– Grease steering rack on toothed side using steering rack
grease - AOF 063 000 04- .
– Turn steering wheel to straight-ahead position.
– Push boot onto track rod and steering rack and secure with
new clamps -arrows-.
– Install track rod ball joint ⇒ page 356 .

8 Vane pump, 6-cylinder petrol engine
8.1 Checking vane pump delivery pressure, 6-cylinder petrol engine

equipment required

♦ Power steering tester - V.A.G 1402-
♦ Adapter - V.A.G 1402/2-
♦ Adapter set - V.A.G 1402/6-

– Clamp off suction hose with hose clamp - 3094- -1-.

– Remove bolts -2- and pull pressure line out of vane pump.
– Connect power steering tester - V.A.G 1402- with adapters as

shown in figure.
1- Power steering tester - V.A.G 1402-
2- Hose from adapter set - V.A.G 1402/6-
3- Bolt
4- Pressure line
5- Adapter - V.A.G 1402/17-2- 1 with angled piece -
V.A.G 1402/17-3-
6- Vane pump
7- Adapter - V.A.G 1402/17-1- with angled piece -
V.A.G 1402/17-3-
1)If seal is leaking or damaged on adapter - V.A.G 1402/17-1- ,
replace it with new seal ⇒ Electronic parts catalogue“ETKA” .
Note
♦ Position angled piece - V.A.G 1402/17-3- on adapter -

V.A.G 1402/17-1- so that the hose from adapter set -
V.A.G 1402/6- does not lie on pulley and/or on poly V-belt.
♦ Tighten union nut of angled piece - V.A.G 1402/17-3- and hose
from adapter set - V.A.G 1402/6- hand-tight using an open-
end spanner.
– Take hose clamp - 3094- off suction hose.
8. Vane pump, 6-cylinder petrol engine 361

Ensure that lever on pressure gauge is in position -2-.

– Start engine and if necessary replenish hydraulic fluid in res‐
ervoir.
– Turn steering wheel approx. 10 times from lock to lock.
– Now, check delivery pressure.
Prerequisites for testing:
• V-belt and V-belt tension OK.
• System must be free of leaks
• Hoses and lines must not be kinked or restricted
– With engine idling, close shut-off valve (position -1-) for no

longer than 5 seconds and note pressure.
Specification for delivery pressure:
120 … 128 bar
If specification is not attained, renew vane pump.
– Remove pressure gauge and adapter.
8.2 Assembly overview: vane pump, 6-cylinder petrol engine

There is no provision for repairing the vane pump. If problems are
reported, determine the cause by means of a pressure test and a
leakage test. If a fault is found, the vane pump unit must be re‐
newed.
Note
♦ Always renew seals.

♦ Do not re-use hydraulic fluid which has been drained off.
♦ Always check steering system for leaks if fluid level in reservoir is low.
♦ If leakage appears near pipe connections, first check lines and connections for leaks, tighten connections
as necessary and wipe dry.
♦ Vane pumps taken from parts stock contain no fluid. Therefore it is essential to fill vane pump with hydraulic
fluid - G 004 000 M2 - and to rotate pump by hand prior to installation. Otherwise vane pump may be damaged
or be noisy during operation.
♦ Fluid type: hydraulic fluid - G 004 000 M2 -

1 - Bracket
2 - Bush
❑ Drive bush back slightly
when installing vane
pump.
3 - Bolt
❑ 22 Nm
4 - Pressure line
Note
When installing, press on to stop in

vane pump.
5 - Bolt
❑ 9 Nm
6 - Seal
❑ Always renew
7 - Suction hose
tion on vane pump:
marking -arrow A- must
align with marking
-arrow B- on vane
pump.
❑ Install on marking on
suction hose.
9 - Vane pump
⇒ page 363
❑ Fill with hydraulic fluid before installing.
❑ Checking delivery pressure ⇒ page 360
10 - Bolt
❑ 22 Nm
❑ Qty. 3
11 - Pulley
12 - Bolt
❑ 22 Nm
❑ Qty. 2
8.3 Removing and installing vane pump, 6-

cylinder petrol engine

♦ Hose clamps up to 25 mm - 3094-

Removing
WARNING
When performing any repair work, especially in the engine

compartment, pay attention to the following due to the cramped
conditions:
♦ Correctly route lines of all kinds (for example for fuel, hy‐
draulic fluid, activated charcoal filter system, coolant, re‐
frigerant, brake fluid, vacuum) and electrical cables. The
original route of the lines must be restored.
♦ Ensure that there is sufficient clearance to all moving or
hot components.

