Workshop Manual Transporter 2016 12-29

Service
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Service Department. Technical Information

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00 - Technical data
40 - Front suspension
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42 - Rear suspension
43 - Self-levelling suspension
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44 - Wheels, tyres, vehicle geometry
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48 - Steering
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Technical information should always be available to the foremen and mechanics, because their
careful and constant adherence to the instructions is essential to ensure vehicle road-worthiness and
safety. In addition, the normal basic safety precautions for working on motor vehicles must, as a
matter of course, be observed.
All rights reserved.

No reproduction without prior agreement from publisher.
Copyright © 2019 Volkswagen AG, Wolfsburg D4B80565308

Running gear, axles, steering - Edition 02.2019
Contents
00 - Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1 Safety information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.1 Safety measures when working on vehicles with a start/stop system . . . . . . . . . . . . . . . . 1
1.2 Safety precautions when working on subframe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2 Repair instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
2.1 Leaks at shock absorbers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
2.2 Noises from shock absorbers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
2.3 Checking shock absorbers when removed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
2.4 Steering rack . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
2.5 Gaskets and seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
2.6 Nuts and bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
2.7 Electrical components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
2.8 Raising suspension to unladen position (vehicles with coil springs) . . . . . . . . . . . . . . . . . . 4
3 Evaluating accident vehicles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
3.1 Check list for evaluating running gear on accident vehicles . . . . . . . . . . . . . . . . . . . . . . . . 9
4 Waste disposal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
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4.1 Releasing gas and draining front gas-filled shock ageabsorbers
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40 - Front suspension . . . . . . . . . . . s.au.t . . .
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1 Front axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
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1.1 Overview of fitting locations - front axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
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2 Subframe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
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2.1 Assembly overview - subframe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
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2.2 Removing and installing subframe without steering rack . . . . . . . . . . . . . . . . . . . . . . . . . . 14
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2.3 Repairing subframe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
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2.4 Removing and installing anti-roll bar . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
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2.5 Renewing anti-roll bar bushes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
2.6 Removing and installing coupling rod . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
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2.7 Fixing position of subframe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
2.8 Lowering subframe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
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3 Suspension strut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
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3.1 Assembly overview - suspension strut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37 f inform

3.2 Removing and installing suspension strut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
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3.3 Repairing suspension strut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48

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4 Lower suspension link, swivel joint . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52

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4.1 Assembly overview - lower suspension link, swivel joint . . . . . . . . . . . . . . . . . . . . . . . . . . 52

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4.2 Removing and installing lower suspension link . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53

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4.3 Checking swivel joint . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55

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4.4 Removing and installing swivel joint . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
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4.5 Renewing bonded rubber bush for lower suspension link . . . . . . . . . . . . . . . . . . . . . . . . . . 57
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5 Wheel bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
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5.1 Assembly overview - wheel bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
5.2 Removing and installing wheel bearing housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
5.3 Removing and installing wheel bearing unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
6 Drive shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
6.1 Overview - drive shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
6.2 Assembly overview - drive shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
6.3 Removing and installing drive shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
6.4 Loosening and tightening threaded connections of drive shaft . . . . . . . . . . . . . . . . . . . . . . 100
6.5 Dismantling and assembling drive shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
6.6 Checking outer constant velocity joint . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118
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6.7 Checking inner constant velocity joint . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119

6.8 Removing and installing jointed shaft support bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120
42 - Rear suspension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123

1 Rear axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123
1.1 Overview - rear axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123
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2 Anti-roll bar . . . . . . . . . . . . . . . . . . . . . . k.sw. a. g.e.n.A.G. . . . . . . e. n.A.G. d.o.es. . . . . . . . . . . . . . . . . . . . 124
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2.3 Renewing anti-roll bar bushes ss . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .c. . . . . . . . .
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Suspension link, track rod . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130
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3.1 Assembly overview - transverse link . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130
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3.2 Removing and installing lower transverse link . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130
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3.3 Renewing bonded rubber bush for suspension link . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132
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4 Suspension strut, shock absorber, spring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139
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4.1 Assembly overview - suspension strut, shock absorber, spring . . . . . . . . . . . . . . . . . . . . . . 139
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4.2 Removing and installing shock absorbers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139
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4.3 Removing and installing spring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141
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5 Wheel bearing assembly, trailing arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144
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5.1 Assembly overview - wheel bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144
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5.2 Removing and installing wheel bearing unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144

6 Drive shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149
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6.1 Assembly overview - drive shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149
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6.2 Removing and installing drive shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 151
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6.3 Dismantling and assembling drive shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 156

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6.4 Loosening and tightening threaded connections of drive shaft . . . . . . . . . . . . . . . . . . . . . . 163
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6.5 Checking inner constant velocity joint . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 164

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43 - Self-levelling suspension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 167

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1 Electronically controlled damping system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 167
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1.1 Assembly overview - electronically controlled damping system . . . . . . . . . . . . . . . . . . . . . . 167
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1.2 Removing and installing electronically controlled damping control unit J250 . . . . . . . . . . 168
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1.3 Removing and installing front body acceleration senders G341 / G342 . . . . . . . . . . . . . . 168
1.4 Removing and installing rear body acceleration sender G343 . . . . . . . . . . . . . . . . . . . . . . 169
2 Vehicle level sender . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 171
2.1 Assembly overview - front vehicle level senders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 171
2.2 Assembly overview - rear vehicle level senders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 174
2.3 Removing and installing front vehicle level senders G78 / G289 . . . . . . . . . . . . . . . . . . . . 174
2.4 Removing and installing rear vehicle level senders G76 / G77 . . . . . . . . . . . . . . . . . . . . . . 176
44 - Wheels, tyres, vehicle geometry . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 178

1 Wheels, tyres . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 178
1.1 Specified torques for wheel bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 178
1.2 Pressing tyre off wheel rim . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 178
1.3 Removing tyre from wheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 179
1.4 Fitting tyres . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 179
1.5 Wheel change . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 180
1.6 Tyre sealant disposal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 183
1.7 Models with breakdown set . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 183
2 Tyre Pressure Monitoring System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 186
2.1 System description – Tyre Pressure Monitoring System . . . . . . . . . . . . . . . . . . . . . . . . . . 186
3 Wheel alignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 187
3.1 Notes for wheel alignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 187
3.2 Conditions for testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 187
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3.3 Test preparations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 188

3.4 Specifications for wheel alignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 190
3.5 Wheel alignment procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 193
3.6 Necessity of wheel alignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 194
3.7 Adjusting camber at front wheels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 195
3.8 Adjusting front axle toe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 196
3.9 Adjusting toe at rear axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 197
3.10 Vehicle data sticker . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 199
4 Adaptive cruise control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
4.1 Calibrating adaptive cruise control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
48 - Steering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 207
1 Steering wheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 207
1.1 Assembly overview - steering wheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 207
1.2 Removing and installing steering wheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 207
2 Steering column . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 210
2.1 Assembly overview - steering column . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 210
2.2 Checking steering column for damage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 211
2.3 Handling and transporting steering column . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 211
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2.4 Removing and installing steering column . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 212
2.5 Removing and installing intermediate steering shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 216
2.6 Removing and installing protective sleeve for intermediate steering shaft . . . . . . . . . . . . . . 220
3 Steering rack . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 222
3.1 Assembly overview - steering rack . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 222
3.2 Removing and installing steering rack . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 224
3.3 Removing and installing track rod . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 228
3.4 Repairing steering rack . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 230
4 Hydraulic power steering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 233
4.1 Assembly overview - vane pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 233
4.2 Checking hydraulic fluid level of power steering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 237
4.3 Bleeding steering system after repairs . . . .. V .................................... 237
n AG olkswagen AG
4.4 Check steering for leaks . . . . . . o.lk.s.w.ag. e. . . . . . . . . . . . . . d. o.e.s .no. . . . . . . . . . . . . . . . . . . . . . . 237
V tg
4.5 Checking delivery pressure of d vane
by pump . . . . . . . . . . . . . . . . . .ua.ra.n. . . . . . . . . . . . . . . . . . 238
ise t
4.6 Removing and installing uvanetho
r
pump . . . . . . . . . . . . . . . . . . . . . . . . . e.e .or. . . . . . . . . . . . . . . 241
a ac
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by c lksw
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Contents
agen
Prote AG.
satelettronica
AG. Volkswagen AG d
agen oes
olksw not
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rise nte
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nl
pt
du
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itte
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ab
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, is n
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spec
es, in part or in w
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rrectness of i
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Prote AG.
iv Contents
00 – Technical data
1 Safety information
(VRL012793; Edition 02.2019)
⇒ “1.1 Safety measures when working on vehicles with a start/
stop system”, page 1
⇒ “1.2 Safety precautions when working on subframe”,
page 1
1.1 Safety measures when working on ve‐

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

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

on vehicles with start/stop system.
♦ On vehicles with an active start/stop system the engine
may start automatically.
♦ Ensure that the start-stop system is deactivated when
working on the vehicle.
AG. Volkswagen AG d
agen oes
ksw
1.2 Safety precautions when working on ol not
y V gu
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ise
subframe uthor nte
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s a c
♦ It is not permitted to weld or straighten load-bearing or wheel- s
ce
le
guiding components of the suspension.

un
pt
an
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♦ Always renew corroded nuts and bolts.

erm
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ility
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♦ Bonded rubber bushes can be twisted only to a limited extent.

wit
is n
Therefore, tighten the bolted connections of components with

h re
bonded rubber bushes only when the wheel bearing housing

ole,
spec
has been raised (unladen state) ⇒ page 4 .

t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
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Prote AG.
1. Safety information 1
2 Repair instructions
⇒ “2.1 Leaks at shock absorbers”, page 2
⇒ “2.2 Noises from shock absorbers”, page 2
⇒ “2.3 Checking shock absorbers when removed”, page 3
⇒ “2.4 Steering rack”, page 3
⇒ “2.5 Gaskets and seals”, page 3
⇒ “2.6 Nuts and bolts”, page 4
⇒ “2.7 Electrical components”, page 4
⇒ “2.8 Raising suspension to unladen position (vehicles with coil
springs)”, page 4
2.1 Leaks at shock absorbers

Shock absorbers are often replaced because of externally visible
leakage. Inspections on the test rig and in the vehicle have shown AG. Volkswagen AG d
agen
that in the majority of cases this replacement is not justified. Volksw
oes
not
gu
d by ara
satelettronica
Slight loss of fluid (“sweating”) at the piston rod seal is not a rea‐
orise nte
eo
son for replacing a shock absorber. An oil sweating shock aab‐ ut
h
ra
sorber is deemed OK under the following conditions: ss c
ce
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nl
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♦ Fluid seepage (as shown in the shaded part of the illustration)
du
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is visible, but the fluid is dull and possibly dried by dust.
y li
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♦ The fluid seepage extends only from the top shock absorber
ot p
wit
seal (piston rod seal) down to the bottom spring plate
, is n
h re
-arrow-.
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
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at
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ate
do
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t.
2.2 Noises from shock absorbers
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Shock absorbers are often replaced because of noises (rumbling, yri
p by
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etc.) experienced by the customer. Inspections on the test rig and
by c lksw
cted agen
in the vehicle have shown that in approx. 70% of these cases
Prote AG.
there is no case for complaint. The replacement was not justified.

In the case of complaints regarding rumbling or knocking noises
please proceed as follows.
– Carry out a road test with the customer - if possible on a dry,
uneven road - to establish when, where and how the noises
occur.
Note
These noises are only very rarely caused by the shock absorbers.
2 Rep. gr.00 - Technical data

2.3 Checking shock absorbers when re‐

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

not be topped up.
After removal, a shock absorber can be checked by hand as fol‐

lows:
– Compress shock absorber by hand.
• The piston rod should move smoothly over the entire stroke
with uniform resistance and without jolts.
– Release piston rod.
• If the shock absorber has sufficient gas pressure the piston
satelettronica
rod will return by itself to its original position.
Note n AG. Volkswagen AG do

lkswage es n
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♦ Even if the gas rpressure
ise
d b
is not sufficient, the shock absorber
ran
tee
may not haveuthto be renewed. Provided there has been no ma‐
o
or
jor loss of fluid,
ss
a it will still be as effective as a conventional ac
shock absorber.
ce
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nl
pt
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♦ Even without gas pressure, the shock absorber will provide full
itte
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damping effect as long as there has been no major loss of fluid.

erm
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However, it may produce more noise.

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2.4 Steering rack

hole
spec
es, in part or in w
To achieve the desired results when performing repairs on the

t to the co
steering rack it is important to work with the greatest possible care

and cleanliness, and to use proper tools in good condition. Also
note the basic rules on safety when performing repair procedures.
rrectness of i
A series of generally valid instructions for individual repairs are

l purpos
summarised here. They are also repeated at numerous places in

the Workshop Manual. The instructions apply to this particular
nf
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workshop manual.
orm
m
♦ Thoroughly clean all unions and the adjacent areas before

atio
om
disconnecting.
n in
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♦ Place removed parts on a clean surface and cover them to

t
sd
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prevent them from getting dirty. Use sheeting and paper for
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this purpose. Use lint-free cloths only.

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♦ Install only clean parts; do not remove new parts from pack‐ . Cop py
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♦ Use only the grease and sealants with specified part numbers.
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Prote AG.
♦ If repair work cannot be performed immediately, cover new
parts which have been removed from their packing.
2.5 Gaskets and seals

♦ Always renew seals and gaskets.
♦ After removing seals, check for burrs and damage, rectify if
necessary.
2. Repair instructions 3
♦ Completely remove all residue from liquid sealants from the

sealing surfaces, making sure that no residual sealant gets
into the steering rack housing.
AG. Volkswagen AG d
agen
2.6 Nuts and boltsby Volksw
oes
not
gu
ara
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♦ Loosen and tighten bolts orisand securing nuts for covers and eo
th
housings diagonally.ss au ra
c
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♦ Avoid canting sensitive parts, such as servo motor with control

nl
pt
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unit. Loosen and tighten them diagonally in stages.
itte
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♦ Specified torques given are for unlubricated nuts, bolts and
ility
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screws.
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♦ Always renew self-locking bolts and nuts.
hole
spec
es, in part or in w
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2.7 Electrical components
rrectness of i
You have certainly felt an electric shock when you have touched
l purpos
something metallic. This is due to the electrostatic charge of the

human body. This charge can cause malfunctions if you touch the
satelettronica
electric steering rack and steering column components.
nf
ercia
orm
– Before working on electrical components, touch an earned
m
atio
m
object, such as a water pipe or a lifting platform. Do not directly

o
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c
touch connector contacts.

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Prote AG.
2.8 Raising suspension to unladen position

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

Special tools and workshop

equipment required
AG. Volkswagen AG d
agen oes
olksw not
byV gu
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cial p
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♦ Engine and gearbox jack - V.A.G 1383 A- discontinued, use Prote
cted AG.
agen
engine and gearbox jack - VAS 6931-
♦ Tensioning strap - T10038-
♦ Support - T10149-
Caution
All bolts on running gear components with bonded rubber

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

tive suspension with the engine and gearbox jack - V.A.G 1383
A- or engine and gearbox jack - VAS 6931- and support -
T10149- .
Before the respective wheel suspension is raised, the vehicle

must be strapped to the lifting platform arms using tensioning
straps - T10038- .
WARNING
If the vehicle is not strapped down, there is a danger that the

vehicle will slip off the lifting platform!
– 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

1BA/ 1BL/ 2MF (standard) 471 ± 10 mm
satelettronica
1BQ 455 ± 10 mm
1BJ /1BB/ 2MG/2MK/2ML 471 ± 10 mm
2MD/ 2MH/ 1BV/ 1BC/ 1BQ 437 ± 10 mm
2MD 455 ± 15 mm
1BH/2 MQ/ 2MR/2MT/2MU 471 ± 15 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. Allocation of PR number to corresponding running gear
⇒ page 199 .
– Raise wheel bearing housing using engine and gearbox jack
olkswagen AG
- V.A.G 1383 A- or engine and gearbox jack - lVAS n AG. Vuntil
6931-
kswage does
not
dimension -a- is attained. by Vo gu
a
ed ran
oris tee
th or
WARNING au ac
ss
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un
pt
♦ Do not raise or lower the vehicle while the engine and

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gearbox jack is positioned under the vehicle.

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ility
♦ Do not leave the engine and gearbox jack - V.A.G 1383

ot p
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A- or engine and gearbox jack - VAS 6931- under the ve‐

is n
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hicle longer than necessary.

ole,
spec
t to the co
– Tighten respective nuts and bolts.

– Lower wheel bearing housing.
rrectne
– Pull out engine and gearbox jack - V.A.G 1383 A- or engine

and gearbox jack - VAS 6931- from underneath the vehicle.
ss o
cial p
– Detach support - T10149- .

f inform
mer
2.8.2 Raising wheel bearing assembly to unladen position (vehicles with coil
atio
om
n
c
springs), rear axle

i
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c by lksw
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Rep. gr.00 - Technical data Prote AG.

equipment required
satelettronica
AG. Volkswagen AG d
agen oes
olksw not
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rise nte
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au ra
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nl
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es, in part or in w
t to the co
♦ Engine and gearbox jack - V.A.G 1383 A- discontinued, use

rrectness of i

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nf
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Caution
orm
m
atio
m
All bolts on running gear components with bonded rubber

o
n in
c
bushes may be tightened only when the component is in the

or
thi
e
unladen position (normal position).

t
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Axle components with bonded rubber bushes must therefore
Co
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be brought to a position equivalent to the unladen (normal) po‐
t. C rig
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sition before being tightened. p by
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Otherwise, the bonded rubber bush would be subject to torsion Prote AG.
loading, shortening its service life.
To simulate this position on the lifting platform, raise the respec‐

tive axle with the engine and gearbox jack - V.A.G 1383 A- or
engine and gearbox jack - VAS 6931- 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- .
1- Tensioning strap - T10038-
WARNING
If the vehicle is not strapped down, there is a danger that the

vehicle will slip off the lifting platform!
– Attach support - T10149- with a wheel bolt.
Respective nuts and bolts may be tightened only when dimension

-a- between the centre of wheel hub and edge of wheel housing
has been attained.
The dimension -a- depends on the ride height of the installed run‐ AG. Volkswagen AG d
agen
ning gear: Volksw
oes
not
by gu
ara
ed
satelettronica
Running gear 1) Ride height -a- in mm
tho
ris nte
eo
au ra
ss c
ce
e
nl
pt
du
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itte
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1BJ/ 1BB/ 1BH/ 2MG/ 2MK/ 2M 479 ± 15 mm
erm
ab
L/ 2MQ/ 2MR/ 2MT/ 2MU
ility
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2MD/ 2MH/ 1BV/ 1BC/ 1BQ 439 ± 10 mm
, is n
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2MD 459 ± 10 mm
spec
es, in part or in w
1BA/ 1BL/ 2MF/ 1BQ 429 ± 10 mm
t to the co
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
rrectness of i
number. Allocation of PR number to corresponding running gear
⇒ page 199 .
l purpos
– Raise wheel bearing housing using engine and gearbox jack

until dimension -a- is attained.
nf
ercia
orm
m
atio
m
WARNING
o
n in
or c
thi
e
♦ Do not raise or lower the vehicle while the engine and

t
sd
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gearbox jack is positioned under the vehicle.

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rp
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f
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♦ Do not leave engine and gearbox jack under vehicle lon‐

t.
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ger than necessary. Cop py
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pyri by
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cted agen
– Tighten respective nuts and bolts. Prote AG.
– Lower wheel bearing housing.

– Remove support - T10149- .

3 Evaluating accident vehicles

⇒ “3.1 Check list for evaluating running gear on accident vehi‐
cles”, page 9
3.1 Check list for evaluating running gear on

accident vehicles
Damage to running gear may go unnoticed during repairs to load-
bearing and suspension parts of accident vehicles. Under certain
circumstances, this undiscovered damage could lead to serious
consequential damage during later vehicle operation. Therefore,
the following parts of accident vehicles must be examined in the
manner and order described independent of wheel alignment
which may have to be performed. If no deviations from specifica‐
tions are measured during wheel alignment, there are no defor‐
mations of the running gear.
Visual and functional examination of steering system
♦ Visual examination for deformation and cracks
♦ Examination for play in track rod joints and steering rack
satelettronica
♦ 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.
olkswagen AG
en AG. V
Visual inspection and functional check of running gear olkswag does
not
V gu
by ara
• Adhere to the sequence of the following inspection
ris
ed steps. nte
ho eo
ut
♦ Check all components shown in the assembly
ss
a overviews for ra
c
deformation, cracks and other damage. ce
le
un
pt
an
d
♦ Renew damaged parts

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♦ Align wheels on a Volkswagen-approved wheel alignment

pe
ility
stand
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Visual and functional check of wheels and tyres

hole
spec
es, in part or in w
♦ Check for true running and imbalance ⇒ VW ServiceNet;

t to the co
Technical information; Reference guides; Wheel and Tyre

Guide; General; Roughness due to wheels and tyres .
♦ Check tread and sidewalls of tyres for cuts and damage from
rrectness of i
blows ⇒ VW ServiceNet; Technical information; Reference

l purpos
guides; Wheel and Tyre Guide; General; Tyre damage .

♦ Check tyre pressure; for information on tyre pressure see
nform
ercia
sticker attached to B-pillar on driver side or to inside of tank

flap.
m
a
com
tio
If rim of wheel and/or tyre is damaged, renew tyre. This also ap‐
n in
r
te o
plies if the circumstances of the accident and the damage to the

thi
s
vehicle indicate possible damage which is not visible.

iva
do
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rp
cum
A further factor in the decision is the age of the tyre. Tyres should
fo
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ng
not be older than 6 years.

t.
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Generally, in case of doubt: opyri
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c lksw
• Whenever there is a risk to safety the tyre must be renewed.
by
cted agen
Prote AG.
3. Evaluating accident vehicles 9

Complete vehicle
Also check other vehicle systems such as:
♦ Brake system including ABS
♦ Visual and functional examination of exhaust system and pas‐
senger protection
Specifications for testing and adjusting are in the respective work‐
shop manual in ELSA.
The examination of accident vehicles described here refers to the
running gear, it is not a complete examination of the entire vehicle.
Electronic vehicle systems
Interrogate safety-relevant systems such as ABS/EDL, airbag,
electronically regulated suspension systems, electromechanical
or electrohydraulic steering and other driver assist systems with
⇒ Vehicle diagnostic tester for fault messages. If faults are stored
in the event memories of the systems mentioned above, repair
the faults according to the instructions in workshop manuals in
ELSA. Following repairs, interrogate the affected systems again
to check for event memory entries to ensure that the function has
been restored.
satelettronica
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c
ce
le
un
pt
an
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ility
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spec
t to the co
rrectness o
cial p
f inform
mer
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Prote AG.

4 Waste disposal
⇒ “4.1 Releasing gas and draining front gas-filled shock absorb‐
ers”, page 11
⇒ “4.2 Releasing gas and draining rear gas-filled shock absorb‐
ers”, page 11
4.1 Releasing gas and draining front gas-fil‐

led shock absorbers
– Clamp gas-filled shock absorber vertically in vice, with piston
rod pointing downwards.
WARNING
Wear eye protection when drilling.
– Drill a 3 mm hole -A- through outer tube of shock

olksw
absorber.
AG. V agen AG
agen does
lksw not
satelettronica
o
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db ara
Note rise nte
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au ra
Gas escapes upon penetration.
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nl
pt
du
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itte
– Continue drilling until the inner tube has been penetrated (ap‐
y li
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prox. 25 mm deep).
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– Drill a 6 mm hole -B- through outer and inner tube of shock
wit
, is n
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absorber.
hole
– Hold shock absorber over an oil drip tray. Move the piston rod spec
es, in part or in w
back and forth over its full extension until no further oil es‐ t to the co
capes.
rrectness of i
4.2 Releasing gas and draining rear gas-fil‐

l purpos
led shock absorbers

– Clamp gas-filled shock absorber vertically in vice.
nform
mercia
at
WARNING
om
ion
c
in t
or
his
e
Safety goggles must be worn when drilling.

at
do
priv
cum
for
en
ng
t.
– Drill a 3 mm hole -A- through outer tube of shock absorber.
yi Co
Cop py
t. rig
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pyri by
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Note
c by lksw
cted agen
Prote AG.
Gas escapes upon penetration.
– Continue drilling until the inner tube has been penetrated (ap‐
prox. 25 mm deep).
– Drill a 6 mm hole -B- through outer and inner tube of shock
absorber.
– Hold shock absorber over an oil drip tray. Move the piston rod
back and forth over its full extension until no further oil es‐
capes.
4. Waste disposal 11
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Running gear,
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40 – Front suspension
an
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1 Front axle
wit
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⇒ “1.1 Overview of fitting locations - front axle”, page 12
es, in part or in w
t to the co
1.1 Overview of fitting locations - front axle
rrectness of i
I-
⇒ “2.1 Assembly overview -
l purpos
subframe”, page 13
II -
nf
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o
rm
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suspension strut”, page 37
atio
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III -
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12 Rep. gr.40 - Front suspension

2 Subframe
⇒ “2.1 Assembly overview - subframe”, page 13
⇒ “2.2 Removing and installing subframe without steering rack”,
page 14
⇒ “2.3 Repairing subframe”, page 18
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⇒ “2.4 Removing and installing
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ks bar”, page 22 ot g
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⇒ “2.5 Renewing anti-roll
hori bar bushes”, page 23
s tee
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⇒ “2.6 Removing and
ss installing coupling rod”, page 25
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⇒ “2.7 Fixing position of subframe”, page 26
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⇒ “2.8 Lowering subframe”, page 32
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2.1 Assembly overview - subframe
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1 - Nut
t to the co
❑ Renew after removal
satelettronica
❑ When tightening, coun‐
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terhold on multipoint
socket of joint pin of cou‐
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pling rod
❑ 60 Nm +45°
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2 - Coupling rod
rm
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❑ Note installation posi‐
om
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tion ⇒ page 14
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❑ Removing and installing

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⇒ page 25
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❑ Allocation ⇒ Electronic
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parts catalogue “ETKA”
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3 - Anti-roll bar
⇒ page 22
4 - Nut
❑ When tightening, coun‐
terhold on multipoint
socket of joint pin of cou‐
pling rod
❑ 60 Nm +45°
5 - Rubber mounting
⇒ page 23
6 - Clip
7 - Bolt
❑ 110 Nm
8 - Bonded rubber bush
❑ Allocation ⇒ Electronic parts catalogue “ETKA”
2. Subframe 13
❑ Pressing out and in ⇒ page 18
❑ Note installation position ⇒ page 18
9 - Subframe
❑ Removing and installing subframe without steering rack ⇒ page 14 .
❑ Fix in position before removal ⇒ page 26 .
❑ Lowering subframe ⇒ page 32
10 - Washer
11 - Bolt
❑ Initial tightening torque: 50 Nm
❑ 150 Nm +180°
Installation position for the coupling rod:

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When fitting the modified coupling rod, ensureauthat
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– Fit coupling rod -1- in such a way that open side of U-type
itte
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profile points towards the engine (towards engine compart‐
erm
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ility
ment).
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2.2 Removing and installing subframe with‐ nf

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out steering rack

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♦ Subframe is removed complete with suspension links and anti-

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roll bar.
Co
Cop py
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♦ Suspension struts with wheel bearing housings as well as
ht
pyri by
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steering rack remain on vehicle.
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Special tools and workshop equipment required

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♦ Hexagon key - T10061-
wit
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mer
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n
c
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♦ Locating pins - T10227-
thi
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♦ Torque wrench - V.A.G 1331-
2. Subframe 15
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♦ Torque wrench - V.A.G 1332- byV
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♦ Engine and gearbox jack - VAS 6931-
ss o
cial p
f inform
mer
atio
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n
c
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satelettronica
thi
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Cop py
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♦ Rear axle support - T10552- cted agen
Prote AG.
Removing
– Loosen wheel bolts.
– Raise vehicle ⇒ Maintenance ; Booklet 20.1 ; Description of
work; Raising vehicle with lifting platform and trolley jack .
– Remove front wheels.
– Unscrew nut -arrow- and pull coupling rod -1- off suspension
strut.
– Remove front engine mounting from subframe ⇒ Rep. gr. 10 ;
Assembly mountings; Removing and installing engine mount‐
ing .
– Remove rear engine mounting from subframe ⇒ Rep. gr. 10 ;
ing .

– Remove nuts -arrows-

– Secure steering rack to body on both sides.
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♦ The protective
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h
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hydraulic lines must not be over-extended or strained.
ss c
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Vehicles with left/right vehicle level sender
es, in part or in w
t to the co
– Unscrew nut -1-.
– Pull front left vehicle level sender - G78- / front right vehicle
level sender - G289- -2- out of suspension link -3-.
rrectness of i
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satelettronica
nform
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at
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ate
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Continued for all vehicles

p
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– Using socket, multi-point bit XZN 14 - T10061- -2-, unscrew

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bolts -1- from swivel joint -3-. C py
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Note Prote AG.
Depending on engine, various brackets are mounted on the sub‐

frame, for example, brackets for the exhaust system, which must
be unbolted in order to remove the subframe.
– Fix subframe in position ⇒ page 26 .
2. Subframe 17
– Use tensioning straps - T10038- or -T10552/3- -3- to locate

and secure subframe -1- on rear axle support - T10552- -2- as
shown in figure.
– Carefully lower subframe with engine and gearbox jack - VAS
6931- .
Note
♦ When lowering the subframe, ensure

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ra
lowest sposition.
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– Secure steering rack to body.

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Installing
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Install in the reverse order of removal, observing the following:
h re
ole,
– Remove assembly tool - T10227- ⇒ page 31 pins.
spec
satelettronica
t to the co
If components such as subframe or suspension link have been
»renewed«, it may be necessary to carry out wheel alignment.
To determine whether wheel alignment is necessary, refer to table
⇒ page 194 . rrectne
If an off-centre steering wheel is determined during the road test

ss o
even though locating pins - T10227- were used, check the wheel
cial p
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alignment. In this case the wheel alignment test results must be

nform
archived in the vehicle files.

mer
atio
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Specified torques
o
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♦ ⇒ “4.1 Assembly overview - lower suspension link, swivel

te
sd
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joint”, page 52
i
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pr
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♦ ⇒ “2.1 Assembly overview - subframe”, page 13

en
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♦ ⇒ “3.1 Assembly overview - steering rack”, page 222
C py
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♦ ⇒ “1.1 Specified torques for wheel bolts”, page 178
cop Vo
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♦ Install front engine mounting to subframe ⇒ Rep. gr. 10 ;
ing .
♦ Install rear engine mounting to subframe ⇒ Rep. gr. 10 ; As‐
sembly mountings; Removing and installing engine mounting .
2.3 Repairing subframe


equipment required
satelettronica
AG. Volkswagen AG d
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♦ Thrust plate - 30 - 205-
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♦ Hydraulic cylinder - VAS 6178-

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♦ Thrust piece - 3351/1- from puller - 3351-

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♦ Assembly tool - T10205-

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spec
♦ Foot pump - VAS 6179-

es, in part or in w
t to the co
Removing
– Remove assembly carrier ⇒ page 14 .
rrectness of i
WARNING
l purpos
For the following assembly work, place the subframe on a

nform
ercia
workbench or the workshop floor.

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Cop py
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2. Subframe 19
– Fit tools as shown in illustration.

1- Threaded rod M20 - T10205/8-1-
2- Nut M20 - T10205/8-2-
3- Thrust head - T10205/13-
olkswagen AG
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4- Hydraulic cylinder - VASol6178-
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5- Support - T10205/4-
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6- Tube - T10205/5-
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7- Press tool - T10205/3-

nl
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8- Nut M20 - T10205/8-2-
erm
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– Pulling out bonded rubber bush.
wit
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Note
es, in part or in w
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The following work is necessary only if the bush jacket remains
in the axle beam.
rrectness of i
satelettronica
Pulling out bush jacket:
l purpos
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mercia
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Note ion
c
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or
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Fit lower nut (item 8) with collar pointing downwards.

at
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1- Threaded rod M20 - T10205/8-1-

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2- Nut M20 - T10205/8-2- t. C rig
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4- Hydraulic cylinder - VAS 6178-
5- Support - T10205/4-
6- Tube - T10205/5-
7- Thrust plate - 30 - 205-
8- Nut M20 - T10205/8-2-
– Pull out bush jacket.
Installing
– Mark installation position on side of bonded rubber bush and
subframe using a felt-tip pen ⇒ page 18 .
– Coat rubber bead with tyre fitting paste.

– Fit bonded rubber bush and tools as shown in illustration.
Note AG. Volkswagen AG d

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Fit lower nut (item 7) with collar pointing downwards.
ised b ara
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1 - Threaded rod M20 - T10205/8-1-s s c
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2- Nut M20 - T10205/8-2-
an
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5- Support - T10205/4-
ole,
spec
6- Thrust plate - 3351/1- from puller - 3351-
t to the co
7- Nut M20 - T10205/8-2-
– Align bonded rubber bush using the marks which have been
rrectne
made.
– Initially press in bush only until rubber bead has slid completely
ss o
into subframe.
satelettronica
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mer
atio
Note
om
n
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It is still possible to correct the installation position by turning the
te
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– Check or adjust the installation position before pressing in the
yi Co
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bush any further.
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– Press bonded rubber bush in to stop.
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Installation position for front bonded rubber bush
2. Subframe 21
Installation position for rear bonded rubber bush

– Install subframe ⇒ page 14 .
AG. Volkswagen AG d
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2.4 Removing and installing anti-roll bar
satelettronica
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atio
♦ Insert tool - T10061-
om
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or c
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Removing
Note
The following procedure is described for one side of the vehicle.

The procedure for the other side of the vehicle is identical.
– Remove wheels.

– If present, detach lower trim on wheel housing liner. To do this,

remove bolts -1- and nut -2-, and remove trim -arrow-.
AG. Volkswagen AG d
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– Separate threaded connection between coupling rod and anti-
es, in part or in w
roll bar by removing nut -arrow-.
t to the co
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satelettronica
nform
mercia
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– Unscrew threaded connections of anti-roll bar/subframe
um
fo
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-arrows- using socket and multi-point bit - T10061- .

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– Then remove anti-roll bar -1- to the left.
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Installing
co lksw
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Prote AG.
Note
♦ Tighten bolted connections to the anti-roll bar only if the vehi‐

cle is standing on its wheels and is unladen or if the vehicle is
raised and is in the unladen position (normal position)
⇒ page 4 .
♦ When tightening the nut -arrow-, counterhold on the multipoint
socket of the joint pin of the coupling rod.
Specified torques
2.5 Renewing anti-roll bar bushes

2. Subframe 23
satelettronica
Removing
AG. Volkswagen AG d
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The following procedure is described for aone
ut
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o eo
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The procedure for the other side of the svehicle is identical.
s c
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an
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ab

ility
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wit
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– Remove wheel.
ole,
spec
– If present, detach lower trim on wheel housing liner. To do this,

t to the co
remove bolts -1- and nut -2-, and remove trim -arrow-.
rrectness o
cial p
f inform
mer
atio
om
n
c
i
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n thi
te
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Cop py
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AG. Volkswagen AG d
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Vol Transporter
not
gu 2016 ➤
d ar
risRunning gear, axles, steering - Edition a02.2019
e nte
ho eo
aut ra
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– Unscrew threaded connections of anti-roll bar/subframe
ss
ce
le
-arrows- using socket and multi-point bit - T10061- .
un
pt
an
d
itte
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– Then pull anti-roll bar -1- forwards slightly and remove rubber
rm
ab
bush -2-.
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Installing
, is n
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spec
es, in part or in w
t to the co
Note
rrectness of i
♦ Thoroughly clean contact surfaces before installing new rub‐
ber bushes. l purpos
♦ Ensure that the outer edge of rubber bush lies against stop.
nform
ercia
♦ Depending on version, the stop can be located on the left or

on the right of rubber bush.
m
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Specified torques
thi
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2.6 Removing and installing coupling rod pyri by
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AG.
Removing
Note
The following procedure is described for one side of the vehicle.

The procedure for the other side of the vehicle is identical.

– Remove wheel.
2. Subframe 25
– Separate threaded connections between coupling rod and

strut as well as between coupling rod and anti-roll bar. Then
remove coupling rod -1-.
Installing
AG. Volkswagen AG d
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Note
ility
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♦ Tighten bolted connections to the anti-roll bar only if the vehi‐
hole
spec
cle is standing on its wheels and is unladen or if the vehicle is
es, in part or in w
raised and is in the unladen position (normal position)
t to the co
⇒ page 4 .
♦ When tightening the nuts -arrows-, counterhold on the multi‐
satelettronica
rrectness of i
point socket of the joint pin of the coupling rod.
l purpos
Specified torques
nform
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m
at
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2.7 Fixing position of subframe
his
ate
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♦ Certain repairs on vehicles require the removal of the sub‐ yri
p by
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frame or the entire front axle.
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♦ The original position of the subframe relative to the body can
be attained with the aid of locating pins - T10227- .


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♦ Torque wrench - V.A.G
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mer
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n
c
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2. Subframe 27
♦ Rear axle support - T10552-
AG. Volkswagen AG d
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Assembly and preparation of engine and gearbox jack - VAS
ility
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6931- with rear axle support - T10552-
wit
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– Adjust both mounting pins, support and mounting block on rear
hole
spec
axle support - T10552- to specified dimensions as follows.
es, in part or in w
t to the co
Note
rrectness of i
satelettronica
Please use the dimensions specified in the text and never use the
l purpos
values shown on the folding rule in the illustrations.
nf
ercia
– Adjust mounting pins -T10552/1- -1- on left and right to di‐
or
mension -a- (40 mm with cap -2- screwed on).
m
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atio
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– Tighten union caps of mounting pins.

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co lksw
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– Adjust height of mounting pins -2- by hand on left and right at

threaded sleeve -1- to dimension -a- (175 mm).
– Adjust support -T10552/2- -1- to dimension -a- (680 mm).

– Tighten bolt -2- in support using hexagon key to specified tor‐

que.
– Adjust support pin -1- to dimension -a- (530 mm).
– Tighten bolts -2- to specified torque ⇒ page 32 .

– Align rear axle support - T10552- above engine and gearbox
jack - VAS 6931- in such a way that mounting block points
downwards.
– Place rear axle support - T10552- with mounting block on en‐
gine and gearbox jack - VAS 6931- .
satelettronica
– Tighten bolt -2- with hexagon key -1- to secure rear axle sup‐
port - T10552- on engine and gearbox jack - VAS 6931- to
specified torque ⇒ page 32 .
Further steps on vehicle
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2. Subframe
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– Press suspension link off swivel joint using ball joint puller -
T10187- -2-.
Note

Installing locating pins

– Position engine and gearbox jack - VAS 6931- with attached
rear axle support - T10552- beneath subframe.
– Allow rear axle support - T10552- to move upwards with en‐
gine and gearbox jack - VAS 6931- .

– Insert front supports -3- in mounting holes -arrows- in sub‐

frame -1- onto stop, free of stress, and position rear support
-2- under transverse reinforcement of subframe -1-.
Note
When positioning the rear axle support - T10552- in the subframe

with the engine and gearbox jack - VAS 6931- , make sure that
the vehicle is not raised as well under any circumstances.
– Replace 4 bolts of subframe onegafter

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♦ The position of the subframe is now fixed.
t to the co
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and secure subframe -1- on rear axle support - T10552- -2-.
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– Use engine and gearbox jack - VAS 6931- -3- to lower sub‐
ht
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frame -1- located on rear axle support - T10552- -2-.
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Removing locating pins
Remove in reverse order, observing the following:
Note
The engine and gearbox jack - VAS 6931- may only be moved
with the subframe on the rear axle support - T10552- in the lowest
position.
2. Subframe 31

shown in figure.
– Carefully allow subframe -1- placed on rear axle support -

T10552- -2- to move upwards againstksw AG. Volkwith
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– One after the other, replace locating pins - T10227- with 4 new
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To determine whether wheel alignment is necessary, refer to table
⇒ page 194 .
If an off-centre steering wheel is determined during the road test
rrectne
even though locating pins - T10227- were used, check the wheel
alignment. In this case the wheel alignment test results must be
archived in the vehicle files. ss o
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Specified torques
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sembly mountings; Removing and installing engine mounting . Prote AG.
Component Specified torque

Locating pins - T10227- 20 Nm
Bolt for securing rear axle sup‐ M6 5 Nm, M8 10 Nm
port - T10552- on engine and
gearbox jack - VAS 6931-
Bolt securing support on rear 10 Nm
axle support - T10552-
2.8 Lowering subframe


AG. Volkswagen AG d
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Running gear, axles, steeringgu
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♦ Ball joint puller - T10187-
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2. Subframe 33

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Sequence of operations
strut.
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Caution
♦ The protective boot for the intermediate steering shaft and


satelettronica
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– Press suspension link off swivelrisjoint
ed using ball joint puller - ara
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– Unscrew nut -1-. s
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– Fix position of subframe ⇒ page 26 .

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2. Subframe 35

shown in figure.
– Carefully lower subframe with engine and gearbox jack - VAS
6931- .
Note
♦ When lowering the subframe, ensure that it does not catch

anywhere or come into contact with other components.
♦ The engine and gearbox jack - VAS 6931- may only be moved
with the subframe on the rear axle support - T10552- in the
lowest position.
Installing
– Remove locating pins - T10227- ⇒ page 31 .
Specified torques
satelettronica
ing .
sembly mountings; Removing and installing engine mounting .
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⇒ “3.1 Assembly overview - suspension strut”, page 37
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⇒ “3.2 Removing and installing suspension strut”, page 38
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⇒ “3.3 Repairing suspension strut”, page 48
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3.1 Assembly overview - suspension strut
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1 - Protective cap
2 - Nut
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❑ 80 Nm
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3 - Stop
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4 - Suspension turret
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5 - Nut
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6 - Suspension strut mounting
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❑ Note allocation ⇒ Elec‐ Prote
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tronic parts catalogue
(ETKA)
❑ Press into upper spring
plate
⇒ Item 7 (page 37) to
stop.
9 - Deep groove ball thrust
bearing
10 - Protective cover
11 - Coil spring
❑ Note allocation ⇒ Elec‐
(ETKA)
⇒ page 48
12 - Protective cap
(ETKA)
13 - Damper
❑ Note allocation ⇒ Electronic parts catalogue (ETKA)
❑ Removing and installing suspension strut ⇒ page 45
❑ Repairing suspension strut ⇒ page 48
14 - Damper
❑ Removing and installing suspension strut ⇒ page 38
❑ Repairing suspension strut ⇒ page 48
15 - Buffer stop
3. Suspension strut 37
❑ Compress together with support ring ⇒ Item 16 (page 38) and then press both parts into upper spring
plate ⇒ Item 7 (page 37) to stop.
16 - Support ring
❑ Compress together with bump stop ⇒ Item 15 (page 37) and then press both parts into upper spring plate
⇒ Item 7 (page 37) to stop.
3.2 Removing and installing suspension

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3.2.1 Removing and installing suspension
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♦ Spreader - 3424-
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♦ Shock absorber tool set - T10001-
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♦ Adapter - T10103/1-
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♦ Ejector - T10520-
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♦ Engine and gearbox jack - VAS 6931-

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

r
te o
terior; Rep. gr. 50 ; Bulkhead; Removing and installing plenum

thi
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chamber cover .
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– Loosen nut for drive shaft ⇒ page 100 .

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Caution
Wheel bearings must not be subjected to load after bolt secur‐

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

satelettronica
– Remove wheel.
– Unbolt coupling rod -1- from suspension strut.
– Swing coupling rod towards rear.
– Press brake line out of retainer on suspension strut.
– Pull off electrical connector for front left brake pad wear sender
- G34- / rear right brake pad wear sender - G37- ⇒ Brake
system; Rep. gr. 46 ; Front brake; Assembly overview - front
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brake . swagen AG does
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– Pull off electrical connector for front dright
by speed sensor - G45- / ara
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front left speed sensor - G47- ⇒ horBrake system; Rep. gr. 45 ; eo
Sensors; Removing and installing aut speed sensors on front axle ra
ss c
-G45- / -G47- .
ce
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nl
pt
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– Push wire for front left brake pad wear sender - G34- / rear
an
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right brake pad wear sender - G37- out of retainer on suspen‐

erm
ab
sion strut.
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– Push wire for front right speed sensor - G45- / front left speed
h re
sensor - G47- out of retainer on suspension strut.

hole
spec
es, in part or in w
– Remove brake caliper ⇒ Brake system; Rep. gr. 46 ; Front

t to the co
brake; Removing and installing brake caliper .

– Secure brake caliper to vehicle with wire.
rrectness of i
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Note
nf
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Observe the following procedure to prevent damage to the drive

or
shaft caused by overstretching.

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– Support wheel bearing housing using engine and gearbox jack
- V.A.G 1383 A- or engine and gearbox jack - VAS 6931- .
WARNING
♦ Never raise or lower the vehicle while the engine and

gearbox jack is positioned beneath the vehicle.
♦ Do not leave the engine and gearbox jack - VAS 6931- or
engine and gearbox jack - V.A.G 1383 A- under the vehicle
longer than necessary.

satelettronica
AG. Volkswagen AG d
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– ut do not remove it completely.
Loosen nut -1- on swivel joints abut ra
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Caution
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T10187- -2-.
t to the co

– Pull suspension link off swivel joint.
rrectness of i
l purpos
Before using press tool - T10520- ensure that thrust piece -1- is
inserted.
nf
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Using ejector - T10520- :

– Use bolts - T 10103/1- to secure adapter - T10103/2- -1- to
wheel bearing. agen
AG. Volkswagen AG d
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– To press out drive shaft -3-,
ed
bysecure ejector - T10520- -2- to
V ua
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wheel hub using 4 wheel
ho
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– It is essential to follow specified sequence.
t to the co
I - Tighten knurled nut -1- hand-tight.
II - Turn only bolt -2- using a spanner in order to press out drive
rrectne
shaft with ejector - T10520- .
ss
Note
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inform
At the end of the procedure or for pressing out drive shaft further,
mer
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the spindle must be moved to its original position in order to apply
om
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– Secure drive shaft to body with wire.

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– Disconnect electrical connector -2-.
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– Remove wiring harness -3- from brackets on shock absorber cted agen
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-1-.
– Move wiring harness -3- aside.
– Separate threaded damper connection on body.

1 - Commercially available ratchet handle
2 - T10001/8
3 - T10001/11
4 - T10001/5
– Lower engine and gearbox jack - V.A.G 1383 A- or engine and
gearbox jack - VAS 6931- as far as necessary.
– Remove shock absorber with wheel bearing housing.
– Place shock absorber with wheel bearing housing on a suita‐
ble surface.
– Unscrew nut -1- from wheel bearing housing -3-.

– Pull out bolts -2-.
– Open wheel bearing housing -1- with spreader - 3424- at po‐

sition -A-.
satelettronica
AG. Volkswagen AG d
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– Remove shock absorber -2- in -direction of arrow B-.

Installing
♦ Check alignment of suspension strut relative to wheel bearing
housing.

When installing, the metal tab on suspension strut must slip into
groove -arrow A- in wheel bearing housing.
– If necessary, turn suspension strut further until this position is
reached.
– Insert wheel bearing housing far enough that suspension strut
sits on stop -arrow B- in wheel bearing housing.
– Insert suspension strut.
– Secure threaded connection of shock absorber on body.

2 - T10001/8
3 - T10001/11
4 - T10001/5
If components such as damper have been renewed, it may be
satelettronica
necessary to carry out wheel alignment.
For information on the necessity of wheel alignment refer to
⇒ page 194 . AG. Volkswagen A
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Specified torques by Vol ot g
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♦ ⇒ “2.1 Assembly overview - subframe”,oris page 13 tee
th or
au ac
♦ ⇒ “6 Drive shaft”, page 78 ss
ce
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♦ Install brake caliper ⇒ Brake system; Rep. gr. 46 ; Front brake;
pe
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Removing and installing brake caliper
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wit
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♦ Plenum chamber bulkhead; Assembly overview - plenum

h re
hole
chamber bulkhead ⇒ General body repairs, exterior; Rep. gr.

50 ; Bulkhead; Assembly overview - plenum chamber bulk‐ spec
es, in part or in w
t to the co
head
3.2.2 Removing and installing suspension strut, suspension strut secured with
rrectness of i
bolts
l purpos
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equipment required
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Removing
chamber cover .
– Remove wheel.


– Unbolt coupling rod from suspension strut and swing back.
– Press brake line out of retainer on suspension strut.
– Pull of connectors for brake pad wear indicator and ABS speed
sensor.
– Press wires for brake pad wear indicator and ABS speed sen‐
sor out of bracket on suspension strut.