⇒ page 259 .


– Clamp off suction hose with hose clamp - 3094- -1-.
– Remove front noise insulation ⇒ General body repairs, front;
Rep. gr. 50 ; Noise insulation .
– Open spring-type clip -1- and pull suction hose off vane pump.
– Unscrew bolts -arrows-.

– Remove poly V-belt ⇒ Rep. gr. 13 ; Dismantling and assem‐
bling engine; Removing and installing poly V-belt .
– Unscrew bolts -arrows- and remove belt pulley -1-.

– Remove bolts -arrows- and remove vane pump -1- from brack‐
et.
Installing
lowing:
Note
♦ Renew gaskets and seals.

♦ Before fitting a new power steering pump, put in hydraulic fluid
at the inlet and turn pump by hand until fluid flows out at the
pressure outlet.
♦ Before mounting, ensure that hose union and suction hose are
♦ Secure all hose connections with new hose clips ⇒ Electronic
parts catalogue “ETKA” .
– Install vane pump, initially tightening only front bolts.
– Install poly V-belt and check belt alignment ⇒ Rep. gr. 13 ;

Dismantling and assembling engine; Removing and installing
poly V-belt .
Note
When installing poly V-belt, make sure that it is correctly seated

on poly V-belt pulley.

Specified torque
Poly-V-belt pulley to vane pump 22 Nm
Pressure line to vane pump 9 Nm
♦ Use new oil seal
Vane pump to bracket 22 Nm

9 Vane pump, 6-cylinder diesel engine
9.1 Checking vane pump delivery pressure, 6-cylinder diesel engine

equipment required

9. Vane pump, 6-cylinder diesel engine 367

– Carefully pull design cover off the 4 retaining bolts -arrows-.
– Remove air ducting hose -1-.
– Clamp suction hose with hose clamp - 3094- .


– Connect power steering tester - V.A.G 1402- with adapters as

shown in figure.
1- Power steering tester - V.A.G 1402-
2- Hose from adapter set - V.A.G 1402/6-
3- Bolt
4- Pressure line
5- Adapter - V.A.G 1402/17-2- 1 with angled piece -
V.A.G 1402/17-3-
6- Vane pump
7- Adapter - V.A.G 1402/17-1- with angled piece -
V.A.G 1402/17-3-
1)If seal is leaking or damaged on adapter - V.A.G 1402/17-1- ,
replace it with new seal ⇒ Electronic parts catalogue“ETKA” .
Note
♦ Position angled piece - V.A.G 1402/17-3- on adapter -

V.A.G 1402/17-1- so that the hose from adapter set -
V.A.G 1402/6- does not lie on pulley and/or on poly V-belt.
♦ Tighten union nut of angled piece - V.A.G 1402/17-3- and hose
from adapter set - V.A.G 1402/6- hand-tight using an open-
end spanner.
– Take hose clamp - 3094- off suction hose.

– Install air ducting hose -1-.

ervoir.
– Now, check delivery pressure.

120 … 128 bar
If specification is not attained, renew vane pump ⇒ page 372 .
– Remove pressure gauge and adapter.
9.2 Assembly overview - vane pump, 6-cylinder diesel engine

newed.
Note


1 - Bracket
2 - Bush
❑ Drive bush back slightly
when installing vane
pump.
3 - Bolt
❑ 22 Nm
4 - Bolt
❑ 9 Nm
5 - Pressure line
Note
When installing, press on to stop in

vane pump.
6 - Seal
❑ Always renew
7 - Suction hose
tion on vane pump:
marking -arrow A- must
align with marking
-arrow B- on vane
pump.
suction hose.
9 - Vane pump
⇒ page 372
❑ Fill with hydraulic fluid before installing.
10 - Bolt
❑ 22 Nm
❑ Qty. 3
11 - Pulley
12 - Bolt
❑ 22 Nm
❑ Qty. 2

9.3 Removing and installing vane pump, 6-cylinder diesel engine

equipment required
♦ Hose clamps up to 25 mm - 3094-

♦ Pin wrench - 3212-


Removing
WARNING
When performing any repair work, especially in the engine

compartment, pay attention to the following due to the cramped
conditions:
♦ Correctly route lines of all kinds (for example for fuel, hy‐
draulic fluid, activated charcoal filter system, coolant, re‐
frigerant, brake fluid, vacuum) and electrical cables. The
original route of the lines must be restored.
♦ Ensure that there is sufficient clearance to all moving or
hot components.
– Carefully pull design cover off the 4 retaining bolts -arrows-.
– Remove air ducting hose -1-.
– If part of equipment, release middle of air guide tube -4- and

swing tube upwards slightly. Remove bolts -1- and -2- and
loosen bolt -3- for this.
Note
Ensure that no parts are damaged when swivelling the air guide
tube -4-.
– Mark running direction of poly V-belt.

– Remove poly V-belt ⇒ Rep. gr. 13 ; Dismantling and assem‐
bling engine; Removing and installing poly V-belt .

– Unscrew bolts -arrows-, counterhold poly V-belt pulley with pin

wrench - 3212- for this.
– Clamp suction hose with hose clamp - 3094- .

– Open spring-type clip -1- and pull suction hose off vane pump.
– Remove bolts -arrows- and remove vane pump -1- from brack‐
et.
Installing
lowing:
Note

pressure outlet.
– Install vane pump, initially tightening only front bolts.

– Install poly V-belt and check belt alignment ⇒ Rep. gr. 13 ;

Dismantling and assembling engine; Removing and installing
poly V-belt .
Note
When installing poly V-belt, make sure that it is correctly seated

on poly V-belt pulley.
1 - Poly V-belt pulley - alternator

2 - Idler roller
3 - Idler roller
4 - Poly V-belt pulley - coolant pump
5 - Poly V-belt pulley - power steering vane pump
6 - Poly V-belt pulley - air conditioner compressor
7 - Tensioning roller
8 - Poly V-belt pulley - crankshaft
Specified torque
Poly-V-belt pulley to vane pump 22 Nm
Vane pump to bracket 22 Nm

10 Vane pump, 8-cylinder petrol and die‐

sel engine
10.1 Checking vane pump delivery pressure, 8-cylinder petrol and diesel engine

equipment required


♦ Drip tray for workshop hoist - VAS 6208-

– Disconnect return hose -2- from hydraulic fluid reservoir.
– Remove noise insulation at rear ⇒ General body repairs, ex‐
terior; Rep. gr. 50 ; Assembly overview - noise insulation .
– Place drip tray for workshop hoist - VAS 6208- beneath vehi‐
cle.

10. Vane pump, 8-cylinder petrol and diesel engine 377

– Unscrew bolt -1-.

– Unscrew union nut -2- and pull the return line -2- out of the
steering rack.
– Unscrew union nut -1- and pull pressure line -2- out of the
steering rack.
– Secure power assisted steering tester - V.A.G 1402- -3- to an‐

ti-roll bar -1 - using a cable tie -2-.
– Screw the adapter from the adapter set - V.A.G 1402/19-1-

into steering rack -2-.
– Connect adapter - V.A.G 1402/2- -3- with the adapter from
adapter set - V.A.G 1402/19-1- .
– Connect hose from adapter set - V.A.G 1402/6- with power
steering tester - V.A.G 1402- .
– Connect the adapter from adapter set - V.A.G 1402/6- with the
hose from adapter set - V.A.G 1402/6- -4-.

– Connect pressure line -1- with the adapter from adapter set -
V.A.G 1402/6- -2-.
– Connect adapter from adapter set - V.A.G 1402/6- -2- with the
hose from adapter set - V.A.G 1402/6- -3-.
– Screw return line -1- with union nut -3- to steering rack -2- and
tighten to prescribed torque.
– Remove hose clamp - 3094- -1- from return hose -2-.


ervoir.
Note
♦ To avoid damaging the pump, please note the following points:

♦ During this test, the shut-off valve of the pressure gauge must
not remain closed for more than 10 seconds.
♦ Start engine without pressing accelerator and leave it running
at idling speed.
♦ Take pump pressure reading at idling speed immediately after
starting engine (have second mechanic take reading).
♦ The pressure will drop during the test; the highest pressure
reading is therefore the required test value.
– Now check delivery pressure.

120 … 128 bar
If specification is not attained, renew vane pump ⇒ page 384 .
– Disconnect return hose -2- from hydraulic fluid reservoir.