– Remove wiring harness -3- from brackets on shock absorber
-1-.
– Move wiring harness -3- aside.
satelettronica

– Support wheel bearing housing using engine and gearbox jack
- V.A.G 1383 A- or engine and gearbox jack - VAS 6931- . . Volkswagen AG d
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WARNING ed nte
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♦ Never raise or lower the vehicle ss the engine and
while
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un
pt
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♦ Do not leave the engine and gearbox jack - V.A.G 1383

erm
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A- or engine and gearbox jack - VAS 6931- under the ve‐

ility
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wit
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– Unscrew nuts -1-.

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– Pull out bolts -2-.

rrectne
– Pull wheel bearing housing -3- out of shock absorber -4-.

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– Separate threaded damper connection on body.

2 - T10001/8
3 - T10001/11
4 - T10001/5
– Lower engine and gearbox jack - V.A.G 1383 A- or engine and
gearbox jack - VAS 6931- as far as necessary, and remove
suspension strut.
Installing
If components such as damper have been renewed, it may be
necessary to carry out wheel alignment.
. Volkswagen AG
To determine whether wheel alignment is necessary, refer to table kswagen AG does
not
⇒ page 194 . Vol gu
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Specified torques tho eo
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♦ ⇒ “2.1 Assembly overview - subframe”, page 13 ss
ce
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♦ Plenum chamber bulkhead; Assembly overview - plenum
ility
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chamber bulkhead ⇒ General body repairs, exterior; Rep. gr.
wit
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50 ; Bulkhead; Assembly overview - plenum chamber bulk‐
h re
head
hole
spec
es, in part or in w
t to the co
3.3 Repairing suspension strut
rrectness of i
l purpos
nform
mercia
at
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ion
c
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ate
do
priv
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for
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Cop py
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AG. Volkswagen AG d
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eo
axles, steering - Edition 02.2019
th
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Special tools and workshop s
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equipment required
un
pt
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♦ Spring compressor - V.A.G 1752/1-
♦ Spring retainer - V.A.G 1752/5-
– Remove coil spring strut ⇒ page 38 .
Removing coil spring

– Clamp suspension strut support clamp - V.A.G 1752/20- -4- in
a vice.
– Clamp suspension strut in suspension strut support clamp -
V.A.G 1752/20- -4-.
– Pre-tension coil spring with spring compressor - V.A.G 1752/1-
until deep groove ball thrust bearing is free at top.
1- Torque wrench - V.A.G 1332-
2- Hexagon bit, long reach - T10001/8-
3- Spring compressor - V.A.G 1752/1-
4- Strut support clamp - V.A.G 1752/20-
5- Spring retainer - V.A.G 1752/5-
6- Hexagon bit, long reach - T10001/5-
7- Ratchet wrench - T10001/11-
WARNING
satelettronica
First compress spring far enough to ensure that upper spring
plate is free.
– Ensure that coil spring is correctly seated in spring retainer -

V.A.G 1752/5- -arrow-.
– Unscrew hexagon nut from piston rod.
– Remove suspension strut mounting, upper spring plate with
bump stop and deep groove ball thrust bearing with protective
boot from piston rod. wage
e ks s no
Vol t
– Remove coil spring withedspring
by compressor from shock ab‐ guara
sorber. tho
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Installing coil spring ss c
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– Fit coil spring with spring compressor - V.A.G 1752/1- onto

ab
ility
lower spring support.

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t to the co
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The end of the coil spring must lie against the stop -arrow-.
– Ensure that bump stop is correctly seated in upper spring
plate.
– Pull lower end of protective boot down far enough that the
locking lugs of the protective cap engage in the groove of the
protective boot.
– Assemble all other parts and use new nut on piston rod.
– Relieve tension on spring compressor - V.A.G 1752/1- and
remove from coil spring.
– Remove suspension strut from suspension strut support
clamp - V.A.G 1752/20- .
– Install suspension strut ⇒ page 38 .
Specified torques
♦ ⇒ “3.1 Assembly overview - suspension strut”, page 37
♦ ⇒ “6 Drive shaft”, page 78
wage
satelettronica
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♦ ⇒ “1.1 Specified torques for wheel bolts”, page 178 y V olks ot g
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4 Lower suspension link, swivel joint

⇒ “4.1 Assembly overview - lower suspension link, swivel joint”,
page 52
⇒ “4.2 Removing and installing lower suspension link”,
page 53
⇒ “4.3 Checking swivel joint”, page 55
⇒ “4.4 Removing and installing swivel joint”, page 55
⇒ “4.5 Renewing bonded rubber bush for lower suspension link”,
page 57
4.1 Assembly overview - lower suspension link, swivel joint
1 - Subframe
❑ Fix in position before re‐
moval ⇒ page 26 .
satelettronica
2 - Bolt
❑ 110 Nm +120°
❑ Tighten only when the
vehicle is standing on its
wheels and is unladen
or when the vehicle is agen
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raised and has been put Volksw not
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in the unladen position d b ara
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⇒ page 4 . thor eo
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3 - Rear bonded rubber bush ss ce
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❑ Pressing out and in

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⇒ page 60
wit
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❑ Observe installation po‐

hole
sition for bush with »kid‐

spec
es, in part or in w
ney-shaped« notch
t to the co
⇒ page 60 .
❑ Tighten only when the
vehicle is standing on its
rrectness of i
wheels and is unladen

or when the vehicle is
l purpos
raised and has been put

in the unladen position
nf
ercia
⇒ page 4 .
orm
m
atio
4 - Suspension link
om
n in
c
❑ If damaged, also renew

or
thi
swivel joint.
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⇒ page 53
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5 - Nut C py
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❑ Renew after removal yri
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6 - Bolt
agen
Prote AG.

❑ 110 Nm +120°

AG. Volkswagen AG Running gear, axles, steering - Edition 02.2019
agen does
olksw not
❑ Tighten only whenedthe by vehicle is standing on its wheels
V guand is unladen or when the vehicle is raised
ara and
has been put inhorthe
is unladen position ⇒ page 4 . nte
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7 - Front bonded rubber
ss bush c
ce
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❑ Pressing out and in ⇒ page 57
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❑ Tighten only when the vehicle is standing on its wheels and is unladen or when the vehicle is raised and
y li
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has been put in the unladen position ⇒ page 4 .
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❑ For front left vehicle level sender - G78-
hole
spec
es, in part or in w
9 - Nut
t to the co
10 - Swivel joint
rrectness of i
l purpos
❑ Renew together with suspension link if suspension link is damaged

❑ Removing and installing ⇒ page 55
nform
ercia
11 - Bolt
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❑ 90 Nm +45°
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12 - Nut
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❑ 60 Nm +90° t. Cop py
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4.2 Removing and installing lower suspen‐
AG.
sion link
4. Lower suspension link, swivel joint 53

Removing
Note
If the suspension link is deformed, the swivel joint must be re‐

newed together with the suspension link.

– Remove wheel.
satelettronica
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Caution
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T10187- -2-.
rrectne

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c
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– Unscrew nut -arrow-.

– Remove bolt -1-.
– Remove bolt -3-.
– Remove suspension link -4- from subframe.
Installing
Note
Tighten the nuts for the suspension link in unladen position

⇒ page 4 .
– Install front wheel and tighten ⇒ page 178 .

Specified torques
joint”, page 52
satelettronica
4.3 Checking swivel joint
Checking axial play
. Volkswagen AG
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– Forcefully pull suspension link down and press up again.
Vol
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Checking radial play rise nte
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– Press lower part of wheel forcefully outwards and inwards. t to the co

rrectne
Note
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♦ There should be no tangible or visible “play” during both tests.

form
mer
♦ Observe swivel joint while performing tests.

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♦ Take into account possible existing wheel bearing play or

i
or
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“play” in upper suspension strut mounting.

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♦ Check rubber boot for damage and renew swivel joint if nec‐
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4.4 Removing and installing swivel joint
op Vo
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AG. Volkswagen AG d
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Removing
Co
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Note Prote
cted AG.
agen
If the suspension link is deformed, the swivel joint must be re‐

newed together with the suspension link.

– Remove wheel.

AG. Volkswagen AG d
agen oes
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by
Vol not
gu Transporter 2016 ➤
d ara
orise Running
nte gear, axles, steering - Edition 02.2019
h eo
aut ra
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Vehicles swith left/right vehicle level sender
s
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mer
Caution
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n
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T10187- -2-.
yi Co
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– Pull suspension link off swivel joint. cted agen
Prote AG.
– Unscrew bolts -arrows- using socket - T10061- -1-.

– Remove swivel joint -2-.
Installing
Note
The lever of the vehicle level sender must point towards the out‐
side of the vehicle.
– Install wheel and tighten bolts or nuts ⇒ page 178 .

Specified torques
joint”, page 52
4.5 Renewing bonded rubber bush for lower

suspension link
⇒ “4.5.1 Renewing front bonded rubber bush for suspension link”,
page 57
⇒ “4.5.2 Renewing rear bonded rubber bush for suspension link”,
page 60
4.5.1 Renewing front bonded rubber bush for suspension link


equipment required
satelettronica
AG. Volkswagen AG d
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♦ Thrust plate - VW 401-

hole
spec

es, in part or in w
t to the co
♦ Press tool - VW 408 A-

♦ Thrust plate - VW 447 i-
rrectness of i
♦ Bolt from fitting tool - 10 - 203-

l purpos
♦ Tube - 3296-
nform
ercia
♦ Thrust piece from assembly tool - 3346-

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Prote AG.

Removing
Caution
♦ When bending up metal collar, do not damage suspension

link.
WARNING
♦ Wear safety goggles and protective gloves.
– To support the suspension link, use a sharp chisel to bend up

metal collar -1- in area -a-.
satelettronica
– Press out bonded rubber bush.
Installing
– Coat rubber bead of bonded rubber bush with tyre fitting paste.
lkswage es n
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un
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– Press bush -A- into suspension link -B- by hand as far as pos‐
ole,
sible.
spec
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
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pr
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ng
t.
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Cop py
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Prote AG.

– Press in bonded rubber bush -A- onto stop.
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– Press in bonded rubber bush further with bolt -A- from fitting
ss
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tool - 10 - 203- .
nl
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Note
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This causes the rubber bead to »pop« out of the suspension link.
hole
spec
es, in part or in w
satelettronica
t to the co
rrectness of i
l purpos
4.5.2 Renewing rear bonded rubber bush for suspension link

nf
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equipment required
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satelettronica
nf
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♦ Press tool - VW 409-
♦ Fitting tool - 2003/3-
♦ Thrust piece from assembly tool - 3346-
♦ Assembly tool - 3347-
♦ Thrust piece - 3416/1-

Removing
– Position listed tools as shown in diagram.
– Press out bonded rubber bush.
Installing
Note
Note the installation position before pressing in bonded rubber

bushes with »kidney-shaped« recess.
Installation position for left side

In the suspension link's installation position, the larger »kidney-
shaped« recess -A- must point to the centre of the vehicle.
The markings -arrows- must align.
satelettronica
AG. Volkswagen AG d
agen oes
olksw not
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d by ara
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or eo
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nl
Installation position for right side
pt
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In the suspension link's installation position, the larger »kidney-
erm
ab
shaped« recess -A- must point to the centre of the vehicle.
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The markings -arrows- must align.
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
– Position listed tools as shown in diagram.

nform
ercia
– Press in bonded rubber bush -A-.

m
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5 Wheel bearing
AG. Volkswagen AG d
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⇒ “5.1 Assembly overview - bwheel
yV
o bearing”, page 63 gu
ara
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⇒ “5.2 Removing and uinstalling
thor
wheel bearing housing”, eo
page 64 ss a ra
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⇒ “5.3 Removing and installing wheel bearing unit”, page 70
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5.1 Assembly overview - wheel bearing
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Note
ole,
spec
♦ Note allocation ⇒ Electronic parts catalogue (ETKA) .
t to the co
♦ Observe the different torque specifications for each of the two wheel bearing housing versions.
rrectne
♦ If a new wheel bearing housing is installed, a new track rod ball joint must always be installed as well.
ss o
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1 - Drive shaft
f inform
satelettronica
mer
2 - Wheel bearing housing
atio
m

o
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⇒ page 64
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If a new wheel bearing housing C py
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joint must always be installed
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agen
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3 - Bolt
❑ M12 × 1.50 × 85
(ETKA)
❑ Initial tightening torque:
25 Nm
❑ 75 Nm +180°
4 - Cover plate
5 - Bolt
❑ 10 Nm
6 - Wheel bearing
⇒ page 70
7 - Nut
❑ Loosening and tighten‐
ing ⇒ page 100
❑ Initially tighten to 200 Nm and then slacken off 180°
❑ Final torque setting: 200 Nm
8 - Wheel bearing housing
5. Wheel bearing 63
If a new wheel bearing housing is installed, a new track rod ball joint must always be installed as well.
9 - Nut
10 - Bolt
❑ M14 × 1.50 × 65
❑ 150 Nm +90°
5.2 Removing and installing wheel bearing

housing
♦ Spreader - 3424-
satelettronica
AG. Volkswagen AG d
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♦ Adapter - T10103/1- s
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♦ Bolts - T10103/2-
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AG. Volkswagen AG d
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Co
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When removing and installing drive shafts, do not allow them
p by
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to hang free and stop against joints due to over bending. cted agen
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Removing
5. Wheel bearing 65
Caution

AG. Volkswagen AG d
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Note auth eo
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If a new wheel bearing housing is installed, a new track rod ball

un
pt
joint must always be installed as well.
an
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work; Raising vehicle with lifting platform and trolley jack . spec
– Remove wheel.
t to the co
– Detach brake caliper and tie to body with wire ⇒ Brake system;
Rep. gr. 46 ; Front brakes; Assembly overview - front brakes .
rrectne
– Remove ABS speed sensor ⇒ Brake system; Rep. gr. 45 ;

Sensors; Removing and installing speed sensor on front axle
ss
-G45- / -G47- .
o
cial p
f inform
– Remove brake disc ⇒ Brake system; Rep. gr. 46 ; Front

mer
brakes; Assembly overview - front brakes

atio
om
– Detach bracket for brake line and electrical wiring from wheel
c
i
or
n thi
bearing housing and move clear.

te
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– Remove splash plate from wheel bearing housing.

p
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– Loosen nut -1- on track rod ball joint but do not remove com‐
t.
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Caution cted agen
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– Press track rod off wheel bearing housing using ball joint puller
- T10187- -2-.


Caution
satelettronica
T10187- -2-.
– Pull suspension link off swivel joint. G. Volkswage
gen A n AG d
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Before using press tool - T10520-
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5. Wheel bearing 67

Note

– Place engine and gearbox jack - V.A.G 1383 A- or engine and
gearbox jack - VAS 6931- under wheel bearing housing.
Clamped suspension strut
AG. Volkswagen AG d
agen oes
– Unscrew nut -1- from wheel bearingyhousing
Vol
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– Open wheel bearing housing -1- with spreader - 3424- at po‐ t to the co
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sition -A-.
ss o
Note
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Make sure that the spreader - 3424- is only inserted into the wheel bearing housing. Insert sufficiently to ensure
atio
m
that the metal tab of the suspension strut is not damaged.

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AG. Volkswagen AG d
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– Turn ratchet handle through 90° and detach from spreader -

3424- .
– Pull wheel bearing housing -1- in opposite
-direction of arrow B- downwards off shock absorber -2-.
5. Wheel bearing 69
AG. Volkswagen AG d
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Bolted suspension strut olksw not
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– Remove nuts -arrows- rise nte
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– Pull out bolts -2-. ss c
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– Pull wheel bearing housing from suspension strut.
du
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Note
hole
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es, in part or in w
If wheel bearing housing is renewed, swivel joint must be trans‐
t to the co
ferred. Always use new bolts.
rrectness of i
Installing l purpos
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Caution
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If a new wheel bearing housing is installed, a new track rod ball

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joint must always be installed as well.
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groove -arrow A- in wheel bearing housing. p by
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– If necessary, turn suspension strut further until this position is Prote AG.
reached.
– Insert wheel bearing housing far enough that suspension strut
sits on stop -arrow B- in wheel bearing housing.
Specified torques
♦ ⇒ “5.1 Assembly overview - wheel bearing”, page 63
joint”, page 52
♦ ⇒ “6.2 Assembly overview - drive shaft”, page 79
♦ Speed sensor bolt ⇒ Brake system; Rep. gr. 45 ; Sensors;
Assembly overview - speed sensor on front axle
♦ Bolts for splash plate, brake caliper, brake disc ⇒ Brake sys‐
tem; Rep. gr. 46 ; Front brakes; Assembly overview - front
brakes

unit
Note
The wheel bearings must always be renewed after removal.

WARNING
♦ Danger of accident through falling parts.

AG. Volkswagen AG d
agen
♦ Place engine and gearbox jack - V.A.G 1383 A- or engine w oes
olks not
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and gearbox jack - VAS 6931- below wheel bearingsehous‐
db ara
nte
ing throughout the entire process. tho
ri eo
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♦ Adapter - T10103/1-
erm
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♦ Bolts - T10103/2-
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♦ Assembly tool - T10205A-
5. Wheel bearing 71
♦ Ejector - T10520- AG. Volkswagen AG d

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♦ Hydraulic cylinder - VAS 6178- gh ht
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♦ Pressure gauge with connection line - VAS 6179/1-
♦ Pressure application device - V.A.G 1389/1-
AG. Volkswagen AG d
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satelettronica
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Removing tion in
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AG.

5. Wheel bearing 73

– Remove wheel.
– Remove brake caliper complete with brake carrier and com‐
ponent and secure to body ⇒ Brake system; Rep. gr. 46 ;
Front brake; Removing and installing brake caliper .
– Remove brake disc ⇒ Brake system; Rep. gr. 46 ; Front brake;
Removing and installing brake disc .
Sensors; Removing and installing speed sensor on front axle
-G45- / -G47- .
satelettronica
lkswage es n
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Caution
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– Press suspension link off swivel joint using ball joint puller - t to the co
T10187- -2-.
rrectness of i

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nf
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wheel bearing.
wheel hub using 4 wheel bolts -3-.

Note
satelettronica

– To stabilise the wheel bearing housing, insert swivel joint back
in wheel bearing housing, and tighten swivel joint nut hand-
tight.
Note
The illustration below shows the rear axle. This is not relevant for
describing the procedure.
wage
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– Centreorisgrip elements
e - T10205/12- »behind« wheelnte hub
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-1-
using
au wheel bolts-2-.
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Note
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Wheel bolts -2- must not protrude from backs of grip elements -
ot
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, is n
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hole
spec
– Place engine and gearbox jack - V.A.G 1383 A- or engine and

es, in part or in w
gearbox jack - VAS 6931- under wheel bearing housing.

t to the co
rrectness of i
l purpos
nform
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copy Vo
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Prote AG.
AG. Volkswagen AG d
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Transporter 2016 ➤ by
Vol not
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Running gear, axles, steering - Edition
orise 02.2019 nte
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– Tools as shown in illustration: ss
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1- Threaded rod M20 - T10205/8-1-
an
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2- Nut M20 - T10205/8-2-
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4- Hydraulic cylinder - VAS 6178- hole
spec
es, in part or in w
5- Bell - T10205/2-
t to the co
6- Grip elements - T10205/12-
rrectness of i
8- Nut M20 - T10205/8-2-
l purpos
9- Threaded rod M20 - T10205/8-1-
nform
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– Press wheel bearing unit with wheel bearing out of wheel
um
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bearing housing, holding the tools steady.

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When setting bell - T10205/2- -1- in place, ensure that the wheel
bolts -arrows- are in the positions shown.
Installing
Note
Note
♦ The illustration below shows the rear axle. This is not relevant
for describing the procedure.
♦ Wheel bolts -2- must not protrude from rear of wheel bearing
unit -1-.
♦ The grip elements - T10205/11- should prevent the retaining
ring from slipping down the wheel bearing during the pressing
in sequence
– Centre grip elements - T10205/11- »behind« new wheel bear‐

ing unit -1- using wheel bolts -2-.

Note
The guide - T10205/15- must always be installed with the recess

facing towards the wheel bearing.
– Fit wheel bearing unit and wheel bearing together with the
tools on the wheel housing as shown in illustration.
1 - Threaded rod M20 - T10205/8-1-
2 - Nut M20 - T10205/8-2-
3 - Thrust head - T10205/13-
4 - Hydraulic cylinder - VAS 6178-
5 - Bell - T10205/2-
6 - Grip elements - T10205/11-
7 - Threaded rod M20 - T10205/8-1-
8 - Nut M20 - T10205/8-2-
9 - Guide - T10205/15-
satelettronica
– Connect pressure gauge with connection line - VAS 6179/1-
between hydraulic cylinder - VAS 6178- and hydraulic line of
pressure application device - V.A.G 1389/1- .
The pressures described below apply to the hydraulic press -
VAS 6178- only.
When pressing in, the pressure reading taken nshortly
AG. Volkbefore the
swagen AG do
end of pressing must be between 90 and l wagebar.
ks140 es n
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The maximum pressure must not
or
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e 310 bar. nte
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– Press in wheel bearing until
ss circlip engages audibly.
a c
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nl
Ensure the wheel bearing does not cant when pressing in.
pt
du
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itte
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– Install drive shaft ⇒ page 78 .

erm
ab
ility
ot p
– Install ABS speed sensor ⇒ Brake system; Rep. gr. 45 ; Sen‐

wit
, is n
sors; Removing and installing speed sensor on front axle -

h re
G45- / -G47- .
hole
spec
es, in part or in w
– Fit brake disc ⇒ Brake system; Rep. gr. 46 ; Front brake;

t to the co

– Install brake caliper complete with brake carrier ⇒ Brake sys‐
rrectness of i
tem; Rep. gr. 46 ; Front brake; Removing and installing brake

caliper .
l purpos
– Install wheel and tighten.

nform
ercia
Specified torques
m
♦ ⇒ “6 Drive shaft”, page 78

at
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ion
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5. Wheel bearing 77
6 Drive shaft
⇒ “6.1 Overview - drive shaft”, page 78
⇒ “6.2 Assembly overview - drive shaft”, page 79
⇒ “6.3 Removing and installing drive shaft”, page 84
⇒ “6.4 Loosening and tightening threaded connections of drive
shaft”, page 100
⇒ “6.5 Dismantling and assembling drive shaft”, page 101
⇒ “6.6 Checking outer constant velocity joint”, page 118
⇒ “6.7 Checking inner constant velocity joint”, page 119
⇒ “6.8 Removing and installing jointed shaft support bearing”,
page 120
6.1 Overview - drive shaft
1-
⇒ “6.2.1 Assembly overview -
satelettronica
drive shaft, constant velocity
joint VL3700LP”, page 79
2-
⇒ “6.2.2 Assembly overview - wage
es n
drive shaft, constant velocity y Volks ot g
ua
joint VL4700”, page 81 ise d b ran
r tee
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3- au
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⇒ “6.2.3 Assembly overview -
ce
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drive shafts, triple roller joint

nl
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an
AAR 3700i”, page 83

itte
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Cop py
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6.2 Assembly overview - drive shaft

⇒ “6.2.1 Assembly overview - drive shaft, constant velocity joint
VL3700LP”, page 79
⇒ “6.2.2 Assembly overview - drive shaft, constant velocity joint
VL4700”, page 81
⇒ “6.2.3 Assembly overview - drive shafts, triple roller joint AAR
3700i”, page 83
6.2.1 Assembly overview - drive shaft, constant velocity joint VL3700LP

5-speed manual gearbox
1 - Outer constant velocity joint

❑ Renew only as com‐
plete unit
⇒ page 101 n AG. Volkswagen AG do
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❑ Procedure for vehicles ed
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with bonded drive or shaft:
is tee
satelettronica
h
clean and degreaseaut or
ac
splines and apply lock‐
ss
ce
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ing fluid to splines ⇒

un
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Electronic Parts Cata‐
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logue “ETKA”
rm
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2 - Twelve-point nut
ot
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hole
spec
es, in part or in w
ing ⇒ page 100

t to the co
❑ Initially tighten to
200 Nm and then slack‐
en off 180°
rrectness of i
❑ Final torque setting:

l purpos
200 Nm
3 - Retaining ring
nform
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m
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❑ Insert in groove in shaft

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4 - Clip
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❑ 25 Nm
en
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5 - Boot
C py
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❑ Removing and installing p by
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lksw
⇒ page 101
by
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Prote AG.
❑ For outer constant ve‐
locity joint.
❑ Check for splits and
chafing
6 - Clip
7 - Drive shafts
❑ Removing and installing drive shafts ⇒ page 84
8 - Boot
❑ Before installing, apply sealant to sealing surface ⇒ Electronic Parts Catalogue “ETKA” .
6. Drive shaft 79
❑ For left inner constant velocity joint.
❑ Check for splits and chafing
❑ Drive off constant velocity joint with a drift
❑ Removing and installing ge⇒ G. Volk101
n Apage swagen AG
does
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9 - Inner constant velocity
db joint ara
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❑ For left drive
ut
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❑ Renews only as complete unit
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10 - Retaining ring
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❑ Remove and install using circlip pliers - VW 161 A- .
h re
hole
spec
11 - Protective cap
es, in part or in w
t to the co
❑ Drive off constant velocity joint with a drift
❑ Before installing, apply sealant - D 454 300 A2- to sealing surface
rrectness of i
12 - Multi-point socket head bolt
l purpos
❑ 50 Nm +90°
satelettronica
nf
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❑ For left drive shaft
orm
m
13 - Locking plate
atio
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14 - Boot
sd
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❑ Before installing, apply sealant to sealing surface ⇒ Electronic Parts Catalogue “ETKA” .
o
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❑ For right inner constant velocity joint.