– Unscrew union nut -3- from steering rack -2- and pull out return
line -1-.
– Unscrew adapter from adapter set - V.A.G 1402/19-1- from

steering rack -2-.
– Separate pressure line -1- from the adapter from adapter set
- V.A.G 1402/6- -2-.

– Insert pressure line -2- into the steering rack and tighten union
nut -1- to the prescribed torque.
– Insert return line -3- into the steering rack and tighten union
nut -2- to the prescribed torque.
– Screw in and tighten bolt -1-.
– Remove hose clamp - 3094- -1- from return hose -2-.

– Remove power steering tester - V.A.G 1402- .
10.2 Assembly overview: vane pump, 8-cylinder petrol and diesel engine
newed.

Note

1 - Seal
❑ Always renew after re‐
moving ⇒ page 386
2 - Bolt
❑ 9 Nm
3 - Pressure line
Caution
Insert
• pressure line com‐
pletely when installing.
4 - Suction hose
❑ The marking “P” on suc‐
tion hose must be
aligned with seam on
power steering pump
⇒ page 387 .
5 - Clip
moval
6 - Bolt
❑ Specified torque for ve‐
hicles with manual gear‐
box ⇒ Rep. gr. 34
❑ Specified torque for ve‐
hicles with automatic
gearbox ⇒ Rep. gr. 37
❑ Securing bolt for: gear‐
box/engine/vane pump
7 - Bolt
❑ 25 Nm
8 - Seal
9 - Input shaft
❑ Grease all the splines of the input shaft and vane pump.
❑ At the pump end, insert grease into hole and, at engine end, insert grease into hole or grease end of
shaft (see ⇒ Electronic spare parts catalogue “ETKA”

10 - Vane pump
❑ Fill with hydraulic fluid - G 004 000 M2 - before installing
10.3 Removing and installing vane pump, 8-

cylinder petrol and diesel engine
♦ Hose clip pliers - V.A.G 1275-
♦ Set of sealing plugs - VAS 6122-

Removing
– Remove left engine support ⇒ Rep. gr. 10 ; Engine and gear‐
box; Removing and installing engine supports .
– Remove catalytic converter on left ⇒ Rep. gr. 26 ; Particulate
filters and catalytic converters; Removing and installing cata‐
lytic converters .

– Open clip -1- and pull suction hose -2- off vane pump.
– Undo bolts -3- and pull pressure line -4- off vane pump.
– Unscrew bolt -1-.

Only for vehicles with 8-cylinder diesel engine
– Unscrew bolts -arrows- and remove bracket -1-.
Note
If necessary, use a commercially available angled multi-point bit

to remove the bolts.
– Undo bolt -arrow- beneath the vane.

– Remove bolts -arrows- for vane pump.

– Pull vane pump off engine.
– If necessary, pull drive shaft -arrow- of vane pump out of en‐

gine by hand.
– Renew seal -arrow-.

Installing
lowing:
Note

pressure outlet.
– Grease all the splines of the drive shaft and vane pump ⇒
Electronic spare parts catalogue “ETKA”
– Push drive shaft into vane pump as far as it will go.
– Mount vane pump on engine.

– Marking “P” -arrow- on suction hose -1- must be in line with

seam -arrow- on vane pump.
– Install left engine support ⇒ Rep. gr. 10 ; Removing and in‐
stalling engine, removing and installing engine supports .
Specified torques
Power steering pump to engine
♦ Securing bolt for: gearbox/engine/vane pump ⇒ Rep. gr. 37
♦ Securing bolts for engine/vane pump 25 Nm


11 Assembly overview: hydraulic lines, 6-cylinder petrol engine

2 - Reservoir
3 - Clip
4 - Return line
5 - Return hose
6 - Oil cooler
⇒ page 391
7 - Return hose
8 - Return line
9 - Suction hose
10 - Vane pump
⇒ page 363
11 - Bolt
❑ 9 Nm
12 - Pressure line

12 Assembly overview - hydraulic lines, 6-cylinder diesel engine

2 - Reservoir
3 - Clip
4 - Return line
5 - Return hose
6 - Oil cooler
⇒ page 391
7 - Return hose
8 - Suction hose
9 - Return line
10 - Vane pump
⇒ page 372
11 - Bolt
❑ 9 Nm
12 - Pressure line
12. Assembly overview - hydraulic lines, 6-cylinder diesel engine 389