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❑ Drive off constant velocity joint with a drift cop Vo
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15 - Retaining ring
16 - Inner constant velocity joint
❑ Renew only as complete unit
❑ For right drive shaft
17 - Bolt
❑ 20 Nm +90°
18 - Support ring
19 - Protective cap

6.2.2 Assembly overview - drive shaft, constant velocity joint VL4700

6-speed manual gearbox

plete unit
⇒ page 106
❑ Procedure for vehicles
with bonded drive shaft:
clean and degrease
splines and apply lock‐
ing fluid to splines ⇒
Electronic Parts Cata‐
logue “ETKA”
AG. Volkswagen AG d
2 - Twelve-point nut lksw
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❑ Renew after removal ed by ara
nte
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❑ Loosening and tighten‐ ut
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satelettronica
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en off 180°
erm
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200 Nm
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3 - Retaining ring
spec
es, in part or in w
t to the co
4 - Clip
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l purpos
❑ 25 Nm
5 - Boot
nf
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or
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m
atio
locity joint.
om
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c

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chafing
t
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⇒ page 106
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6 - Clip
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❑ Renew after removal p by
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❑ 25 Nm
agen
Prote AG.
7 - Drive shafts
8 - Clip
❑ 25 Nm
9 - Boot
10 - Clip
6. Drive shaft 81
❑ 25 Nm
11 - Retaining ring
13 - Bolt
❑ 20 Nm +90°
14 - Support ring
15 - Protective cap
satelettronica
❑ Also for right drive shaft on vehicles with all-wheel drive
AG. Volkswagen AG d
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Rep. gr.40 - Front suspension
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6.2.3 Assembly overview - drive shafts, triple roller joint AAR 3700i
7-speed dual clutch gearbox n AG. Volkswagen AG do
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1 - Outer constant velocity jointutho
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❑ Renew only as com‐ ss
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nl
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⇒ page 108
ab
ility
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❑ For vehicles with bon‐
wit
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ded drive shaft, clean
h re
and degrease splines
hole
spec
and apply locking fluid to
es, in part or in w
splines ⇒ Electronic
t to the co
Parts Catalogue “ETKA”
rrectness of i
l purpos

ing ⇒ page 100
nf
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satelettronica
or
m
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om
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200 Nm
t
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4 - Clip
c by lksw
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Prote AG.
❑ 25 Nm
❑ Tightening hose clip
⇒ page 111
5 - Boot
locity joint.
chafing
6 - Clip
❑ 25 Nm
7 - Drive shafts
8 - Clip
❑ 25 Nm
9 - Inner joint boot
10 - Clip
6. Drive shaft 83
Running gear, axles, steering - Edition 02.2019 AG. Volkswagen AG d
agen oes
olksw not
❑ 25 Nm d by V gu
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11 - Triple roller star with rollers autho eo
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❑ Removing and installing ⇒ page 108 s
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12 - Retaining ring
an
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13 - Triple roller shaft
wit
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14 - Support ring
rrectness of i
❑ Removing and installing ⇒ page 120 l purpos
15 - O-ring
nform
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16 - Inner triple roller joint

m
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tion in
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❑ For right drive shaft on vehicles with all-wheel drive
s
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❑ Dismantling and assembling triple roller joint AAR 3700i/SX for drive shaft ⇒ page 108 .
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17 - Bolt
Co
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❑ Bearing securing bolt for right drive shaft opyri
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❑ 20 Nm +90°
6.3 Removing and installing drive shaft

⇒ “6.3.1 Removing and installing drive shaft, constant velocity
⇒ “6.3.2 Removing and installing drive shaft, constant velocity
joint VL4700”, page 89
⇒ “6.3.3 Removing and installing drive shaft, triple roller joint AAR
3700i”, page 95
6.3.1 Removing and installing drive shaft,

constant velocity joint VL3700LP
♦ Adapter - T10103/1-
♦ Bolts - T10103/2-

AG. Volkswagen AG d
agen oes
olksw not
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♦ Locking fluid ⇒ Electronic Parts Catalogue “ETKA”

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♦ Grease ⇒ Electronic Parts Catalogue “ETKA”

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6. Drive shaft 85
Caution

AG. Volkswagen AG d
♦ Install an outer joint instead of the drive shaft. olksw
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♦ Tighten outer joint to 120 Nm. rised ara
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– Remove wheel.
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– Unclip both lines from retainer on suspension strut and lay
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rrectness of i
Removing left drive shaft:
l purpos
– Unbolt drive shaft from gearbox flange.

Removing right drive shaft:
nform
ercia
– Unscrew support bearing ⇒ Item 18 (page 80) .

m
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Continued procedure for both sides:
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Caution
T10187- -2-.
inserted.
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6. Drive shaft 87

Note
the spindle must be moved to its original position in order. Vto apply
olkswagen AG
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spec
satelettronica
Removing right drive shaft:
t to the co
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rrectne
– Remove drive shafts.
ss o
Installing
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Installing left drive shaft:
mer
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– Bolt inner joint of drive shaft on gearbox flange

t
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⇒ Item 12 (page 80) .

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Installing right drive shaft:

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Cop py
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Prote AG.
– Grease area between -A- and -B- »copiously« with lubricating

grease ⇒ Electronics Parts Catalogue “ETKA” .
– Place stub shaft on greased splines of final drive.
– Tighten support bearing ⇒ Item 18 (page 80) .
Continued procedure for both sides of vehicle with »bonded«
drive shafts:

– Completely remove residual locking fluid from splines of drive

shaft -arrow A- and from contact surface/gap -arrow B- of
wheel hub. AG. Volkswagen n AG do
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around« area on drive shaft with splines. rised ran
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and fit electrical connectors.
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es, in part or in w
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– Install front wheels.
rrectness of i
Note
l purpos
Tighten twelve-point nut immediately after installing drive shaft so

that locking fluid does not harden first.
satelettronica
nform
mercia
at
Continued procedure for both sides of vehicle with »unbonded«
om
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drive shafts:
c
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– Fit drive shaft into wheel bearing.

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Specified torques
♦ ⇒ “6.2.1 Assembly overview - drive shaft, constant velocity

constant velocity joint VL4700
♦ Adapter - T10103/1-
6. Drive shaft 89
♦ Bolts - T10103/2-
satelettronica
AG. Volkswagen AG d
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Cop py
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Caution


satelettronica
Removing left drive shaft: agen
AG. Volkswagen AG d
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– Lever off inner joint of drive shaft from gearbox with a dtyre
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Note
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Do not damage protective cap on inner constant velocity joint.
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Removing right drive shaft »only vehicles without all-wheel drive«:
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6. Drive shaft 91
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inserted.
rrectness of i
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wheel bearing.


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At the end of the procedure or for pressing outut drive shaft further,
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sensor.
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aside.
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– Pull wheel bearing housing outwards and wedge between
form
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mer
atio
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Removing right drive shaft »only vehicles with all-wheel drive«:

o
n
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or
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– Pull off right drive shaft from gearbox.
te
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Cop py
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– Remove drive shaft. Prote
cted AG.
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Installing
Note
Before installing drive shafts, ensure that the O-rings on both

sides of the gearbox splines are not damaged. Renew them if
necessary.
Installing left drive shaft:
– Renew »old« circlip -B- with a »new one« -A-.
6. Drive shaft 93

– Place drive shaft on splines of final drive.
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– With a hefty »jolt«, by V push drive shaft as far as possible
o lk not
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♦ Ensure that the inner joint has been driven onto the stub shaft
erm
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ility
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♦ The retaining ring must be »felt« to engage.
h re
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Installing right drive shaft »vehicles without all-wheel drive only«:
es, in part or in w
t to the co

rrectness of i

l purpos

– Tighten support bearing ⇒ Item 18 (page 80) .
nf
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or
Continued procedure for both sides of vehicle with »bonded«

m
m
atio
drive shafts:
om
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or c
thi
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Cop py
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rig ht
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by lksw
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Prote AG.

– Completely remove residual locking fluid from splines of drive

shaft -arrow A- and from contact surface/gap -arrow B- of
wheel hub.
– Apply locking fluid ⇒ Electronic Parts Catalogue “ETKA” »all
around« area on drive shaft with splines.
link.
Note
Tighten twelve-point nut immediately after installing drive shaft so

that locking fluid does not harden first.
satelettronica
Continued procedure for both sides of vehicle with »unbonded«
drive shafts:
link.
– Tighten twelve-point nut ⇒ page 100 . agen
AG. Volkswagen AG d
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– Install front wheels. ed b ara
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Specified torques aut
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6.3.3 Removing and installing drive shaft, tri‐

es, in part or in w
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ple roller joint AAR 3700i

rrectness of i
♦ Adapter - T10103/1-
l purpos
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6. Drive shaft 95
♦ Bolts - T10103/2- AG. Volkswagen AG d

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atio
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om
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t.
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Cop py
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Procedure for both sides:

Caution
Wheel bearings must not be subjected nAtoGload

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If wheel bearings are loaded
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level sender - G289- -2- out of suspension link -3-. cted agen
Prote AG.
Caution
T10187- -2-.
6. Drive shaft 97
inserted.
satelettronica
wheel bearing.
AG. Volkswagen AG d
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Note
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Note
m
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tion in

r
te o
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t.
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Cop py
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by
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Prote AG.

– Pull wheel bearing housing outwards and place between body

and suspension strut using a suitable block of wood.
– Push drive shaft in direction of -arrow B- and pull outer joint of
drive shaft out of wheel bearing housing.
– Pull out right drive shaft from gearbox splines and remove
complete drive shaft.
Continued procedure for left side:
– Press off triple roller joint of drive shaft from gearbox housing
using wedge - T10161- .
– Remove drive shaft from gearbox splines and pull out com‐
plete drive shaft.
AG. Volkswagen AG d
Note lksw
agen oes
not
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♦ When removing drive shafts, make sure that orisethe triple roller nte
eo
spider with rollers is not pulled out of the a triple roller joint.
th
satelettronica
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ss c
♦ If triple roller star with rollers has slipped out, joint protective
ce
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pt
boot must be opened and triple roller star with rollers must be
an
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re-inserted in triple roller joint.
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Installing
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Procedure for both sides:
t to the co
Note
rrectness of i
l purpos
Before installing the drive shafts, ensure that the O-rings on both
sides of the gearbox splines are not damaged. Renew them if
necessary.
nform
mercia
Installing left drive shaft: a

com
tion in
– Replace old retaining ring of drive shaft with a new one.

r
te o
thi
s
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Note
en
ng
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op py
Insert »new« retaining ring directly into groove of drive shaft. It is
t. C rig
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not permitted for retaining ring to be pushed over splines. This will p by
co Vo
overstretch retaining ring and render it unusable.
by lksw
cted agen
Prote AG.
– Grease final drive on gearbox »copiously« with lubricating

grease ⇒ Electronic Parts Catalogue “ETKA” .
– Place drive shaft in splines of final drive.
6. Drive shaft 99
– With a hefty »jolt«, push drive shaft as far as possible in di‐

rection -B- of gearbox.
Note
♦ Make sure that the inner joint is inserted as far as it will go.
♦ The retaining ring must be »felt« to engage.
Installing right drive shaft »vehicles without all-wheel drive only«:

– Grease final drive on gearbox »copiously« with lubricating
grease ⇒ Electronic Parts Catalogue “ETKA” .
– Tighten support bearing. n AG. Volkswagen AG do
lkswage es n
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Continued procedure for both sides: ir se
d b ua
ran
o tee
h
– Fit drive shaft into wheel bearing. aut or
ac
ss
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e
nl
pt
du
an
itte
satelettronica
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erm
ab
link.
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, is n
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es, in part or in w
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Specified torques
rrectness of i
♦ ⇒ “6.2.3 Assembly overview - drive shafts, triple roller joint
l purpos

nf
ercia
o
rm
m
atio
om
n in
c
6.4 Loosening and tightening threaded con‐

or
thi
te
nections of drive shaft

sd
iva
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f

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ng
t.
yi Co
op
♦ Torque angle wrench - V.A.G 1756 A-
C py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

Caution

Loosen twelve point nut.

– With vehicle still standing on its wheels, loosen the twelve-
point nut a maximum of 90°, as the wheel bearing will other‐
satelettronica
wise be damaged.
– Raise vehicle so that wheels are off the ground.
– Have second mechanic apply brakes.
– Unscrew twelve-point nut -1- from drive shaft.
Screwing on twelve-point nut
– Replace hexagonal nut. agen
AG. Volkswagen AG d
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Note utho eo
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It must be ensured that the wheels do not yet touch the floor when
le
un
pt
the drive shaft is being tightened. Otherwise the wheel bearing

an
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may be damaged.
rm
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pe
ility
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, is n
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hole
– Tighten twelve-point nut to 200 Nm.

spec
es, in part or in w
– Loosen twelve-point nut 180°.

t to the co

rrectness of i
6.5 Dismantling and assembling drive shaft

l purpos
⇒ “6.5.1 Dismantling and assembling drive shaft, constant veloc‐

ity joint VL3700LP”, page 101
nform
ercia
⇒ “6.5.2 Dismantling and assembling drive shaft, constant veloc‐

m
a
com
ity joint VL4700”, page 106

ion in
r
te o
⇒ “6.5.3 Dismantling and assembling drive shaft, triple roller joint

thi
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iva

do
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rp
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fo
6.5.1 Dismantling and assembling drive shaft,

en
ng
t.
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constant velocity joint VL3700LP Cop py
t. rig
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Remove outer constant velocity joint of drive shafts: cop Vo
by lksw
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– Remove drive shaft ⇒ page 84 .
6. Drive shaft 101

lkswage es n
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Transporter 2016 ➤ ir se
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Running gear, axles, steering - Editionau02.2019
th or
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– Detach clamps of boot -1- and pull back boot on drive shaft
un
pt
an
-4-.
d
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erm
ab
– Remove remains of grease using a clean cloth.
ility
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is n
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ole,
spec
t to the co
rrectness o
cial p
f
– Drive off outer constant velocity joint -3- from drive shaft -4-
inform
using a plastic hammer -2-.
mer
atio
om
n
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or
n
Note
thi
te
sd
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r
♦ The outer constant velocity joint is secured to the drive shaft

p
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with a circlip -2-.
en
ng
t.
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satelettronica
op
♦ Always renew circlip -2- after removing.
C py
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Install outer constant velocity joint of drive shafts: Prote
cted AG.
agen
– Push boot -3- onto drive shaft -1-.

– Insert circlip -2-.
– Drive clean outer constant velocity joint -4- onto drive shaft
-1- using a plastic hammer until circlip -2- engages.
– Inject 70 grammes of lubricating grease ⇒ Electronic Parts
Catalogue “ETKA” into outer constant velocity joint through
ball tracks.
– Fill boot of joint with 70 grammes of lubricating grease ⇒
Electronic Parts Catalogue “ETKA” .
– Install boot for joint.
Tightening large clip on outer constant velocity joint:

– Position clamp tensioner - V.A.G 1682- as shown in illustra‐
tion. Ensure edges of tool lie in corners of ear -B- on clip.
– Tension clamp by turning spindle -A- with a torque wrench -
V.A.G 1331- -C-.

Tightening small clip on outer constant velocity joint:

V.A.G 1331- -C-.
Note
♦ Due to the hard material of the joint boot and, consequently,

to the use of a stainless steel clamp, it is possible to tension
the clamps only with clamp tensioner - V.A.G 1682- .
♦ The clamp tensioner - V.A.G 1682- must not be twisted or
canted as it is tightened.
Removing inner constant velocity joint of left drive shaft:

– Clamp drive shaft in vice with protective jaw covers.
– Drive off outer protective cap using e.g. a brass drift or copper
satelettronica
drift.
Note
The outer protective cap for the inner constant velocity

gen AG
. Volkswjoint
agen Amust
G do
be renewed each time it is removed.Volkswa es n
ot
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tho eo
– Remove retaining ring ⇒s auItem 10 (page 80) . ra
c
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– Detach clamps of boot and push back boot on drive shaft.

un
pt
an
d
itte
– Remove grease using a clean cloth.

y li
erm
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ility
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ole,
spec
t to the co
rrectness o
cial p
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mer
atio
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c
i
or
n thi
te
sd
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pr
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fo
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ng
t.
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Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
6. Drive shaft 103


– Press drive shaft downwards off inner constant velocity joint.
Installing inner constant velocity joint of left drive shaft:
– Push joint boot onto drive shaft.
– Position tools as shown in figure.
satelettronica
– Press inner constant velocity joint on drive shaft as far as it will
go.
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
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un
pt
an
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ab
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t to the co
rrectne
– Install »new« circlip.

– Check that circlip is seated correctly.
ss o
cial p

in

form
mer
atio

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c
i
or
Tension clamps on inner constant velocity joint:

thi
te
sd
va

i
o
pr
cum
r

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


V.A.G 1331- -C-. Tightening torque is 25 Nm.
Note

– Inject 60 grammes of lubricating grease ⇒ Electronic parts

catalogue “ETKA” into inner constant velocity joint through ball
track.
– Clean contact surfaces of inner constant velocity joint for as‐
sembly of protective cap.
– Apply sealant ⇒ Electronic Parts Catalogue “ETKA” to contact

surface -shaded area- of new protective cap as shown
-arrow-.
satelettronica
Note
♦ Apply sealant bead measuring 2 - 3 mm in one line (without

gaps).
♦ The cap must be positioned very precisely.
. Volkswagen AG
gen AG d
– Align protective cap precisely to bolt
Vol
kholes
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position as it cannot be turnedeafter
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– Drive protective cap onto adrive
ut
h shaft without damaging it using ra
a plastic hammer. ss c
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e
nl
pt
– Remove any sealant that has escaped.

du
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itte
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erm

ab
ility
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Removing inner constant velocity joint of right drive shaft:

wit
, is n
h re

hole
spec
es, in part or in w

t to the co
– Detach clamps of boot and pull back boot on drive shaft.

rrectness of i
l purpos
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6. Drive shaft 105


– Using circlip pliers - VW 161A- , spread circlip -1- as far as stop
-2-, and hold circlip in this position.
– Detach inner constant velocity joint -4- from drive shaft -3-.
Installing inner constant velocity joint of right drive shaft:
– Install in reverse order of removal. During this procedure, ob‐
serve the following:
Inject 60 grammes of lubricating grease ⇒ Electronic parts cata‐
logue “ETKA” into inner constant velocity joint through ball tracks.
Fill boot of joint with 60 grammes of lubricating grease ⇒ Elec‐
tronic Parts Catalogue “ETKA” .
Specified torques
satelettronica
constant velocity joint VL4700
Remove outer constant velocity joint of drive shafts:
– Detach clamps of boot -1- and push back boot on drive shaft
-4-.
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ball tracks.

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– Detach clamps of boot and pull back boot on drive shaft. cted agen
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6. Drive shaft 107


– Using circlip pliers - VW 161A- , spread circlip -1- as far as stop
-2-, and hold circlip in this position.
– Detach inner constant velocity joint -4- from drive shaft -3-.
Installing inner constant velocity joint of right drive shaft:
agen
AG. Volkswagen AG d
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Install in the reverse order of removal, observing
ed
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V ua
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tho Electronic parts cata‐ or
ac
logue “ETKA” into inner constant velocity
s joint through ball tracks.
s
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Fill boot of joint with 135 grammes of lubricating grease ⇒ Elec‐
pt
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Specified torques
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triple roller joint AAR 3700i
ss o
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Removing outer CV joint ⇒ page 108
nform
mer
Removing triple roller joint ⇒ page 111
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Removing outer CV joint
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equipment required
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6. Drive shaft 109

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♦ Snap ring pliers - VW 161 A-

♦ Clamp tensioner - V.A.G 1682-
– Detach clamps of boot -1- and push back boot on drive shaft
-4-.

using a plastic hammer -2-. AG. Volkswagen n AG do
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Installing outer CV joint
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ball tracks.
satelettronica
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V.A.G 1331- .

V.A.G 1331- -C-.
Note

Removing triple roller joint
6. Drive shaft 111

♦ Assembly tool - T10065/7-
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♦ Clamp tensioner - V.A.G 1682-
AG. Volkswagen AG d
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6. Drive shaft 113

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Removing
– Clamp drive shaft in vice.
– Open clamps -1-.
– Push back drive shaft boot -2-.
AG. Volkswagen AG d
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– Pull off joint -3-. olksw not
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6. Drive shaft 115

– Insert drive shaft into assembly tool - T10065- .

1 - Press tool - VW 408 A-
2 - Pressure plate - VW 402-
3 - Assembly tool - T10065/1-
– Press drive shaft out of triple roller spider -6-.
– Pull boot off shaft.
– Clean shaft, joint body and groove for seal.
Vehicles with 7-speed dual clutch gearbox
1 - Press tool - VW 408 A-
satelettronica
– Press drive shaft out of triple aroller
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– Push smaller clamp for boot onto shaft.

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– Push boot onto shaft.

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– Push triple roller spider onto shaft.

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• Chamfer on triple roller star faces towards shaft and serves as

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an assembly aid.
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AG. Volkswagen AG d
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olksw not
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– Insert drive
ris shaft into assembly tool - T10065- . ntee
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2- Pressure
ss
au plate - VW 402- ac
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6 - Tube - VW 416 B-
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7 - Thrust pad - VW 447 H-
es, in part or in w
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8 - Press tool - VW 411-
– Coat splines of drive shaft and triple roller spider -1- with lu‐
rrectness of i
bricating paste.
l purpos
– Fit triple roller spider -1- on shaft as far as splines.

• Chamfer on triple roller star faces towards shaft and serves as
nf
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an assembly aid.
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– Press on triple roller spider -1- as far as stop.
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Vehicles with 7-speed dual clutch gearbox

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6 - Tube - VW 416 B-
7 - Thrust pad - VW 447 H-
8 - Press tool - VW 411-
– Coat splines of drive shaft and triple roller spider -1- with lu‐
bricating paste.
– Fit triple roller spider -1- on drive shaft until splines engage
precisely.
– Press on triple roller spider -1- as far as stop.
– Using circlip pliers - VW 161 A- -1-, install circlip -2-.

– Press 80 gm of lubricating grease into triple roller joint ⇒ Elec‐
tronic parts catalogue “ETKA” .
– Slide joint body over rollers and hold.
– Press 80 gm of lubricating grease into back of triple roller joint
⇒ Electronic parts catalogue “ETKA” .
6. Drive shaft 117

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Transporter 2016 ➤ ir se
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Running gear, axles, steering -auEdition 02.2019
th or
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– Position boot in groove -1-.
nl
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– Push both clamps onto drive shaft boot and mount as follows:
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– Position clamp tensioner - V.A.G 1682- -1- as shown in illus‐
nform
ercia
tration. Ensure when doing this that teeth of tensioner are in

corners -2- of clamp -3-.
m
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– Tension clamps by turning spindle -4- with torque wrench -
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6.6 Checking outer constant velocity joint

The joint is to be dismantled to renew the grease if it is heavily
soiled, or to check the contact 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.
– Turn cage until the two rectangular windows -arrow- lie on joint
body.
– Take out cage with hub.

– Swing segment of hub into square cage window.