13 Assembly overview - hydraulic lines, 8-cylinder diesel engine

2 - Reservoir
3 - Clip
4 - Return line
5 - Return hose
6 - Oil cooler
⇒ page 391
7 - Return hose
8 - Suction hose
9 - Return line
10 - Pressure line
11 - Bolt
❑ 9 Nm
12 - Vane pump
⇒ page 384

14 Removing and installing oil cooler

♦ Hose clamps up to 25 mm in diameter - 3094-

Removing
Caution
Observe the following points during all installation work, in par‐

ticular in the engine compartment, due to the space limitations:
♦ Route all the various lines (e.g. for fuel, hydraulics, acti‐
vated charcoal filter system, coolant, refrigerant, brake
fluid and vacuum) and electrical wiring in their original po‐
sitions.
♦ To avoid damage to lines, ensure sufficient clearance to
all moving or hot components.
– Remove front noise insulation ⇒ General body repairs, exte‐

rior; Rep. gr. 50 .
– Remove front bumper ⇒ General body repairs, exterior; Rep.
gr. 63 .
– Remove impact bar ⇒ General body repairs, exterior; Rep.
gr. 63 ; Front bumper cover; Assembly overview - impact bar .
14. Removing and installing oil cooler 391

– Clamp off suction hose and return hose with hose clamps up
to 25 mm in diameter - 3094- -1-.
– Open clamps -1- and push to side.

– Pull suction hose and return hose from oil cooler.
– Unscrew bolt -arrow- for oil cooler bracket -2- and remove
bracket.
– Unscrew upper bolts for cooler module -arrow- on both sides.
– Unscrew lower left bolts for cooler module -A-:

– Push oil cooler -1- to left in -direction of arrow- out of retainers

-arrows-.
– Press cooler module backwards, turning oil cooler so that it

can be removed forwards through guide -arrow-.
Installing
lowing:
Note installation position of bracket -1- on oil cooler.

Lugs -arrows- of bracket -1- must point forwards to oil cooler.
– Bolt bracket -1- on with bolt -2-.
– Push suction hose and return hose onto bracket -1- to stop.
Note
♦ Secure all hose connections with hose clamps corresponding

to series equipment ⇒ electronic parts catalogue “ETKA” .
♦ Oil type: ⇒ electronic parts catalogue “ETKA” .

– Bleed steering system and check for leaks ⇒ page 398 .
Specified torque
Bracket to oil cooler 9 Nm
14. Removing and installing oil cooler 393

15 Motor/pump unit
15.1 Assembly overview - motor/pump unit

There is no provision for repairing motor/pump unit. If problems
are reported, determine the cause by means of a pressure test
and a leakage test. If a fault is found, the motor/pump unit must
be renewed.
Note

1 - Motor/pump unit
❑ With power steering
control unit - J500-
❑ No provision for repair‐
ing
⇒ page 395
2 - Clip
suction hose.
3 - Suction hose
4 - Seal
❑ Always renew
5 - Mountings
❑ 8 Nm
❑ Check for damage, such
as cracks in rubber, sep‐
aration of metal plate
from rubber, and renew
if necessary.
6 - Bolt
❑ 20 Nm
7 - Pressure line
Note
When installing, press into engine

pump unit as far as it will go.
8 - Nut
❑ 8 Nm

❑ Qty. 4
9 - Bracket
10 - Bolt
❑ 9 Nm
❑ Bracket for coolant line also secured
11 - Bolt
❑ 25 Nm
❑ Qty. 3
15.2 Removing and installing motor/pump

unit
♦ Engine bung set - VAS 6122-

Removing
– With ignition switched off, disconnect battery earth strap ⇒
Electrical system; Rep. gr. 27 ; Battery; Disconnecting and
connecting battery .
lifting platform.
– Loosen wheel bolt.
– Raise vehicle.
– Remove wheel.
15. Motor/pump unit 395

– Remove front left wheel housing liner ⇒ General body repairs,

exterior; Rep. gr. 66 ; Wheel housing liners .
– Clamp off suction hose -3- using hose clamp - 3094- -2-.
– Open clip -1- and pull suction hose -3- off unions of engine
pump unit -4-.
– Pull connectors -5- and -6- off motor/pump unit -4-.
– Detach pressure line -1- at connecting point -2-.
– Loosen securing nuts -1- at engine pump unit -2- but do not
completely unscrew.
– Remove engine pump unit -2- from bracket.
Installing
lowing:
Note