– Tip hub out of cage.
Volkswa
The 6 balls for each joint belong swa
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axle, hub, cage and balls by Volkfor small indentations (pitting)
not
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traces of seizing. rExcessive
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utho load change jolts. In this case the joint mustor
be replaced.ssSmoothing and traces of wear of the balls are no ac
a
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Installing
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– Pack half of total grease quantity (40 g) into joint body.
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– Fit cage with hub into joint body.
h re
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– Press in opposing balls one after the other; the original position
of the hub relative to the cage and joint body must be restored.
t to the co
– Fit new retaining ring into hub.
– Distribute remaining grease in boot.
rrectne
6.7 Checking inner constant velocity joint
ss o
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Removing
form
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The joint is to be dismantled when following work is done:
atio
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♦ Replacement of grease if very contaminated
i
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♦ Check of contact surface for wear

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– Press out joint body in direction of arrow. cop Vo
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– Press balls out of cage.
AG.
Note
The ball hub and joint body are paired. Do not interchange them.
– Tip ball hub out of ball cage via ball track -arrows-.
– Check joint body, ball hub, ball cage and balls for pitting and
traces of seizing.
Excessive circumferential backlash in the joint is noticeable dur‐
ing load change jolts. In this case the joint must be replaced.
Smoothing and traces of wear of the balls are no reason to renew
the joint.
Installing
6. Drive shaft 119

– Insert hub into cage via the two chamfers. The hub can be
installed in any position. Press balls into cage.
The ball hub has two different distances between the ball tracks:
a smaller one and a larger one.
– Insert hub with cage and balls at a right angle to joint body.
When inserting, ensure that the wide spacing -a- on the joint body
is aligned with the narrow spacing -b- on the hub after it is swung
in.
Chamfer on internal diameter of ball hub (splines) must face large
diameter of joint body.
– Also take note of chamfer on interior diameter of ball hub. It
must be visible after swivelling in.
satelettronica
– Swivel the hub into the joint body; at the same time the hub
must be swivelled out of the cage -arrows- far enough to allow
the balls to fit into the ball tracks.
AG. Volkswagen AG d
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– Swivel in hub with balls by applying firm pressure to cage

-arrow-.
nf
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Checking function of constant velocity joint

rm
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atio
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The constant velocity joint is correctly assembled if the ball hub

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can be moved by hand backwards and forwards over its entire

or
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range of axial movement.

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6.8 Removing and installing jointed shaft support bearing


equipment required
satelettronica
AG. Volkswagen AG d
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♦ Thrust plate - VW 401- rrectness of i
♦ Support - 40 - 103-
l purpos
♦ Support - VW 441-
nform
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♦ Thrust piece - VW 442-

m
at
♦ Splitter KUKKO 17-2 - VAS 251411-

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Pressing off support bearing:

o
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ate
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– Remove right drive shaft ⇒ page 78 .

p
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– Separate drive shaft at inner constant velocity joint

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⇒ page 78 . Cop py
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6. Drive shaft 121

– Pull protective cover -1- from drive shaft -2- in

-direction of arrow-, if present.
AG. Volkswagen AG d
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– Fit splitter KUKKO 17-2 - VAS 251411- between inner con‐
t to the co
stant velocity joint and support bearing -2-.
– Fit thrust plate - VW 401- -5- and thrust plate - VW 402- -4-
onto press as shown in illustration.
rrectness of i
– Fit drive shaft -2- on thrust plates with splitter KUKKO 17-2 -
l purpos
VAS 251411- -6-.

– Set thrust piece - VW 442- -1- on upper end of drive shaft
nform
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satelettronica
-2-.
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Note
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Hold drive shaft at inner joint from below because this can other‐
um
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wise fall to the ground.

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Cop py
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– Press drive shaft -2- downwards out of support bearing -3-.
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– Remove drive shaft from below.
agen
Prote AG.
Pressing on support bearing:
– Set thrust plate - VW 401- and thrust plate - VW 402- as shown

on the press.
– Push support bearing -2- onto drive shaft.
Note
Observe installation position of support bearing. Push support

bearing onto drive shaft as shown in figure.
– Push support - 40 - 103- onto drive shaft.

– Set drive shaft wit support bearing -2- and support - 40 - 103-
onto press plates.
– Set support - VW 441- on inner constant velocity joint -1-.
– Press drive shaft downwards onto support bearing -2- to stop.
– Remove drive shaft from press and check that support bearing
moves freely.
– Press protective cover onto drive shaft, if one was removed.
– Assembling drive shaft ⇒ page 78 .

42 – Rear suspensionby Volkswagen A

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1 Rear axle t eo
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⇒ “1.1 Overview - rear axle”, page 123
nl
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1.1 Overview - rear axle
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⇒ “2.1 Assembly overview - an‐
spec
ti-roll bar”, page 124
es, in part or in w
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II -
transverse link”, page 130
rrectness of i
III -
l purpos

suspension strut, shock ab‐
nform
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sorber, spring”, page 139

m
satelettronica
IV -
at
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wheel bearing”, page 144

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1. Rear axle 123

2 Anti-roll bar
⇒ “2.1 Assembly overview - anti-roll bar”, page 124
⇒ “2.2 Removing and installing anti-roll bar”, page 124
⇒ “2.3 Renewing anti-roll bar bushes”, page 126
2.1 Assembly overview

wage
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G.anti-roll bar
Volkswagen AG do
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1 - Suspension link thori eo
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2 - Bolt ss
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pt
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3 - Clip
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4 - Mountings
wit
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❑ Inner for anti-roll bar
ole,
spec
⇒ page 128
t to the co
satelettronica
5 - Anti-roll bar
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⇒ page 124
s
6 - Bolt
s o
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❑ 30 Nm
inform
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7 - Clip
atio
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8 - Mountings
o
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❑ Outer for anti-roll bar

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⇒ page 126
fo
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9 - Mounting bracket Cop py
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10 - Bolt p by
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❑ 30 Nm
agen
Prote AG.
2.2 Removing and installing anti-roll bar

124 Rep. gr.42 - Rear suspension

♦ tensioning straps - T10038-
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2. Anti-roll bar 125

Removing
Caution

Tighten threaded connections on components with bonded
rubber bushes only if the vehicle is standing on its wheels and
is unladen or if the vehicle is raised and is in the unladen po‐
sition (normal position) ⇒ page 6 .

– Remove rear wheels.
– Unscrew bolts -arrows- on both sides.
– Remove clamp -1-.
satelettronica
AG. Volkswagen AG d
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– Remove anti-roll bar -2-.

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Installing
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Specified torques
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♦ ⇒ “2.1 Assembly overview - anti-roll bar”, page 124

cial p
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2.3 Renewing anti-roll bar bushes

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⇒ “2.3.1 Renewing anti-roll bar bushes, outer”, page 126

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Special tools and workshop equipment required Prote AG.

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Removing d byV ua
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– Raise vehicle ⇒ Maintenance ; Booklet 20.1 uth ; Description of
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– Turn anti-roll bar downwards.
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– Pull off bush -1- in direction of -arrow- from anti-roll bar -2-.
nform
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Installing
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Install in reverse order. During this procedure, observe the fol‐
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– Coat bush -1- on inside with soap solution and push onto anti-
roll bar -2-.
– Push on bush, ensuring that gap -a- is adhered to.
a = 6 ± 2 mm
Note
The flat side of the bush must point towards the suspension link.

– Turn anti-roll bar upwards and fit clamp -1-.

– Tighten bolts -arrows- on both sides.
Specified torques
2.3.2 Renewing anti-roll bar bushes, inner

satelettronica
AG. Volkswagen AG d
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Removing d by V o gu
ara
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– Raise vehicle ⇒ Maintenance
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work; Raising vehicle
ss a with lifting platform and trolley jack . c
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– Open bush -1- in direction of -arrows- and pull off from anti-roll
nform
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bar -2-.
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– Place bush -1- on anti-roll bar -2-.

– Install bush, ensuring that gap -a- is adhered to.
a = 1050 ± 3 mm
– Fit clamp -1-.

– Tighten bolts -arrows- on both sides.
Specified torques
satelettronica
AG. Volkswagen AG d
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3 Suspension link, track rod

⇒ “3.1 Assembly overview - transverse link”, page 130
⇒ “3.2 Removing and installing lowerAGtransverse
. Volkswagenlink”, page 130 n AG do
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❑ 100 Nm +180°
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2 - Eccentric washer
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3 - Inner bonded rubber bush
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❑ Pressing out and in
⇒ page 132
rrectne
4 - Eccentric bolt
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5 - Suspension link
inform
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⇒ page 130
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❑ Pressing out and in Prote AG.
⇒ page 132
8 - Nut
❑ 120 Nm +180°
3.2 Removing and installing lower trans‐

verse link

Removing
Caution
swage es n
Bonded rubber bushes can be twisted only to a limited by V extent.
olk ot g
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Tighten threaded connections on components th with bonded
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satelettronica
ss
is unladen or if the vehicle is raised and is in the unladen po‐
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sition (normal position) ⇒ page 6 .
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– Remove wheel.
– Remove brake disc ⇒ Brake system; Rep. gr. 46 ; Rear brake;
rrectness of i
– Detach handbrake cable from retainers on suspension link
l purpos
-arrows-.
– Unscrew brake line from brake hose.
nf
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– Remove brake line from bracket.
m
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– Remove spring ⇒ page 141 . n in

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– Turn anti-roll bar downwards.
3. Suspension link, track rod 131


– Pull bolt -1- out of suspension link -2-.

– Pull bolt -1- out of suspension link -2-.
– Remove suspension link -2-.
Installing
– Bleed hydraulic system following standard procedure ⇒ Brake
satelettronica
system; Rep. gr. 47 ; Hydraulic system; Bleeding hydraulic
system following standard procedure .
Specified torques
♦ ⇒ “3.1 Assembly overview - transverse link”, page 130
♦ ⇒ “4.1 Assembly overview - suspension strut, shock absorber,
spring”, page 139
♦ Brake disc ⇒ Brake system; Rep. gr. 46 ; Rear brake; Re‐
moving and installing brake disc agen
AG. Volkswagen AG d
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3.3 Renewing bonded rubber bush for sus‐ thorise nte
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Note
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♦ The contact surfaces of waxed parts must be cleaned before

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the parts are installed. Contact surfaces must be free of wax

hole
and grease.
spec
es, in part or in w
♦ Load-bearing components and other suspension parts must

t to the co
not be welded or straightened.

♦ Do not attempt to move the vehicle without the drive shafts
rrectness of i
fitted as this would damage the wheel bearing.

l purpos
♦ Bonded rubber bushes can be twisted only to a limited extent.

♦ Tighten axle components with bonded rubber bushes only if
nf
ercia
the vehicle is standing on its wheels and is unladen or if the

orm
vehicle is raised and is in the unladen position ⇒ page 6 .

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equipment required
satelettronica
AG. Volkswagen AG d
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♦ Workshop press - V.A.G 1290/A-

rrectness of i
♦ Thrust ring - VW 429-

l purpos

nform
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♦ Tube - 3110-
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♦ Drift sleeve - V.A.G 40-21-

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♦ Thrust piece - VW 459/2-
♦ Tube - 2039-
♦ Removal wedge - 3409-
– Remove suspension link ⇒ page 130 .
Pressing out
Note
♦ The bonded rubber bushes cannot be removed from the suspension link without damage.
♦ Bonded rubber bush -1- is pressed out in -direction of arrow A- and bonded rubber bush -2- in
-direction of arrow B-.
♦ Bonded rubber bushes -1- and -2- are different. The removal of outer bonded rubber bush -2- is described
below. The procedure for the inner bonded rubber bush -1- is identical.

satelettronica
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– Remove rear suspension link.
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– Using a chisel , bend up metal collar of bonded rubber bush

wit
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-3- around circumference. h re

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spec
– Applying a hack saw -4- in resulting gap, cut off metal collar
es, in part or in w
-5- flush with suspension link.

t to the co
– Remove metal collar -5- from bonded rubber bush.

This preparatory work is necessary so that the bonded rubber
rrectness of i
bush -2- can be pressed out in the -direction of arrow B-.

l purpos
Note
nf
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Do not damage suspension link when folding up or sawing collar.

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– Assemble tools as shown in illustration.

– Press out bonded rubber bush from suspension link.
Pressing in
Note
The installation of outer bonded rubber bush -2- is described below. The procedure for the inner bonded rubber
bush is identical. swa
gen AG
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• Before pressing in, coat theolower
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bonded rubber bush -2- with th tyre fitting paste.
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Note
Ensure that the marking -3- of the bonded rubber bush -2- aligns exactly with the marking -3- on the suspension
link -1-.
– Using workshop press - V.A.G 1290/A- , apply light pressure

to bonded rubber bush -2- and maintain pressure.
– Press rubber bead -4- into suspension link using wedge -
3409- .
Note
Make sure that rubber bead -4- of bonded rubber bush -2- is correctly pushed into suspension link -1-. This
prevents rubber bead being damaged (shearing off) when pressing in.
– Press bonded rubber bush -2- into suspension link -1- as far
as it will go.
Pressing bonded rubber bush further:
satelettronica
Note
. Volkswagen AG
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Continued pressing is necessary
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olk to press the rubbers nbead
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– Assemble tools
auth as shown in illustration. or
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c
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AG. Volkswagen AG d
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satelettronica
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Prote AG.
– Place thrust rod - VW 407- centrally -arrow- on bonded rubber

bush -2-.
– Press with light pressure until rubber bead -3- can be »heard«
to pop out of suspension link -1-.
Note
♦ To avoid damage to the bonded rubber bush -2-, stop pressing as soon as the rubber bead -3- has popped
out.
♦ Check that rubber bead -3- is positioned correctly.
– Install suspension link ⇒ page 130 .

Specified torques

AG. Volkswagen AG d
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4 Suspension strut, shock absorber, d b ara
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or eo
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spring ss aut ra
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⇒ “4.1 Assembly overview - suspension strut, shock absorber,
pt
an
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spring”, page 139
itte
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ab
⇒ “4.2 Removing and installing shock absorbers”, page 139
ility
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⇒ “4.3 Removing and installing spring”, page 141
h re
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spec
4.1 Assembly overview - suspension strut, shock absorber, spring
t to the co
1 - Buffer stop
rrectne
2 - Upper damping ring
ss
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3 - Spring
form
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❑ Install coil spring so that
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the colour mark on the

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❑ Removing and installing C py
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⇒ page 141 rig ht
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agen
5 - Suspension link
6 - Bolt
❑ 80 Nm +90°
7 - Shock absorbers
⇒ page 139
8 - Nut
❑ 120 Nm +180°
9 - Bolt
4.2 Removing and installing shock absorb‐

ers
4. Suspension strut, shock absorber, spring 139

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Prote AG.
Removing
– Remove wheel.
– Secure vehicle to support arms of lifting platform on both sides
using tensioning straps - T10038- .
– Attach support - T10149- with a wheel bolt.

– Preload suspension link slightly using engine and gearbox

jack - V.A.G 1383 A- or engine and gearbox jack - VAS 6931- .
AG. Volkswagen AG d
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– Remove wiring harness from brackets -arrow- on shock ab‐
sorber -2-.
rrectne
– Move wiring harness aside.
satelettronica
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– Pull bolt -1- out of shock absorber -2-.
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– Unscrew upper bolt -arrow- of shock absorber.

– Remove shock absorber -1-.
Installing
lowing:
– Lower suspension link.
Specified torques
spring”, page 139
4.3 Removing and installing spring


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Prote AG.
Removing
– Remove wheel.
– Secure vehicle to support arms of lifting platform on both sides
using tensioning straps - T10038- .

AG. Volkswagen AG d
agen Transporter
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olksw not
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Running
ed b gear, axles, steering - Edition 02.2019
ara
nte
ris
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– Attach support - T10149- with a wheel bolt. ss a c
ce
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nl
– Unscrew outer left clamp and outer right clamp for anti-roll bar
pt
du
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on suspension links.
itte
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– Preload suspension link slightly using engine and gearbox
ility
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jack - V.A.G 1383 A- or engine and gearbox jack - VAS 6931- .
wit
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es, in part or in w
t to the co
rrectness of i
l purpos
– Pull bolt -1- out of shock absorber -2-.
nf
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– Remove spring.
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Specified torques
spring”, page 139

AG. Volkswagen AG d
agen oes
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Transporter 2016 ➤ rise
d b ara
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autho
- Edition 02.2019 eo
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ss c
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5 Wheel bearing assembly, trailing arm
an
d
itte
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⇒ “5.1 Assembly overview - wheel bearing”, page 144
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ility
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⇒ “5.2 Removing and installing wheel bearing unit”, page 144
h re
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spec
5.1 Assembly overview - wheel bearing
es, in part or in w
t to the co
1 - Suspension link
rrectness of i
2 - Cover
l purpos
❑ For vehicles with front-

wheel drive
❑ Observe installation in‐
nform
ercia
structions ⇒ page 148 .

m
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3 - Drive shaft
on in
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❑ For vehicles with all-
thi
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wheel drive
iva
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4 - Cover plate
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5 - Bolt Cop py
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❑ 8 Nm
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6 - Wheel bearing
agen
Prote AG.

⇒ page 144
7 - Nut
❑ For vehicles with all-
wheel drive
en off 180°
200 Nm

unit
Note
Caution
♦ Always ensure proper seating of tools and components

(wheel bearing and hub) throughout the entire procedure.

AG. Volkswagen AG d
agen
Volksw
oes
not Transporter 2016 ➤
by gu
ed Running gear, axles,
ara
nte steering - Edition 02.2019
ris
tho eo
au ra
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WARNING
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nl
pt
du
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♦ Place engine and gearbox jack - V.A.G 1383 A- or engine
erm
ab
and gearbox jack - VAS 6931- below wheel bearing hous‐
ility
ing throughout the entire process (to prevent accidents ot p
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h re
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rrectness of i
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Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.

♦ Hydraulic cylinder - VAS 6178-
5. Wheel bearing assembly, trailing arm 145

♦ Pressure gauge with connection line - VAS 6179/1-

– Remove wheel.
– Vehicles with front-wheel drive: remove cap
⇒ Item 2 (page 144) . AG. Volkswagen AG d
satelettronica
agen oes
ksw
Vehicles with all-wheel drive byV
ol not
gu
d ara
ise nte
– Remove drive shaft ⇒ page 149 . tho r eo
au ra
c
Continued for all vehicles: ss
ce
e
nl
pt
du
– Remove brake caliper with brake carrier and secure it to body
an
itte
using wire ⇒ Brake system; Rep. gr. 46 ; Rear brake; Re‐
y li
erm
ab
moving and installing brake caliper .
ility
ot p
wit
– Remove brake disc.
, is n
h re
hole
spec
Sensors; Removing and installing speed sensor on rear axle
es, in part or in w
t to the co
-G44- / -G46- .
– Centre grip elements - T10205/12- »behind« wheel hub -1-
using wheel bolts-2-. rrectness of i
The wheel bolts -2- must not protrude from backs of grip elements
l purpos
- T10205/12- .
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
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m
f
en
ng
t.
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Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.


1- Threaded rod M20 - T10205/8-1-
2- Nut M20 - T10205/8-2-
5- Bell - T10205/2-
6- Grip elements - T10205/12-
7- Threaded rod M20 - T10205/8-1-
8- Nut M20 - T10205/8-2-
– Turn bell - T10205/2 - until bridge -1- is in the position shown.
satelettronica
– Turn hub until wheel bolts -arrows- are in the position shown.
– Hold appliance firmly and pull out wheel hub with wheel bear‐
ing.
Installing
Note agen
AG. Volkswagen AG d
oes
olksw not
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by ara
♦ The wheel bearingsorised
must always be renewed after removal.nte
h eo
ut
♦ The grip elements - T10205/11- should prevent the retaining
a ra
ss c
ring from slipping down the wheel bearing during the pressing
ce
le
un
in sequence
pt
an
d
itte
y li
erm
ab
ility
ot p
– Centre grip elements - T10205/11- »behind« wheel hub -1-

wit
is n
using wheel bolts-2-.

h re
ole,
spec
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
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o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
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by c lksw
cted agen
Prote AG.
5. Wheel bearing assembly, trailing arm 147

AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
Transporter 2016 ➤ orise nte
h eo
Running gear, axles, steering - Edition 02.2019 aut ra
c
ss
ce
e
nl
pt
du
an
itte
Note
y li
erm
ab
ility
ot p
The guide - T10205/16- must always be installed with the recess
wit
, is n
facing towards the wheel bearing.
h re
hole
spec
es, in part or in w
t to the co
1- Threaded rod M20 - T10205/8-1-
2- Nut M20 - T10205/8-2-
rrectness of i
l purpos
nf
ercia
5- Bell - T10205/2-
orm
m
atio
6- Grip elements - T10205/11- om
n in
or c
7- Threaded rod M20 - T10205/8-1-
thi
te
sd
iva
8- Nut M20 - T10205/8-2-
o
r
rp
cu
o
m
f
en
ng
9- Guide - T10205/16-
t.
yi Co
satelettronica
op py
– Connect pressure gauge with connection line - VAS 6179/1-
t. C rig
gh ht
yri
between hydraulic press - VAS 6178- and hydraulic line for p by
o Vo
by c
foot pump - VAS 6179- .
lksw
cted agen
Prote AG.
The pressures described below apply to the hydraulic press -
VAS 6178- only.
When pressing in, the pressure reading taken shortly before the
end of pressing must be between 90 and 140 bar.
The maximum pressure must not exceed 310 bar.
– Press in wheel bearing until circlip engages audibly.
Ensure the wheel bearing does not cant when pressing in.
Vehicles with front-wheel drive
– When installing cap -1-, ensure that recess -arrow A- is oppo‐

site colour marking -arrow B-.
Specified torques

6 Drive shaft
⇒ “6.1 Assembly overview - drive shaft”, page 149
⇒ “6.2 Removing and installing drive shaft”, page 151
⇒ “6.3 Dismantling and assembling drive shaft”, page 156
⇒ “6.4 Loosening and tightening threaded connections of drive
shaft”, page 163
⇒ “6.5 Checking inner constant velocity joint”, page 164
6.1 Assembly overview - drive shaft
1 - Drive shaft
⇒ page 149
satelettronica
ing ⇒ page 163
200 Nm and then slack‐ n AG. Volkswagen AG do
swage es n
en off 180° byV
olk ot g
ua
d ran
❑ Final torque setting: ir se tee
ho
200 Nm aut or
ac
ss
ce
e
nl
pt
du
with drive shaft
an
itte
y li
erm
ab
plete unit
ility
ot p
wit
, is n
❑ If boot on outer joint has
h re
to be renewed, inner
hole
spec
constant velocity joint
es, in part or in w
must first be removed t to the co

from drive shaft.
4 - Clip
rrectness of i
❑ Always renew
l purpos
❑ Tightening ⇒ page 162

❑ 25 Nm
nform
ercia
5 - Boot
m
at

om
ion
chafing, renew if neces‐

c
in t
or
sary
his
ate
do
riv
❑ Renewing ⇒ page 156

p
cum
for
en
g
6 - Clip
n
t.
yi Co
op
❑ Always renew
C py
t. rig
gh ht
yri
❑ Tightening ⇒ page 162 p by
co Vo
by lksw
cted agen
7 - Cap Prote AG.
❑ Using a drift, carefully drive from inner constant velocity joint.

❑ Always renew
❑ Before attaching to constant velocity joint, coat sealing surface with sealant - D 454 300 A2-
⇒ page 160 .
❑ Align cover with bolt holes
8 - Retaining ring
❑ Always renew
6. Drive shaft 149


❑ Checking ⇒ page 164
❑ Pressing off ⇒ page 159
❑ Pressing on ⇒ page 160
❑ Lubricating ⇒ page 150 .
❑ Adhesive surfaces must be free of oil and grease
10 - Cap
❑ Drive off carefully with drift
❑ Always renew
❑ Check inner constant velocity joint if boot is damaged ⇒ page 164
❑ Before attaching to constant velocity joint, coat sealing surface with sealant - D 454 300 A2-
⇒ page 160 .
❑ Align with bolt holes.
❑ Adhesive surfaces must be free of oil geand
n AG. grease
Volkswagen AG
d wa oes
olks not
11 - Clip db
yV gu
ara
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❑ Always renew tho
r eo
satelettronica
au ra
ss c
ce
le
❑ 25 Nm
un
pt
an
d
itte
y li
12 - Boot
rm
ab
pe
ility
❑ Check for splits and chafing, renew if necessary
ot
wit
, is n
❑ Renewing ⇒ page 156
h re
hole
spec
13 - Clip
es, in part or in w
❑ Always renew
t to the co
14 - Bolt
rrectness of i
❑ Always renew
l purpos
Initial tightening torque: 10 Nm

nform
ercia
30 Nm +90°
m
a
com
ti
15 - Locking plate
on in
r
te o
thi
s
iva
do
r
rp
Grease quantities and types

um
fo
en
ng
t.
yi
Regrease joint when renewing boot.
Co
Cop py
t. rig
Filling joints with high-temperature grease ⇒ Electronic Parts
gh ht
pyri by
Catalogue “ETKA” .
co Vo
by lksw
cted agen
Prote AG.
Outer side Grease quan‐ of which in:
tity
[mm] [g] [g] [g]
Outer joint Total quantity Joint Boot
97 80 40 40
Inner joint
104 80 40 40

6.2 Removing and installing drive shaft

⇒ “6.2.1 Removing and installing drive shaft, left drive shaft”, page
151
⇒ “6.2.2 Removing and installing drive shaft, right drive shaft”,
page 153
6.2.1 Removing and installing drive shaft, left

drive shaft
♦ Adapter - T10103/1-
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c
ce
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nl
pt
du
an
itte
y li
erm
ab
satelettronica
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
♦ Bolts - T10103/2-
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
♦ Torque wrench - V.A.G 1332- yri
p by
co Vo
by lksw
cted agen
Prote AG.

6. Drive shaft 151

Caution


satelettronica
– Remove wheel.
– Remove twelve-point nut.
– Unbolt drive shaft from rear final drive.
– Pull drive shaft out of wheel hub.
If the drive shaft cannot be pulled out of the wheel bearing by AG. Volkswagen A
hand, use ejector - T10520- . olks
wage
n G do
es n
o V t gu
by
Before using press tool - T10520- ensure that thrust
ris
ed piece -1- is
ara
nte
inserted. ut
ho eo
ra
a c
ss
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.


wheel bearing.
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
ss c
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
Note
rrectne
satelettronica
ss
o
cial p
f
inform
mer
atio
Installing
om
n
c
i
or
n thi
te
sd
a
Remove any paint residues and/or corrosion on thread and

iv
o
pr
c
splines of outer joint.
um
r
fo
en
ng
t.
yi
– Insert drive shaft and push into wheel hub as far as possible.
Co
Cop py
ht. rig
– Draw in outer joint with new twelve-point nut as far as stop.
rig ht
py by
co Vo
by lksw
– Secure drive shaft to rear final drive.
cted agen
Prote AG.
– Tighten nut for drive shaft ⇒ page 163 .

Specified torques

right drive shaft
♦ Adapter - T10103/1-
6. Drive shaft 153

♦ Bolts - T10103/2-
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
satelettronica
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
or

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


– Remove wheel.
– Remove twelve-point nut.
– Unbolt drive shaft from rear final drive.
– Lower gearbox carrier with rear final drive ⇒ Rep. gr. 39 ;
Final drive; Removing and installing final drive .

– Push drive shaft over rear final drive up to middle.

– Pull drive shaft out of wheel hub.
If the drive shaft cannot be pulled out of the wheel bearing by
hand, use ejector - T10520- .
inserted.
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
satelettronica
t to the co
rrectness of i
l purpos

nform
ercia
wheel bearing.
m
a
com
tio
n in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
6. Drive shaft 155


Note
– Pull out drive shaft to rear and down.

Installing
G. Volkswagen AG d
Remove any paint residues and/or corrosion on thread and lkswagen A oes
not
splines of outer joint. by
Vo gu
ara
d
ise nte
– Insert drive shaft and push into wheel hub as far
ut
hoas possible.
r eo
ra
sa
satelettronica
c
– Draw in outer joint with new twelve-point nuts as far as stop.
ce
e
nl
pt
du
– Install gearbox carrier with rear final drive ⇒ Rep. gr. 39 ; Final
an
itte
y li
drive; Removing and installing final drive .
erm
ab
ility
ot p
– Secure drive shaft to rear final drive.
wit
, is n
h re
– Tighten nut for drive shaft ⇒ page 163 .
hole
spec
es, in part or in w
t to the co
Specified torques
rrectness of i
l purpos
6.3 Dismantling and assembling drive shaft
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.


equipment required agen
AG. Volkswagen AG d
oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
orm
satelettronica
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

♦ Tube - VW 416 B-
6. Drive shaft 157

lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
satelettronica
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

♦ Thrust piece - VW 454-
♦ Bracket - 2036/1- from valve assembly device - 2036-
♦ Sleeve - 3144-
♦ Sealant - D 454 300 A2-
♦ Pliers - V.A.G 1682-

AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
ss c
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
Removing inner constant velocity joint:
h re
ole,
spec
– Clamp drive shaft in vice using jaw protectors.
t to the co
– Drive off cap using a brass or copper drift.
– Use brass or copper drift to drive off cap of boot.
rrectne
satelettronica
Note
ss o
cial p
f i
Do not open O-type clip.
nform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
ht. rig
– Remove retaining ring. rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
6. Drive shaft 159

– Press off inner constant velocity joint.

– Open small O-type clip on drive shaft and pull boot off drive
shaft.
Note
Renew cap for boot.

AG. Volkswagen AG d
agen oes
olksw not
Installing inner constant velocity d byjoint.
V gu
ara
ise nte
or eo
h
aut ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
– Apply sealant ⇒ Electronic Parts Catalogue “ETKA” to
satelettronica
-hatched area- of clean surface of inner side of cap for con‐
stant velocity joint boot. Apply continuous bead of sealant (2
rrectness of i
… 3 mm in diameter), passing holes on inner side -arrow-.
l purpos
– Push boot with new cap and small O-type clip onto drive shaft.
Drive shaft, boot and contact surface of cap must be free from
nform
ercia
grease!
m
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
g
– Press joint on to stop.

n
t.
yi Co
Cop py
Chamfer on internal circumference of ball hub (splines) must face
t. rig
gh ht
yri by
contact shoulder on drive shaft. op Vo
by c lksw
cted agen
Prote AG.

– Fit new retaining ring.

– Check that circlip is seated correctly.
– Before installing cap, inject 40 grammes of drive shaft grease
into boot.
Note
Take care not to damage the sealant bead.
– Align cap and bolts -arrows- with bolt holes.

The alignment must be very accurate, because no further align‐
ment is possible once the part has been hammered on.
– Drive on cap using a plastic head hammer.
– Remove sealant which has been pressed out.
– Inject 40 grammes of drive shaft grease in constant velocity
satelettronica
joint through ball tracks.
– Clean contact surface for sealing cover.
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
o
– Apply sealant ⇒ Electronic
aut Parts Catalogue “ETKA” to
h eo
ra
-hatched area- of clean
s surface of inner side of cap for con‐
s c
stant velocity joint boot. Apply continuous bead of sealant (2 ce
e
nl
pt
du
… 3 mm in diameter), passing holes on inner side -arrow-.

an
itte
y li
erm
– Align new sealing cover with bolt holes. ab

ility
ot p
wit
The alignment must be very accurate, because no further align‐
, is n
h re
ment is possible once the cover has been pressed on.
hole
spec
es, in part or in w
t to the co
rrectness of i
– Press on sealing cover -A-.

l purpos
– Remove sealant which has been pressed out.

nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
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rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
6. Drive shaft 161

– Position boot in outer groove -arrow 2-. Inner groove

-arrow 1- must remain visible.
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss
ce
e
nl
pt
du
an
itte
y li
Fit and tighten clip on inner joint.
erm
ab
ility
ot p
– Apply clamp tensioner - V.A.G 1682- as shown in figure. En‐
wit
, is n
sure jaws of tensioner lie in corners -arrows B- of ears on O-
h re
hole
type clip.
spec
es, in part or in w
– Tighten O-type clip by turning spindle -A- with a torque wrench
t to the co
-C- (do not cant pliers).
satelettronica
rrectness of i
Note
l purpos
♦ Due to the hard material of the protective bellows (compared

to rubber) and the necessity of using a stainless steel clip, it is
nform
ercia
only possible to tension the clip with clamp tensioner -

V.A.G 1682- .
m
at
om
ion
♦ Use torque wrench with 5…50 Nm range (e.g. torque wrench
c
in t
or
- V.A.G 1331- ).
his
ate
do
riv
♦ Ensure that the spindle thread -A- moves smoothly. Lubricate

p
cum
or
with MOS2 grease if necessary.

f
en
ng
t.
yi Co
op py
♦ If the thread is tight (e.g. due to dirt), the required clamping t. C rig
gh ht
force for the stainless steel clamp will not be attained despite yri
p by
o Vo
the specified tightening torque being applied.
c by lksw
cted agen
Prote AG.
Renewing boot on outer joint

– Detach inner constant velocity joint from drive shaft
⇒ page 159 .
– Open both hose clips and pull off joint boot from outer joint.
– Push new joint boot onto drive shaft.
– Pack 40 grammes of drive shaft grease into joint (boot side).
– Slide boot onto outer joint.
– Make sure boot is properly positioned on outer joint.
– Position boot in outer groove -arrow 2- of drive shaft. Inner

groove -arrow 1- must remain visible.

Fit clamp and tighten on outer joint.

– Apply clamp tensioner - V.A.G 1682- as shown in figure. En‐
sure jaws of tensioner lie in corners -arrows B- of ears on
stainless steel O-type clip.
– Tighten stainless steel O-type clip by turning spindle -A- with
a torque wrench (do not cant pliers).
Note
lkswage es n
♦ Due to the hard material of the dprotective
by
Vo bellows (compared ot guar
to rubber) and the necessity oofris using a stainless steel clip, it is
e an
tee
only possible to tension the
au clip with clamp tensioner -
th or
ac
V.A.G 1682- . ss
ce
le
un
pt
♦ Use torque wrench with 5…50 Nm range (e.g. torque wrench
an
d
itte
- V.A.G 1331- ).
y li
erm
ab
ility
♦ Ensure that the spindle thread -A- moves smoothly. Lubricate
ot p
with MOS2 grease if necessary.
wit
is n
h re
ole,
♦ If the thread is tight (e.g. due to dirt), the required clamping
spec
force for the stainless steel clamp will not be attained despite
satelettronica
t to the co
the specified tightening torque being applied.
rrectne
6.4 Loosening and tightening threaded con‐
nections of drive shaft
ss o
cial p
f
inform
mer
♦ Torque angle wrench - V.A.G 1756 A-
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
Caution

6. Drive shaft 163

. Volkswage
AG n AG d
agen oes
olksw not
Loosen twelve point nut. d by V gu
ara
rise nte
– With vehicle still standing
utho on its wheels, loosen the twelve- eo
ra
point nut a maximumss a
of 90°, as the wheel bearing will other‐ c
wise be damaged.
ce
le
un
pt
an
d
– Raise vehicle so that wheels are off the ground.

itte
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– Unscrew twelve-point nut -arrow- from drive shaft.
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Screwing on twelve-point nut
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– Replace hexagonal nut.
rrectness of i
Note
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It must be ensured that the wheels do not yet touch the floor when
the drive shaft is being tightened. Otherwise the wheel bearing
nform
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may be damaged.
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Joint must be dismantled to renew grease if heavily soiled. Con‐
tact surfaces and balls are to be examined for wear and damage.
Dismantling
Note
Ball hub and joint part are matched and must be marked before
dismantling. Do not interchange race allocation.
– Swing ball hub and ball cage.

– Press out joint body in direction of arrow.
– Press balls out of cage.

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– Tip ball hub out of ball cage via ball track -arrows-.
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– Check joint body, ball hub, ball cage and balls for pitting and
ility
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traces of seizing.
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Note
t to the co
Excessive circumferential backlash in the joint is noticeable dur‐
ing load change jolts. In this case the joint must be replaced.
Smoothing and traces of wear of the balls are no reason to renew
rrectne
the joint.
ss
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– Insert hub into cage via the two chamfers. The hub can be
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installed in any position. Press balls into cage.

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– Insert hub with cage and balls at a right angle to joint body.
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♦ When inserting, ensure that the wide spacing -a- on the joint
body is aligned with the narrow spacing -b- on the hub after it
is swung in.
♦ Chamfer on internal diameter of ball hub (splines) must face
drive shaft.
– Swivel the hub into the joint body; at the same time the hub
must be swivelled out of the cage -arrows- far enough to allow
the balls to fit into the ball tracks.
6. Drive shaft 165

– Swivel in hub with balls by applying firm pressure to cage

-arrow-.
Checking function of constant velocity joint:
The constant velocity joint is correctly assembled if the ball hub
can be moved by hand backwards and forwards over its entire
range of axial movement.
– Pack required amount of grease into joint
agen
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Volkswagen AG
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Grease quantity and type ⇒ page
ed
by 150
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43 – Self-levelling suspension
1 Electronically controlled damping
system
⇒ “1.1 Assembly overview - electronically controlled damping
system”, page 167 en AG. V
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ot g
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db
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1 - Front right body accelera‐
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tion sender - G342-
satelettronica
⇒ page 168
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2 - Body acceleration sender,
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rear - G343-
❑ Fitting location: on rear
nf
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left wheel housing be‐

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hind side trim panel

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⇒ page 169
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damping control unit - J250-
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⇒ page 168
❑ Location: electronically
controlled damping con‐
trol unit - J250- is instal‐
led on right next to steer‐
ing column.
❑ Function Replace con-
trol unit must be per‐
formed with ⇒ Vehicle
diagnostic tester if elec‐
tronically controlled
damping control unit -
J250- is renewed.
5 - Front left body acceleration
sender - G341-
⇒ page 168
6 - Front left vehicle level sender - G78-
7 - Front right vehicle level sender - G289-
1. Electronically controlled damping system 167

8 - Shock absorber with front right shock absorber damper adjustment valve - N337-
❑ Removing and installing suspension strut ⇒ page 38 .
9 - Shock absorber with rear right shock absorber damper adjustment valve - N339- .
❑ Removing and installing shock absorber ⇒ page 139 .
10 - Shock absorber with rear left shock absorber damper adjustment valve - N338- .
❑ Removing and installing shock absorber ⇒ page 139
agen
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11 - Shock absorber with front left shock absorber
edb
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❑ Removing and installing suspension ut
ho strut ⇒ page 38 . eo
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1.2 Removing and installing electronically
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Removing
Location: electronically controlled damping control unit - J250- is
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installed on right next to steering column.
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– Disconnect battery ⇒ Electrical system; Rep. gr. 27 ; Battery;
l purpos
Disconnecting and reconnecting battery .

– Switch off ignition and open driver’s door so that the steering
nf
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lock engages.
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– Remove footwell cover ⇒ General body repairs, interior; Rep.

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gr. 68 ; Compartments/covers; Removing and installing foot‐

or
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well cover .
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Carry out installation in the reverse sequence, noting the follow‐
ing:
– Function Replace control unit must be performed with
⇒ Vehicle diagnostic tester if electronically controlled damping
control unit - J250- has been renewed.
1.3 Removing and installing front body ac‐

celeration senders -G341- / -G342-
168 Rep. gr.43 - Self-levelling suspension

Removing
chamber cover .
satelettronica
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– Remove front body acceleration sender -2-.
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Install in reverse order. ut procedure,
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– Perform basic setting of wheel damper electronics ⇒ Vehicle
an
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diagnostic tester.
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Specified torques
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Front body acceleration sender 8 Nm

t to the co
to bracket
1.4 Removing and installing rear body ac‐

rrectness of i
celeration sender - G343-

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Removing
– Remove left luggage compartment side trim ⇒ General body
repairs, interior; Rep. gr. 70 ; Luggage compartment trims;
Removing and installing luggage compartment side trim .
1. Electronically controlled damping system 169


– Remove rear body acceleration sender - G343- -2-.
Installing
lowing:
– Perform basic setting of wheel damper electronics ⇒ Vehicle
diagnostic tester.
Specified torques
Rear body acceleration sender 8 Nm
- G343- to bracket
satelettronica
AG. Volkswagen AG d
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2 Vehicle level sender

⇒ “2.1 Assembly overview - front vehicle level senders”,
page 171
⇒ “2.2 Assembly overview - rear vehicle level senders”,
page 174
⇒ “2.3 Removing and installing front vehicle level senders G78 /
G289 ”, page 174
⇒ “2.4 Removing and installing rear vehicle level senders G76 /
G77 ”, page 176
2.1 Assembly overview - front vehicle level

senders
⇒ “2.1.1 Assembly overview - front left vehicle level sender G78
”, page 171
⇒ “2.1.2 Assembly overview - front right vehicle level sender G289
”, page 173
2.1.1 Assembly overview - front left vehicle level sender - G78-
satelettronica
Note
The front left vehicle level sender - G78- is only available as a replacement part as a complete unit comprising
the coupling rod and upper and lower retaining plates.
AG. Volkswagen AG d
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2. Vehicle level sender 171

1 - Front left vehicle level send‐

er - G78-
❑ Complete with attach‐
ments
❑ Lever must face out‐
wards
⇒ page 174
❑ Carry out basic setting
of headlights ⇒ Electri‐
cal system; Rep. gr. 94 ;
Headlights; Adjusting
headlights
2 - Bolt
❑ 5 Nm
3 - Nut
❑ 8 Nm
satelettronica
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2.1.2 Assembly overview - front right vehicle level sender - G289-
Note
The front right vehicle level sender - G289- is only available as a replacement part as a complete unit comprising
the coupling rod and upper and lower retaining plates.
1 - Bolt
2 - Front right vehicle level
sender - G289-
ments
❑ Lever must face out‐
wards
⇒ page 175
❑ Carry out basic setting
of headlights ⇒ Electri‐
satelettronica
cal system; Rep. gr. 94 ; swa
gen AG
. Volkswagen AG
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Headlights; Adjusting by Volk not
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tho or
3 - Nut au ac
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❑ ⇒ Item 9 (page 53)
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❑ 8 Nm wit
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2.2 Assembly overview - rear vehicle level senders
Note
The vehicle level sender is available as a replacement part only complete with coupling rod and upper and
lower retaining plates.
1 - Anti-roll bar
2 - Washer
3 - Bolt
❑ ⇒ Item 2 (page 124)
4 - Vehicle level sender at rear
ments
❑ Lever must point in op‐
posite direction of travel
satelettronica
⇒ page 176
❑ Perform basic setting of
wheel damper electron‐
ics ⇒ Vehicle diagnostic
tester.
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❑ Carry out basic setting agen oes
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of headlights ⇒ Electri‐ d byV gu
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❑ 20 Nm +45°
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2.3 Removing and installing front vehicle

n
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level senders -G78- / -G289-

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⇒ “2.3.1 Removing and installing front left vehicle level sender

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G78 ”, page 174

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⇒ “2.3.2 Removing and installing front right vehicle level sender
ht. rig
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2.3.1 Removing and installing front left vehicle
AG.
level sender - G78-


Removing
– Separate electrical connector -1- from front left vehicle level
sender - G78- .
– Unscrew bolt -2-. AG. Volkswagen AG d
agen oes
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– Remove front left vehicle level sender - G78- -3-. V
satelettronica
by gu
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Installing ut
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Install in reverse order. During this procedure, observe the fol‐ s
ce
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pt
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Note
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• Perform basic setting of wheel damper electronics ⇒ Vehicle
diagnostic tester.
rrectness of i
• Carry out basic setting of headlights ⇒ Electrical system; Rep.
l purpos
gr. 94 ; Headlights; Adjusting headlights .

Specified torques
nf
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♦ ⇒ “2.1 Assembly overview - front vehicle level senders”, page orm

m
171
atio
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n in
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2.3.2 Removing and installing front right vehi‐

te
sd
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cle level sender - G289-

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AG. Volkswagen AG d
agen oes
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Transporter 2016 ➤ ed b ara
nte
ris
Running gear, axles, steering - Edition 02.2019 utho eo
ra
s a c
s
Removing
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un
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an
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– Disconnect connector -1- on front right vehicle level sender -
y li
rm
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G289- .
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– Pull out bolt -3- upwards.
spec
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– Remove front right vehicle level sender - G289- -3-.
Installing
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Note
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diagnostic tester.
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gr. 94 ; Headlights; Adjusting headlights . by c lksw
cted agen
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Specified torques
♦ ⇒ “2.1 Assembly overview - front vehicle level senders”, page
171
joint”, page 52
2.4 Removing and installing rear vehicle

level senders -G76- / -G77-

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Removing byV
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– Disconnect connector -1-. uthor eo
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– Remove bolts -2-. s
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– Unscrew bolts -arrows-.
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– Take out rear left vehicle level sender - G76- -3-.
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Lever on vehicle level sender must point in opposite direction of
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diagnostic tester.
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gr. 94 ; Headlights; Adjusting headlights .
nform
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Specified torques
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♦ ⇒ “2.2 Assembly overview - rear vehicle level senders”,
n in
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page 174
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44 – Wheels, tyres, vehicle geometry

1 Wheels, tyres
⇒ “1.1 Specified torques for wheel bolts”, page 178
⇒ “1.2 Pressing tyre off wheel rim”, page 178
⇒ “1.3 Removing tyre from wheel”, page 179
⇒ “1.4 Fitting tyres”, page 179
⇒ “1.5 Wheel change”, page 180
⇒ “1.6 Tyre sealant disposal”, page 183
⇒ “1.7 Models with breakdown set”, page 183
1.1 Specified torques for wheel bolts

Wheel bolt to wheel hub for all vehicles:
Specified torque: 180 Nm
satelettronica
– Before fitting wheel, protect wheel centring seat against cor‐
rosion ⇒ page 180 .
♦ Install anti-theft wheel bolts using adapter set for wheel bolts .
1.2 Pressing tyre off wheel rim

The tyre fitting unit must be furnished with the tyre fitting
agen
AGhead
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WARNING tho or
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Otherwise there is a danger of the rim becoming damaged.

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If your tyre fitting unit has not yet been modified, please contact
ot
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the manufacturer of the unit.

h re
hole
Safety instructions and conditions for removing and installing

spec
tyres
es, in part or in w
t to the co
• It is extremely important to adhere to the instructions and

warnings in the following descriptions.
rrectness of i
– Remove air from tyre by screwing out the nickel-plate valve

element.
l purpos
– Always ensure when pressing off a tyre using tyre fitting equip‐
ment with a press-off plate, that the tyre valve -arrow- is
nform
ercia
directly opposite the press-off plate -1-.

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The bead breaker must be positioned no more than 2 cm away

on in
from the rim flange.

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– Remove balancing weights and dirt from wheel rim.

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

– Press both tyre beads off all round and liberally coat tyre and
wheel rim flange with tyre assembly paste -arrow-.
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1.3 Removing tyre from wheel

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Tyres which have been filled or sealed using tyre sealant must be
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♦ Avoid eye and skin contact with tyre sealant.
satelettronica
♦ It is damaging to health and can cause eye irritation and
allergies.
rrectness of i
♦ During this work, wear protective gloves and safety gog‐
l purpos
gles.
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– Place the wheel on an even surface.

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– Unscrew and remove the valve insert of tyre valve.

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– Use a suitable drill or mill to carefully drill a hole in shoulder

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1.4 Fitting tyres

• Ensure that the wheel rim is clean.
– Insert new tyre valve with -VAS 6459- -1-.
– Unscrew and remove valve insert.
– Inflate tyre to approx. 3 … 4 bar. The bead of the tyre must slip
audibly over the hump of the rim.
– Screw in valve insert.
– Check tyre pressure to make sure prescribed pressure has
been reached.
– Balance wheel.
1. Wheels, tyres 179

1.5 Wheel change

⇒ “1.5.1 Wheel change, protecting wheel centring seat against
corrosion”, page 180
⇒ “1.5.2 Wheel change, installation requirements”, page 180
⇒ “1.5.3 Wheel change, installation instructions for wheel
change”, page 181
⇒ “1.5.4 Wheel change, wheel installation”, page 183
1.5.1 Wheel change, protecting wheel cen‐

tring seat against corrosion
Applies to alloy and steel wheels
When changing a wheel, wheel centring seat should be waxed
using wax spray to prevent corrosion between wheel centring seat
and wheel rim ⇒ Electronic parts catalogue “ETKA” . AG. Volkswagen AG d
agen oes
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– Remove wheel. d byV
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– Thoroughly clean wheel centring seat on wheel hub and uthe
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centring ring of the wheel rim. s a c
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– Apply wax to centring area -arrow- with a brush.