Specified torque
Engine pump unit to bracket 8 Nm
Union nut of pressure line to connecting point 40 Nm
15. Motor/pump unit 397

16 Bleeding steering system and check‐

ing for leaks
16.1 Bleeding steering system

– Raise vehicle until front wheels are free.
– Start engine and run at idle for about 5 seconds.
– Switch engine off and check level of hydraulic oil.
– Repeat the procedure.
– Start engine again and with engine idling, turn steering wheel
from lock to lock three times.
– Switch engine off and check level of hydraulic oil, if necessary
replenishing it.
– Repeat the procedure twice.
Leave engine off for 2 to 3 minutes to allow air bubbles to escape
from hydraulic fluid.
– Lower vehicle.
– With engine idling, turn steering wheel five times from lock to
lock again.
The system is bled when no more air bubbles rise into hydraulic
fluid reservoir.
16.2 Check steering system for leaks
Note
If hydraulic fluid level in reservoir is low after repairs are comple‐

ted, steering system must be checked for leaks.
– Start engine.
– Turn steering from lock to lock and hold briefly. This produces
maximum possible pressure (only at idling speed).
In this position, the following components must be checked for
leaks:
♦ Pinion seal on steering rack valve housing.
♦ All pipe connections.
♦ Steering rack seals.
This check can only be carried out when the boots are pushed
back.
– Open clip on bellows.
– Push boot back. If hydraulic fluid is visible in steering rack
housing or in boot, steering rack must be replaced.

VW Touareg 2 Running Gear Axles Steering Eng

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Service

Service Department. Technical Information

10.7 Assembly overview - front air spring strut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110

42 - Rear suspension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141

11.2 Removing and installing drive shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 248

43 - Self-levelling suspension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 258

44 - Wheels, tyres, vehicle geometry . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 284

1. Checklist for evaluating running gear of accident vehicles 1

2 Rep. gr.00 - Technical data

4 Rep. gr.40 - Front suspension

2 Lifting front axle in unladen state

Special tools and workshop

♦ Engine and gearbox jack - V.A.G 1383 A-

All bolts on running gear components with bonded rubber

2. Lifting front axle in unladen state 5

To simulate this position on the lifting platform, raise the respec‐

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

Running gear 1) Ride height -a- in mm

♦ Never raise or lower the vehicle while the engine and

– Tighten respective nuts and bolts.

6 Rep. gr.40 - Front suspension

3 Overview - front axle

♦ It is not permitted to weld or straighten load-bearing or wheel-guiding components of the suspension.

I - Assembly overview: sub‐

3. Overview - front axle 7

V - Assembly overview: anti-

8 Rep. gr.40 - Front suspension

4 Assembly overview: subframe

♦ It is not permitted to weld or straighten load-bearing or wheel-guiding components of the suspension.

1 - Front final drive

4. Assembly overview: subframe 9

4.1 Repairing thread in longitudinal member

Volkswagen Technical Site: http://vwts.ru http://vwts.info

10 Rep. gr.40 - Front suspension

4.2 Fixing subframe in position, vehicles with V6 engines

Special tools and workshop

♦ Locating pins - T10300-

4. Assembly overview: subframe 11

– Remove one of the rear bolts of the subframe -arrow-

– Screw in locating pins - T10300- -1-.

– Screw in locating pins - T10300- »by hand« as far as the

4.3 Fixing subframe in position, vehicles

12 Rep. gr.40 - Front suspension

♦ Counter-hold tool - T10172-

♦ Torque wrench - V.A.G 1332-

Perform the following steps:

4. Assembly overview: subframe 13

– Screw in locating pins - T10463- -1-.

– Bolt on subframe using new bolts -1-.

– When tightening bolt -arrow-, hold thrust washer -3- in position

4.4 Removing and installing subframe

14 Rep. gr.40 - Front suspension

Special tools and workshop

♦ Hose clamps to 25 mm - 3094-

♦ Engine and gearbox jack - V.A.G 1383 A-

4. Assembly overview: subframe 15

♦ Scissor-type assembly platform - VAS 6131-

♦ Left subframe mounting - VAS 6131/6-1-

16 Rep. gr.40 - Front suspension

– Insert spring tensioner - VW 552- -1- into upper opening of

– Remove upper bracket for brake line -1 - from wheel bearing

– Pull connector -1- and cable out of the bracket -3-.

– Press out top suspension link