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Ensure that only centring ring -arrow- but not contact surface of
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wheel rim has been waxed. Otherwise, the brakes will be soiled,
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which would reduce the braking efficiency.
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WARNING
es, in part or in w
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Wheel bolts, contact surfaces of wheel hub and wheel rim and
wheel hub threads must not be waxed. Never treat wheel se‐
curing bolts with lubricant or corrosion protection materials!
rrectness of i
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– Install wheel and tighten bolts or nuts ⇒ page 178 .
nform
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1.5.2 Wheel change, installation require‐

m
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ments
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Warming cold tyres to minimum fitting temperature
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This instruction also applies to ultra-high performance tyres (as‐ copy Vo
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pect ratio less than or equal to 45% and speed symbol V or cted agen
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higher).
WARNING
The minimum fitting temperature of a tyre should be between

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

warm the upper part of the sidewall and the inside of the upper
bead to at least 15°C.
• This internal temperature is referred to as the core tempera‐
ture.
• Rubber is a poor conductor of heat. Therefore, a cold tyre must
be left in an area with the correct temperature for a sufficiently

long period so the inner rubber layers can warm up to at least

15°C.
• The surface temperature of the tyre during the warming up
phase is no indication of the internal temperature of the tyre.
• To enable cold tyres to absorb heat from the ambient air as
quickly as possible, they should not be stacked on top of one
another. Instead, the tyres should be stored individually in or‐
der to allow the warm air to “circulate” around them effectively.
• Tyres must never be placed in front of a radiator or hot air
blower for warming, since this can very quickly lead to critical
surface temperatures.
• Heating the tyres without damage can only be achieved by
heating with warm water or warm air (max. 50°C)!
• If cold tyres (below 0°C) are transferred to a warm environment
(above 0°C), a layer of condensation immediately forms on the
AG. Volkswagen AG d
surface of the tyre. This layer of condensation kswindicates
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• Once the layer of frost has thawed, condensate water forms.
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The condensation should be dried with a cloth so that the fur‐
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ther warming process is not delayed due to a temperature drop
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Warming times:
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♦ Tyres with a temperature of above 0°C must be kept at least
spec
at 19°C for at least 2 hours.
t to the co
♦ Tyres with a temperature of below 0°C must be kept at least
at 19°C for at least 2.5 hours.
rrectne
Warming recommendations:
♦ If possible, tyres should be stored in the workshop 1 day before
ss
they are fitted (order preparation).
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♦ Store on an insulated base, pallet or on a similar surface raised
form
mer
from the floor. atio

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♦ Position the tyres individually to allow the warm air to “circu‐

n
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or
late” around them effectively.

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♦ Wipe off condensation

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♦ Never heat with a radiator or hot air blower!

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1.5.3 Wheel change, installation instructions
by lksw
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for wheel change
WARNING
Perform the checks and follow the instructions listed below.

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

Loss Indicator has to be recalibrated any time one or more wheels
are removed or fitted ⇒ page 186 .

– Check to ensure that contact surfaces -arrows- on brake disc

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

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

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

must be renewed.

1.5.4 Wheel change, wheel installation

– Preserving wheel centring seat ⇒ page 180 .
1- When fitting the wheel, pull in all wheel bolts uniformly by
hand.
2- Tighten diagonally to 30 Nm.
3- Lower vehicle onto floor. Use torque wrench to firmly tighten
wheel bolts diagonally to specified torque ⇒ page 178 .
WARNING
Do not use an impact screwdriver to screw in the bolts.
1.6 Tyre sealant disposal

♦ Tyre sealant or residue must not be mixed or disposed of with gen AG. Volkswagen AG d
other fluids. Vol
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♦ Excess tyre sealant must be collected and stored in risa plastic
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container. The plastic container can be disposed
au
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the disposal system along with the breakdownssset (when the c
ce
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expiry date is exceeded)

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♦ The items can be returned or disposed of through the existing
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workshop disposal system.
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♦ Contact the service provider or the waste disposal officer of
, is n
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the sales centre or importer.
hole
spec
1.7 Models with breakdown set
es, in part or in w
t to the co
These vehicles are equipped with either a spare wheel or a break‐
down set.
rrectness of i
Depending on the vehicle model and equipment, the breakdown
l purpos
set is installed in different locations:

♦ Commercial vehicles ⇒ page 183
nform
ercia
♦ Multivan with triple rear seat bench ⇒ page 184

m
a
com
ti
♦ Multivan with individual seats (swivel seats) ⇒ page 184
on in
r
te o
♦ Commercial vehicle/Multivan with co-pack set ⇒ page 184 thi

s
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Breakdown set in commercial vehicles

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Location: In commercial vehicles without a second battery, the
yi Co
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breakdown set is stowed in the driver's seat chassis.
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pyri by
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by c lksw
cted agen
Prote AG.

Breakdown set in the Multivan with triple rear seat bench

Location: In the Multivan with triple rear seat bench, the break‐
down set is stowed in the left drawer in the triple seat bench.
Breakdown set in the Multivan with individual seats (swivel seats)
satelettronica
Location: In the Multivan with individual seats (swivel seats), the
breakdown set is stowed in the individual seat's (swivel seat's)
drawer.
AG. Volkswagen AG d
agen oes
olksw not
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spec
es, in part or in w
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Breakdown set in the commercial vehicle/Multivan as a parts con‐

signment set
Location: In commercial vehicles with a second battery and in
rrectness of i
certain Multivan vehicles, the breakdown set is stored as a parts

l purpos
consignment set in the passenger door storage compartment.

The tyre sealant in the bottle has a limited shelf life.
nform
ercia
Therefore, the expiry date is indicated on the bottle -arrow-.

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In this example, the expiry date 05/2003 has expired. The bottle
must be renewed.
If the bottle was opened e.g. at a "flat tyre", it must also be re‐
newed.
AG. Volkswagen AG d
agen oes
olksw not
byV gu
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, is n
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spec
satelettronica
es, in part or in w
t to the co
rrectness of i
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nf
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orm
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atio
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Cop py
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rig ht
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by lksw
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AG. Volkswagen AG d
agen
2 Tyre Pressure MonitoringVol System
oes
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⇒ “2.1 System description – Tyre Pressure oris Monitoring System”, eo
th
page 186 ss
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2.1 System description – Tyre Pressure
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Monitoring System
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General mode of function
wit
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The tyre pressure monitor display serves as a warning device in
ole,
spec
the event of a slow puncture. Within certain limits, this system is
able to draw conclusions about changes in tyre pressures based
t to the co
on changes in the rotation speed ratios (data obtained using ABS
speed sensors). In this way, the tyre pressure monitor display can
in most cases detect a pressure loss on one wheel.
rrectne
A change in a wheel's rolling circumference will be indicated by
the tyre pressure monitor warning lamp - K220- lighting up in the
ss
dash panel insert. A tyre's rolling circumference may change as
o
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f
a result of:
inform
mer
♦ Insufficient tyre inflation pressure
atio
m
satelettronica
o
n
♦ Structural tyre damage
c
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or
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♦ One-sided loading of vehicle
sd
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♦ Increased load on one axle, e.g. due to towing a trailer

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♦ Use of snow chains t. Cop py
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♦ Temporary spare wheel installed p by
co Vo
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♦ Wheel renewal Prote AG.
Tyre Pressure Loss Indicator: calibrating

– Perform calibration ⇒ Maintenance ; Booklet 20.1 .

3 Wheel alignment
⇒ “3.1 Notes for wheel alignment”, page 187
⇒ “3.2 Conditions for testing”, page 187
⇒ “3.3 Test preparations”, page 188
⇒ “3.4 Specifications for wheel alignment”, page 190
⇒ “3.5 Wheel alignment procedure”, page 193
⇒ “3.6 Necessity of wheel alignment”, page 194
⇒ “3.7 Adjusting camber at front wheels”, page 195
⇒ “3.8 Adjusting front axle toe”, page 196
⇒ “3.9 Adjusting toe at rear axle”, page 197
⇒ “3.10 Vehicle data sticker”, page 199
3.1 Notes for wheel alignment

Wheel alignment must be performed only using a VW/AUDI-ap‐
proved wheel alignment unit!
satelettronica
Whenever wheels are aligned, both the front and rear axles must
be measured.
Otherwise, the steering rack may not be centred!
All information required for vehicle geometry measurement is in
the wheel alignment computer.
Current data »updates« are located in Volkswagen ServiceNet.
n AG. Volkswagen A ge G do
swa es
⇒ VW ServiceNet; by
VoSystems;
lk Wheel alignment computer
not
gu
ara
soft‐
ware; Beissbarth
ris
ed
nte
tho eo
⇒ VW ServiceNet;
ss
au Systems; Wheel alignment computer soft‐
ra
c
ware; Hunter
ce
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nl
pt
du
an
⇒ VW ServiceNet; Systems; Wheel alignment computer soft‐

itte
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erm
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ility
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⇒ VW ServiceNet; Systems; Wheel alignment computer soft‐

wit
, is n
ware; John Bean

h re
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spec
3.2 Conditions for testing

es, in part or in w
t to the co
• Check suspension, wheel bearings, steering and steering link‐

age for excessive play and damage.
rrectness of i
• Tread depth difference does not exceed 2 mm on one axle.

l purpos
• Check prescribed inflation pressure of tyres.

• Ensure vehicle is unladen.
nform
ercia
• Fuel tank must be full.

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at
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• The spare tyre and vehicle tool set must be secured at the
n
c
in t
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specified locations in the vehicle.

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ate
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• The washer fluid reservoir must be full.

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• When checking wheel alignment, ensure that sliding plates

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and turn tables are not touching end stop.
t. Cop py
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by
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3. Wheel alignment 187

Note
♦ To allow running gear to »fully settle«, wheel alignment should

not be checked before the vehicle has completed 1000 to
2000 km.
♦ When making adjustments, try to adhere to the relevant spec‐
ifications precisely.
♦ Refer to the user's manual of the equipment maker for proper
attachment and adjustment of the measuring devices.
♦ Wheel alignment platforms and alignment units and comput‐
ers should be checked and adjusted as necessary during n AG. Volkswagen AG do
inspection and maintenance at least once per year! lkswage es n
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♦ Handle these highly sensitive measuring devices carefully
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conscientiously. au
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3.3 Test preparations
pt
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⇒ “3.3.1 Test preparations, wheel alignment with no driver assist
pe
ility
systems”, page 188
ot
satelettronica
wit
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⇒ “3.3.2 Test preparations, wheel alignment with driver assist
hole
systems”, page 190
spec
es, in part or in w
t to the co
3.3.1 Test preparations, wheel alignment with no driver assist systems
rrectness of i
l purpos
nform
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com
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equipment required
satelettronica
AG. Volkswagen AG d
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♦ Wheel alignment computer - V.A.G 1813F- or VW/Audi-ap‐

proved wheel alignment units
rrectness of i
♦ Brake pedal depressor - V.A.G 1869/2-

l purpos
♦ Insert tool, 18 mm - T10179-

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

m
at
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Otherwise, the result of the measurement will be incorrect.

ion
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in t
or
If runout compensation is not performed, it is not possible to adjust

his
ate
toe-in correctly!
do
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Please follow the instructions of the manufacturer of the wheel

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t.
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alignment equipment.
Co
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– Carry out wheel runout compensation.
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– Apply brake pedal depressor - V.A.G 1869/2- . cted agen
Prote AG.
– Use brake pedal depressor to depress brake pedal.

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

driver assist systems
The following steps are required if one or more driver assist sys‐
tems on the vehicle are to be calibrated via the “Quick-start”
procedure (i.e. without first checking and adjusting the wheel
alignment):
• Before driving the vehicle onto the alignment platform, make
sure there is sufficient space between the vehicle and the cal‐
ibration unit. The distance between the calibrating device and
the vehicle must be 120 cm ± 2.5 cm.
• If the available space is not adequate, move the vehicle back‐
wards on the alignment platform as required. This allows the
use of the respective floor area.
• Before starting calibration, read out event memory and rectify
any faults.
• Vehicle accurately aligned, suspension bounced and rocked
several times.
satelettronica
• When checking wheel alignment, ensure that sliding plates
Volkswagen AG
and turn tables are not touching
sw ageend
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• Connect battery charger d b ⇒ Vehicle electrics; Rep. gr. 27 u; ara
ise nte
Battery; Chargingthbattery
or . eo
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• Move front wheels
ss to straight-ahead position.
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nl
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• Connect ⇒ Vehicle diagnostic tester to vehicle, route diagnos‐

an
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tic cable through open door window.

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• Vehicle exterior lighting switched off.

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• All doors of vehicle are closed.

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spec
• Press button to select required calibration on wheel alignment

es, in part or in w
computer.
t to the co
3.4 Specifications for wheel alignment

rrectness of i
l purpos
Note
nform
ercia
The ride heights shown in the table refer to dimension -a-.

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Front axle
PR num‐ A8B A8B A8J 1/2 payload Full load
bers A9K+1BA A8E A8Q+2MD+A8M
1BL A9K+2MD+A8J +2MD+K4H
2MF+1BB K4H A9W
1BH AG. Volkswagen AGA8Z+2MD+1BV
K4J+0E1+1BA
swagen does
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2MG rised 1BL+K4L 2MH+1BQ ran
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2MK+2MLut
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2MQ
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2MT 2MF
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2MU+K4H 1BQ +A8Q
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A9W A9W
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A8M+0E2+1BA A8M+0E1+1BA
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1BL 1BL
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2MF 2MF
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spec
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Toe-in at 5' ± 10' 5' ± 10' 5' ± 10' 5' ± 10' 0' ± 10'
t to the co
wheel
Total toe 10′ ± 20′ 10′ ± 20′ 10′ ± 20′ 10' ± 20' 0' ± 20'
(without
rrectness of i
load)
satelettronica
l purpos
Camber -20′ ± 45′ -30′ ± 45′ -40′ ± 45′ -35' ± 45' -1° ± 45'
(in
straight-
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sition)
at
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Maximum Max. 1° Max. 1° Max. 1° - -
in t
or
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sides Cop py
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Caster 4° 10′ ± 40′ yri
4° 20′ ± 40′ 4° 30′ ± 40′ 4° 40' ± 40' 5° ± 40'
p by
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Maximum Max. 1° cted
Max. 1° Max. 1° Max. 1° Max. 1°
agen
Prote AG.
permissi‐
ble differ‐
ence be‐
tween
sides
Checking dimensions for ride height, front axle

Dampers 1BA 1BA 1BQ 1BJ 2MD 2MD 1BH
1BL 1BL 1BB 2MH 2MQ
2MF (stand‐ 2MF (stand‐ 2MG 1BV 2MR
ard) ard) 2MK 1BC 2MT
2ML 1BQ 2MU
PR num‐ A8B K4H K4L All vehicles K4H A8B/ All vehi‐
bers A9K+K4H K4L K4K A8Z A9K cles
A9W K4J A9A A9W (not
A8M+0E2 A8J A8M+0E1 BlueMo‐
A8E K4A tion)
A8Q A8J
A9A+A9W A8Q
A8M+0E1
Ride 471 ± 10 mm 455 ± 10 mm 455 ± 471 ± 10 mm 437 ± 10 mm 455 ± 471 ±
height 10 mm 15 mm 15 mm

Front axle special vehicle Rockton

Volkswagen Seikel chassis with eleva‐ Special vehicle Rockton
ted height agen
AG. Volkswagen AG d
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Toe-in at wheel d byV
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+0° 05′ ± 05′ gu
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Total toe (without load) hor +0° 10′ ± 10′ eo
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Camber (in straight-ahead position) ss +0° 15′ ± 30′ c
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Caster +3° 50′ ±30′
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Rear axle , is n
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PR num‐ A8B A8B A8M+2MD K4L 1/2 Full
spec
bers A9K+1BA A9K+2MD+K4H 1BQ+A8J K4K pay‐ load1)
es, in part or in w
t to the co
1BL K4J A8Z A9A+1BA load
2MF+1BB A8J A8Q+2MD 1BL
1BH A8E 1BQ+K4H 2MF
rrectness of i
1BJ A8Q+1BA A9W+2MD 1BQ
2MG 1BL 1BQ+1BV
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2ML+2MK 2MF+A9W 1BC

2MQ A8M+0E1+1BA 2MH
satelettronica
2MR 1BL
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2MT 2MF
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2MU+K4H
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Toe-in at 5' ± 10' 5' ± 10' 5' ± 10' 5' ± 10' 15' 25'
n
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wheel ± 10' ± 10'
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Total toe 10′ ± 20′ 10′ ± 20′ 10′ ± 20′ 10′ ± 20′ 30' 50'
py by
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AG.
Camber -50′ ± 45′ -1′ ± 45′ -1° 10′ ± 45′ -1° 15′ ± 45′ -1° 25' -2° ±
(in ± 45' 45'
straight-
ahead po‐
sition)
Maximum Max. 1° Max. 1° Max. 1° Max. 1° Max. Max. 1°
permissi‐ 1°
ble differ‐
ence be‐
tween
sides
1) Vehicles which permanently travel with gross axle weight rating must be set to these values.

lkswage es n
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Running gear, axles,acsteering - Edition 02.2019
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Checking dimensions for ride height, rear axle
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Dampers 1BA 1BA 1BJ 2MD 2MD 1BA
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2MK 1BQ
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2MQ
2MR
2MT
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2MU
PR numbers A8B K4H All vehicles K4H A8B/A9K +K4L
ss
A9K+K4H K4J A8Z (not BlueMo‐ K4K
o
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A9W A8E A9W tion) A9A
nform
A8M+0E2 A8J A8M+0E1
mer
A9W+0E1 A8J
atio
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A8Q
n
c
i
or
n
K4A
thi
te
sd
va
Ride height 479 ± 15 mm 459 ± 10 mm 479 ± 15 mm 439 ± 10 mm 459 ± 10 mm 429 ± 10 mm

i
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t.
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satelettronica
t. C rig
Rear axle special vehicle Rockton gh ht
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Volkswagen Seikel chassis with eleva‐ Special vehicle Rockton
cted agen
Prote AG.
ted height
Toe-in at wheel +0° 05′ ± 05′
Total toe (without load) +0° 10′ ± 10′
Camber (in straight-ahead position) +0° 00′ ± 30′
3.5 Wheel alignment procedure
Note
Always adhere to the following procedure!
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 Inspect axle components and
body ⇒ page 195
↓ ↓
↓ ← ← ← ← ←
↓
Check rear axle camber → Is actual value within toler‐ → No
ance?
↓ ↓

↓ ← ← yes Inspect axle components and

body
↓ ↓
↓ ← ← ← ← ←
↓
Check rear axle toe → Is actual value within toler‐ → No
ance?
↓ ↓
↓ ← ← yes Adjusting ⇒ page 197
↓ ↓
↓ ← ← ← ← ←
↓
Check front axle caster → Is actual value within toler‐ → No
ance?
↓ ↓
G. Volkswagen AG
↓ ← ← wayes
gen A does Inspect axle components and
olks not
body
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↓ r is nte
↓
satelettronica
tho eo
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↓ ← s←
s ← ← c ←
ce
le
↓
un
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Check front axle toe → Is actual value within toler‐ → No
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ance?
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↓ ↓
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, is n
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End ← yes Adjusting ⇒ page 196
hole
spec
↑ ↓
es, in part or in w
t to the co
↑ ← ← ← ← ←
1)If steering wheel is not centred, it must be straightened after rrectness of i
wheel alignment is finished. Then carry out basic setting for steer‐
ing angle sender - G85- using ⇒ Vehicle diagnostic tester.
l purpos
nform
ercia
3.6 Necessity of wheel alignment

m
a
com
tio
♦ The vehicle does not handle properly.

n in
r
te o
thi
♦ Vehicle has been involved in an accident and components

s
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have been renewed.

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♦ Axle components have been removed and reinstalled.

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♦ Tyres are worn more on one side. ht. rig
rig ht
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Front axle component was Alignment neces‐ Rear axle component re‐ Alignment necessary
by lksw
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renewed. sary newed
AG.
yes No yes No
Suspension link X Suspension link X
Bonded rubber bush in sus‐ X Bonded rubber bush in sus‐ X
pension link pension link
Wheel bearing housing X Wheel bearing X
Wheel bearing X Coil spring X
Track rod/track rod ball joint X Shock absorbers X
Steering rack X Anti-roll bar X
Subframe X
Suspension strut X
Anti-roll bar X

Front axle component was Alignment neces‐ Rear axle component re‐ Alignment necessary
renewed. sary newed
yes No yes No
Swivel joint X
Bonded rubber bush in sub‐ X
frame
Coil spring X
Shock absorbers X3) X4)
3) Always Transporter Maxi and also all vehicles with suspension
strut secured with threaded connection.
4) Suspension strut with clamp connection.
Front axle component re‐ Alignment neces‐ Rear axle component re‐ Alignment necessary
moved and reinstalled sary moved and reinstalled
yes No yes No
Subframe X 1) Suspension link X
satelettronica
Suspension link X Coil spring X
Wheel bearing housing X Shock absorbers AG. Volkswagen A X
n G do
wage es n
Suspension strut X3) X4) Anti-roll bar
yV
olks ot g X
b ua
ed ran
Swivel joint X horis tee
t or
Anti-roll bar X au ac
ss
ce
le
Steering rack removed X 2)

un
pt
from subframe, raised and
an
d
itte
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secured
rm
ab
pe
ility
Coil spring X
ot
wit
, is n
Shock absorbers X3) X4)
h re
hole
spec
1 Misalignment of steering wheel following removal and installa‐
es, in part or in w
t to the co
tion of subframe is permitted within a tolerance of ± 1.5° without
requiring wheel alignment.
2)
rrectness of i
Misalignment of steering wheel following removal and installa‐
tion of steering rack on subframe is permitted within a tolerance
l purpos
of ± 1.5° without requiring wheel alignment.

3) Always Transporter Maxi and also all vehicles with suspension nform
ercia
strut secured with threaded connection.

m
4)
com
Suspension strut with clamp connection.

ion in
r
te o
thi
s
iva
do
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3.7 Adjusting camber at front wheels

um
fo
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ng
t.
yi Co
Cop py
t. rig
gh
Note
ht
pyri by
Vo
co lksw
by
cted agen
Prote
♦ It is not possible to adjust camber of front wheels!
AG.
♦ If the measured values are outside the allowed tolerance,

camber can only be corrected by renewing the affected axle
components.

3.8 Adjusting front axle toe

Required special tools, testers, measuring instruments and aux‐
iliary items wage
es
olks not
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edb ara
ris nte
tho eo
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c
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ce
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un
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spec
es, in part or in w
t to the co
rrectness of i
♦ Torque wrench - V.A.G 1332/-
l purpos
♦ Insert - V.A.G 1332/11-
satelettronica
nform
ercia
Note
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a
com
tio
♦ Before carrying out the adjustments, turn the steering to the
n in
r
centre position as requested by the wheel alignment comput‐

te o
thi
er.
s
iva
do
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rp
cum
♦ Procedure for adjusting toe on front axle is explained for left
fo
en
ng
track rod. Setting must be performed on right side as well if

t.
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op
necessary. C py
ht. rig
rig ht
py by
co Vo
by lksw
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Prote AG.

– Loosen lock nut -1- while counterholding track rod ball joint
-4-.
– Loosen clip -2- using hose clip pliers - V.A.G 1921- . Push
clamp off boot.
– Turn track rod on hexagon -3- until specified value is attained.
Note
♦ After completing the adjustment, ensure that the boot is not

twisted.
♦ Twisted boots have a shorter service life.
– Tighten lock nut -1- with insert tool - V.A.G 1332/11- . Coun‐
terhold on track rod ball joint -4-.
– Check specified value of toe setting again.
Note
satelettronica
♦ It is possible that the value will change slightly when lock nut
is tightened.
♦ If the measured toe value lies within the tolerance, the adjust‐
ment is correct.
– Fit clamp -2- properly. AG. Volkswagen AG d

agen oes
ksw
Specified torques by V ol not
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ara
ed
is nte
♦ ⇒ “3.4 Repairing
hor steering rack”, page 230 eo
aut ra
ss c
3.9 Adjusting toe at rear axle

ce
le
un
pt
an
d
itte
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Required special tools, testers, measuring instruments and aux‐

rm
ab
iliary items
pe
ility
ot
wit
, is n
♦ Torque wrench - V.A.G 1332/-

h re
hole
spec
es, in part or in w
t to the co
rrectness of i
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nform
mercia
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com
tion in
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Note
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♦ Note that loosened nuts and bolts must be renewed.
Co
Cop py
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♦ Do not tighten the threaded connection until the vehicle is standing on its wheels in unladen state or, if the
gh ht
pyri by
vehicle is raised, it is brought to the unladen position.
o Vo
by c lksw
cted agen
Prote AG.

lkswage es n
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byV ua
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ir se tee
tho
u or
a ac
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ce
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nl
pt
du
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erm
ab
ility
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wit
, is n
h re
hole
spec
es, in part or in w
t to the co
satelettronica
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
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r
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cu
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f
en
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t.
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Cop py
t. rig
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pyri by
Vo
co lksw
by
cted agen
Prote AG.
– Remove eccentric bolt and renew with new eccentric bolt ⇒
Electronic Parts Catalogue (ETKA) .
– Do not tighten eccentric bolt yet.
– Turn eccentric bolt -2- until specification is attained.
– Tighten nut -1-.
Specified torques

3.10 Vehicle data sticker
Note
♦ Various types of running gear are installed depending on en‐

gine and equipment level. These are identified by production
control numbers.
♦ Production control numbers are relevant for the wheel align‐
ment specifications.
♦ The appropriate production control numbersagon vehicle
en A data
G. Volkswagen AG
do
sticker or in "Vehicle-specific notes" indicate
yV
olks which running
w es n
ot g
gear is fitted to a vehicle ⇒ Vehicle-specific
ed
b notes; Vehicle ua
ran
data; PR numbers . ris tee
tho or
au ac
♦ The vehicle data sticker is located
ss in the area of the front seats
ce
le
on the left, on the footwell trim.

un
pt
an
d
itte
♦ From production date March 2007, the vehicle data sticker
y li
rm
ab
-1- is located on the frame of the driver seat.
pe
ility
ot
wit
, is n
h re
satelettronica
hole
Example of PR number allocation:
spec
es, in part or in w
In this example, the vehicle is a Multivan (K4H) with the running
t to the co
gear -arrow- 1BA, standard springs and dampers. The vehicle
should be adjusted according to the specifications table for Mul‐
tivan (K4H), column 1BA/2MF, Standard without basic or shuttle
rrectness of i
equipment ⇒ page 190 .
l purpos
Some important “PR numbers” are listed in the table below.

PR number table:
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
PR number Definition
r
rp
cum
fo
en
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1BA Standard suspension

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1BB Heavy duty suspension
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1BC Lowered suspension, panel van BlueMotion cop Vo
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1BH Standard 2 (Maxi) suspension Prote AG.
1BJ Reinforced suspension

1BL Suspension, electronically controlled (DCC)
1BQ Lowered suspension, heavy duty anti-roll bars, electronically controlled (DCC)
1BV Sport suspension
2MD Lowered suspension
2MF Reinforced anti-roll bar at front and rear
2MG Reinforced springs, dampers and anti-roll bar at front and rear
2MH Lowered springs/dampers + reinforced anti-roll bar at front and rear
2MK Reinforced rear springs
2ML Reinforced dampers front and rear
2MQ/2MT Springs and dampers with increased front axle load
2MR/2MU Springs and dampers with increased front axle load + reinforced anti-roll bars front and rear
OE1 Short wheelbase
OE2 Long wheelbase
K4H Multivan
K4L Camper

PR number Definition
A8B Basic Equipment
A8J Multivan Trendline
A8M Caravelle Highline
A8Q Multivan Conceptline
A9A California Beach
A9K Caravelle Trendline
A9W Caravelle Comfortline
gen AG
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d
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ris
tho eo
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un
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pe
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wit
, is n
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hole
spec
satelettronica
es, in part or in w
t to the co
rrectness of i
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nform
mercia
a
com
tion in
r
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s
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Cop py
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Prote AG.

4 Adaptive cruise control

⇒ “4.1 Calibrating adaptive cruise control”, page 201
4.1 Calibrating adaptive cruise control

⇒ “4.1.1 Calibrating adaptive cruise control (ACC)”, page 201
4.1.1 Calibrating adaptive cruise control

(ACC)
Before adjusting the adaptive cruise control (ACC) system, check
the sensor, its bracket and its securing elements for damage, ex‐
ternal influence and secure seating. Repair any damaged parts if
necessary.
Before adjusting the adaptive cruise control (ACC) system, read
out the event memory and rectify any faults found.
The “measured misalignment-angle value” of the ACC control unit
indicates whether or not the sensor is out of adjustment.
Use only a wheel alignment machine and adjusting devices ap‐
proved by VW/AUDI to adjust the adaptive cruise control (ACC)
satelettronica
system.
Correct adjustment is an essential prerequisite for the perfect
functioning of the adaptive cruise control (ACC) system.
Note AG. Volkswagen AG d

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♦ Re-adjustment is required when: sed b gu
ara
nte
ri
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♦ The rear axle toe setting has been
aut
h
adjusted. ra
ss c
♦ The adaptive cruise control unit - J428- has been removed and
ce
le
un
pt
reinstalled.
an
d
itte
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erm
♦ The lock carrier has been removed and installed.

ab
ility
ot p
♦ The lock carrier has been released or displaced.

wit
is n
h re
ole,
♦ The lock carrier has been moved to the service position.

spec
♦ The misalignment angle is greater than –0.8° to +0.8°.

t to the co

rrectne
♦ Setting device - VAS 6430- or setting device, basic kit - VAS

6430/1-
ss o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
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sd
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cum
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fo
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rig ht
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♦ ACC reflector mirror - VAS 6430/3- Prote AG.
♦ Wheel alignment computer
4. Adaptive cruise control 201

Note
n AG. Volkswagen A
♦ Before driving vehicle onto owheel
lksw alignment platform, emake
age G do
s no
sure there is sufficient spaceby
V between vehicle and settingt de‐
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ara
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vice - VAS 6430- . The or distance between ACC reflecting mirror ntee
is
- VAS 6430/3- and au the sensor must be 120 cm ± 2.5 cm.
th or
a
ss c
♦ If available space is not adequate, move vehicle backwards
ce
le
un
pt
onto alignment platform as required to achieve space re‐
an
d
itte
quired.
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erm
ab
ility
♦ If the position of the ACC reflecting mirror - VAS 6430/3- on
ot p
wit
alignment beam is changed during the adjustment work, the
is n
h re
setting of setting device - VAS 6430- must always be checked
ole,
spec
(e.g. spirit levels, individual toe values on adjusting beam,
etc.).
t to the co
• Before starting adjustment, read out event memory and rectify
any faults.
rrectne
Adjustment procedure described here is based on setting device
s
- VAS 6430- .
s o
cial p
satelettronica
f
The following setting sequence is to be adhered to:
inform
mer
1- Establish a distance of 120 cm ± 2.5 cm between the ACC
atio
m
reflecting mirror - VAS 6430/3- fitted in the middle and the

o
n
c
sensor in the radiator grille.
i
or
n thi
te
sd
a
2- Install ACC reflector mirror - VAS 6430/3- centred on align‐

iv
o
pr
ment beam.
um
r
fo
en
ng
t.
yi
3- Adjust adaptive cruise control unit - J428- .
Co
Cop py
t. rig
If wheel alignment has just been carried out, the steps described
gh ht
pyri by
under “Setting without preceding wheel alignment” do not have to
co Vo
by lksw
cted
be carried out.
agen
Prote AG.
Setting without preceding wheel alignment

– Press button to select ACC calibration in wheel alignment
computer.
– Note testing preconditions for wheel alignment ⇒ page 187 .
– Drive car onto wheel alignment platform.
– Connect battery charger ⇒ Electrical system; General infor‐
mation; Rep. gr. 27 ; Charging battery .
– Connect ⇒ Vehicle diagnostic tester. (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 exterior lighting is switched off.
– Move front wheels to straight-ahead position.

– Mount quick-release clamps on rear wheels.
– Mount measurement transducers on rear wheels.
– Carry out wheel run-out compensation at rear wheels.

Setting with or without preceding wheel alignment

– If fitted, remove trim -1-.
– Detach trim -1- in -direction of arrow-.

– Remove dirt, if there is any, from the sensor lens.
AG. Volkswagen AG d
agen oes
olksw not
V
satelettronica
by gu
d ara
ise nte
or eo
h
aut ra
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ce
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un
pt
an
d
itte
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erm
ab
ility
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– Position ACC setting device - VAS 6430/3- centrally and par‐
is n
h re
allel at a distance -a- from centrally fitted ACC reflector mirror
ole,
- VAS 6430/3- to adaptive cruise control unit - J428- .
spec
t to the co
a - 120 cm ± 2.5 cm
rrectne
Note
ACC setting device - VAS 6430- is not allowed to be moved on

ss
alignment beam.
o
cial p
f inform
mer
atio
om
n
c
i
or
– Mount measurement transducers -1- of front wheels on align‐

thi
te
ment beam.
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
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pyri by
Vo
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by c lksw
cted agen
Prote AG.

– 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-
satelettronica
and -B- to - VAS 6430/3- horizontal.
– Adjust mirror -4- by means of crank handle -arrow- in such a
way that the laser beam contacts the centre of the sensor lens.
AG. Volkswagen AG d
agen oes
olksw not
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d b ara
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au ra
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nl
pt
du
an
itte
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erm
ab
ility
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, is n
h re
hole
– Position the mirror on side of the alignment beam so that the

spec
laser beam contacts the centre of the sensor lens -1-.

es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
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Cop py
t. rig
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co lksw
by
cted agen
Prote AG.

agen
Running
Volksw gear, axles, steering
oes
n-oEdition
t 02.2019
y gu
db ara
ise nte
– Level spirit levels -2- of the measurement utransducer
tho
r
-1-. eo
a ra
ss c
ce
e
nl
pt
du
an
itte
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erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
e
– Turn fine adjuster screw -5- until display on wheel alignment

at
do
riv
satelettronica
computer is within tolerance.
p
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.

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

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

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

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

cruise control unit - J428- :
– On the screen, click the following buttons one after the other:
♦ Running gear (Rep. Gr. 01; 40 - 49)
♦ 13 - Proximity control
♦ 01 - Onboard-diagnostic capable system AG. Volkswagen AG d
satelettronica
agen oes
olksw not
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♦ 13 - Proximity control ise
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♦ s au
13 - Adaptive cruise control, functions ra
c
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♦ 13 - Calibration
un
pt
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Follow the instructions on the screen to adjust the control unit.
erm
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ility
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Designation of adjusting screws of adaptive cruise control unit -
wit
is n
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J428-
ole,
spec
1- Adjuster screw 1
t to the co
2- Adjuster screw 2
rrectne
Note
ss
♦ For adjustment, use tool and clips from repair kit ⇒ Electronic
o
cial p
parts catalogue (ETKA) .

inform
mer
♦ For vehicles from July 2019, a different repair kit is used ⇒

atio
m
Electronic parts catalogue (ETKA) .

o
n
c
i
or
n thi
te
sd
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cted agen
Prote AG.

48 – Steering
1 Steering wheel
⇒ “1.1 Assembly overview - steering wheel”, page 207
⇒ “1.2 Removing and installing steering wheel”, page 207
1.1 Assembly overview - steering wheel
1 - Steering column
⇒ page 212
2 - Steering wheel
⇒ page 207
❑ Different versions, allo‐
cation ⇒ Electronic
Parts Catalogue “ETKA”
satelettronica
3 - Bolt
❑ 30 Nm + 90°
AG. Volkswagen AG d
agen oes
olksw not
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ara
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un
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ab
ility
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spec
t to the co
rrectness o
cial p
f in
1.2 Removing and installing steering wheel

form
mer
atio
m

o
n
c
i
or
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te
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fo
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Cop py
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rig ht
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Prote AG.
1. Steering wheel 207

AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
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un
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Removing
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WARNING
ole,
spec
The following conditions must be met before starting work on
t to the co
the electrical system and removing the steering wheel:
♦ Disconnect earth strap from battery ⇒ Electrical system;
satelettronica
rrectne
Rep. gr. 27 ; Battery; Disconnecting and reconnecting the
battery .
ss
♦ The wheels must be in straight-ahead position.
o
cial p
f inform
Failure to comply with these precautions may lead to subse‐
mer
quent failure of the airbag system!
atio
om
n
c
i
or
n thi
e
– Move steering column to middle height position.

t
sd
iva
o
pr
– Remove airbag unit ⇒ General body repairs, interior; Rep. gr. cum
r
fo
en
ng
69 ; Driver side airbag; Removing and installing airbag unit

t.
yi Co
op
with igniter . C py
ht. rig
rig ht
– Turn wheels to straight-ahead position.
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co Vo
by lksw
cted agen
Prote AG.
Note
The steering wheel must be removed/installed in the middle po‐

sition (wheels facing straight ahead).
208 Rep. gr.48 - Steering

. Volkswage
- Edition 02.2019
AG n AG d
agen oes
olksw not
– Remove bolt -1-. db
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ara
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– Mark position of steering wheel/steering columnutwith
ho a felt- eo
ra
tipped pen. ss a c
ce
le
un
– Pull steering wheel -2- off steering column.
pt
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Installing
erm
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ility
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is n
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spec
Note
t to the co
♦ Make sure that the wheels are pointing straight ahead before
fitting the steering wheel.
rrectne
♦ When installing a steering wheel that has been removed,
make sure that the markings on the steering column and steer‐
s
ing wheel are in line.
s o
cial p
f in
♦ When installing a new steering wheel (without marking), the
form
mer
steering wheel must be mounted in middle position (steering
atio
wheel spoke must be horizontal and wheels in straight posi‐
om
n
tion).
c
i
or
satelettronica
thi
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Specified torques
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o
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fo
en
ng
♦ ⇒ “1.1 Assembly overview - steering wheel”, page 207

t.
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op py
– Carry out road test.
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pyri by
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– If the steering wheel is skewed, the steering wheel must be
co lksw
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cted agen
removed again and fitted onto the splines of the steering col‐ Prote AG.
umn.
1. Steering wheel 209

2 Steering column
⇒ “2.1 Assembly overview - steering column”, page 210
⇒ “2.2 Checking steering column for damage”, page 211
⇒ “2.3 Handling and transporting steering column”, page 211
⇒ “2.4 Removing and installing steering column”, page 212
⇒ “2.5 Removing and installing intermediate steering shaft”, page
216
⇒ “2.6 Removing and installing protective sleeve for intermediate
steering shaft”, page 220
2.1 Assembly overview - steering column
1 - Steering column
❑ There is no provision for
repairing the steering
column
❑ Supplied as complete
satelettronica
component
⇒ page 212
2 - Bolt
❑ 20 Nm
3 - Bolt
AG. Volkswagen AG d
❑ 20 Nm agen oes
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4 - Bolt orise nte
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❑ 20 Nm aut ra
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5 - Nut
un
pt
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❑ 20 Nm +90°
itte
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rm
ab
pe
ility
ot
wit
❑ Ensure it is properly
, is n
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seated
hole
spec
❑ Part of steering column.

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t to the co
7 - Clip
rrectness of i
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❑ For intermediate steer‐

ing shaft.
nform
ercia
❑ Ensure it is properly
seated
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a
com

ion in
⇒ page 220
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9 - Power steering rack

do
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10 - Eccentric bolt
en
ng
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❑ Observe fitting instructions ⇒ page 216 ht. Cop py
rig
rig ht
11 - Intermediate steering shaft py by
co Vo
by lksw
cted agen
Prote AG.
12 - Bolt
❑ 25 Nm

2.2 Checking steering column for damage

Visual check
– Check all steering column parts for damage.
Checking function
– Check that steering column turns smoothly and easily.
– Check whether steering column can be moved in the longitu‐
dinal direction and vertically.
2.3 Handling and transporting steering col‐

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

tial.
♦ Improper handling of steering column may damage the
steering column, leading to safety risks.
satelettronica
Proper steering column handling and transport
♦ It is essential that gloves are worn.
♦ Use both hands to transport steering column.
♦ Hold steering column upper jacket tube and in area of upper
universal joint. olksw AG. V agen AG
agen does
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es, in part or in w
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Improper handling of steering column

rrectness of i
Transportation using the clamping lever leads to primary steering

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column damage.
nform
mercia
a
com
tion in
r
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thi
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cum
fo
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Cop py
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pyri by
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co lksw
by
cted agen
Prote AG.
2. Steering column 211

Improper handling of steering column with safety risks

Following methods of handling will damage universal joint bushes
and lower steering column bearing:
♦ Transporting steering column with one hand on jointed shaft.
♦ Bending joints more than 90°.
2.4 Removing and installing steering col‐
satelettronica
umn
lkswage es n
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es, in part or in w
t to the co
Removing
rrectness of i
Note
l purpos
♦ Only the complete steering column is supplied as a replace‐

ment part. Repair is not possible.
nf
ercia
or
♦ Steering lock housing can be transferred ⇒ Electrical system;

m
m
atio
Rep. gr. 94 ; Steering column switch module; Removing and

om
n in
installing steering lock housing .

or c
thi
te
sd
iva
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f
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ng
t.
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Cop py
t. rig
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pyri by
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co lksw
by
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Prote AG.

WARNING
The following conditions must be met before starting work on

the electrical system and removing the steering wheel:
♦ Mechanic must electrostatically discharge himself/herself.
This can be done by touching a suitable earthed metal
part, for example, a water pipe, a heating system pipe, a
metal frame or a lifting platform ⇒ page 4 .
Failure to comply with this precaution may lead to subsequent
failure of the electronic steering column lock control unit -
J764- !
♦ Disconnect earth strap from battery ⇒ Electrical system;
Rep. gr. 27 ; Battery; Disconnecting and reconnecting the
battery . wage
e ks s no
Vol t gu
♦ The wheels must be in straight-ahead
ed position.
by ara
is nte
or
Failure to comply with these precautions may lead to subse‐
th eo
au ra
quent failure of the airbag system!ss c
ce
e
nl
pt
du
an
itte
satelettronica
y li
erm
ab
ility
ot p
– Pull down lever under steering column.
wit
, is n
h re
– Swing steering column down as far as possible and pull out.
hole
spec
– Press lever under steering column back up again.
es, in part or in w
t to the co
– Remove airbag from steering wheel ⇒ General body repairs,
interior; Rep. gr. 69 ; Driver airbag; Removing and installing
airbag unit with igniter .
rrectness of i
– Remove steering wheel ⇒ page 207 .
l purpos
– Remove upper steering column trim ⇒ General body repairs,

interior; Rep. gr. 68 ; Compartments and covers; Removing
nform
ercia
and installing upper steering column trim .

m
at
om
– Remove lower steering column trim ⇒ General body repairs, ion

c
in t
interior; Rep. gr. 68 ; Compartments/covers; Removing and
or
his
e
installing lower steering column trim .

at
do
priv
– Remove steering column switch module ⇒ Electrical system;

um
for
en
g

n
t.
yi Co
installing steering column switch module . Cop py
ht. rig
rig ht
– Remove dash panel ⇒ General body repairs, interior; Rep. gr. py by
co Vo
70 ; Dash panel: Removing and installing dash panel .
by lksw
cted agen
Prote AG.
– Fold protective sleeve -1- upwards.
– Remove nut -3-, counter holding on eccentric bolt -2-.
– Unscrew eccentric bolt -2- in direction of -arrow- from its clam‐
ped connection. Remove eccentric bolt from universal joint.

– Pull universal joint off intermediate steering shaft.

– Unscrew bolt -1- and remove earth wire from steering column.
– Separate electrical connector of immobiliser -2- on reader coil.
AG. Volkswagen AG d
agen oes
olksw not
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ed
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, is n
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hole
spec
es, in part or in w
t to the co
– Separate electrical connector of ignition/starter switch -3- on
satelettronica
steering lock housing.
– Pull off complete wiring harness -3- with cable guide -2- from
rrectness of i
steering column.
l purpos
Vehicles with automatic gearbox:

– Detach cable for ignition key removal lock on steering lock
nform
ercia
housing ⇒ Electrical system; Rep. gr. 94 ; Steering column

m
switch module; Removing and installing steering lock hous‐

at
om
io
ing .
n
c
in t
or
his
e
Continuation for all vehicles:

at
do
priv
– Unscrew and remove bolts -4-, -5- and -1- of steering column
um
for
one after the another.

en
ng
t.
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Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
– Unscrew and remove bolts -3-, -2- and -1- of steering column
one after the another.

– Remove complete steering column -3- in direction of -arrow-

from assembly guide -2- of subframe -1-.
Installing
Install in reverse order of removal. During this procedure, observe
the following:
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
d
– Engage complete steering column -4- in risdirection of -arrow- in
e nte
satelettronica
o
subframe -1-. Guide centring pin -3-auinto
th assembly hole -2- eo
ra
when doing this. ss c
ce
le
un
pt
an
d
itte
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erm
ab
ility
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wit
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ole,
spec
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
– Start all securing bolts of steering column on left and right.

thi
te
sd
iva
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r
– First tighten left and right bolts -1- to specified torque.

p
cum
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fo
en
ng
– Then tighten left and right bolts -2- and -3- to specified torque
t.
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op
one after the other. C py
ht. rig
rig ht
by
– Fit universal joint to intermediate steering shaft. copy Vo
by lksw
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Prote AG.

swage es n
– Insert eccentric bolt in universalbyjoint.
Volk ot g
ua
d ran
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– Turn eccentric bolt -2- in anti-clockwise
tho direction “onto stop” tee
or
-arrow-. ss
au ac
ce
le
– Hold eccentric bolt in this position. Install nut -3- in this position
un
pt
an
and tighten to specified torque. d
itte
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erm
ab
– Fold protective sleeve -1- downwards.
ility
ot p
wit
– Install dash panel ⇒ General body repairs, interior; Rep. gr.
is n
h re
70 ; Dash panel; Removing and installing dash panel .
ole,
spec
– Install steering column switch module ⇒ Electrical system;
t to the co
installing steering column switch module .
– Install lower steering column trim ⇒ General body repairs, in‐
rrectne
terior; Rep. gr. 68 ; Compartments/covers; Removing and
installing lower steering column trim .
ss o
– Install upper steering column trim ⇒ General body repairs,
cial p
f in
interior; Rep. gr. 68 ; Compartments/covers; Removing and
form
mer
installing upper steering column trim .
atio
m
– Install steering wheel ⇒ page 207 .

o
n
c
i
or
satelettronica
thi
e
– Install airbag in steering wheel ⇒ General body repairs, inte‐

t
sd
va
rior; Rep. gr. 69 ; Driver side airbag; Removing and installing

i
o
pr
cum
r
airbag unit with igniter .

fo
en
ng
t.
yi Co
After complete installation, position of steering wheel must be . Cop py
checked during road test.
t rig
gh ht
pyri by
Vo
co
– Carry out basic setting for steering angle sender - G85- using
by lksw
cted agen
Prote
⇒ Vehicle diagnostic tester.
AG.
Specified torques
♦ ⇒ “2.1 Assembly overview - steering column”, page 210
♦ Steering column switch module ⇒ Electrical system; Rep. gr.
94 ; Steering column switch module; Removing and installing
steering column switch module .
♦ Driver side airbag unit ⇒ General body repairs, interior; Rep.
gr. 69 ; Driver side airbag; Assembly overview - driver side
airbag .
♦ Lower steering column trim ⇒ General body repairs, interior;
Rep. gr. 68 ; Compartments/covers; Removing and installing
lower steering column trim .
♦ Upper steering column trim ⇒ General body repairs, interior;
Rep. gr. 68 ; Compartments/covers; Removing and installing
upper steering column trim .
2.5 Removing and installing intermediate

steering shaft


AG. Volkswagen AG d
agen oes
olksw not
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d by ara
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or eo
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pt
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ility
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, is n
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hole
spec
es, in part or in w
t to the co
♦ Locking pliers for Phaeton steering rack - VAS 6199-
rrectness of i
l purpos
nform
ercia
satelettronica
m
at
om
ion
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in t
or
his
ate
do
priv
cum
for
en
ng
t.
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op
Removing C py
t. rig
gh ht
yri by
op Vo
by c lksw
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Prote
– Fold protective sleeve -1- upwards.
AG.
– Unscrew nut -3-, counterholding eccentric bolt -2- in direction

of -arrow- while doing so.
– Pull out eccentric bolt -2- from universal joint.
– Move universal joint back away from intermediate steering
shaft.
– Fold back floor covering beneath pedal cluster towards driver
seat.
– Remove bolts -1-.

– Lower intermediate steering shaft -2- slightly.
– Remove front left wheel.

– If fitted, remove cover -1- in area of wheel housing liner.
– Remove clip on protective sleeve -1-.

– Push protective sleeve -1- upwards and secure it from slipping
down, e.g. with a 6 mm hexagon socket wrench -A-.
– Pull out eccentric bolt -2- from universal joint.
satelettronica
shaft.
– Remove intermediate steering shaft downwards.
Installing
AG. Volkswagen AG d
agen oes
– Insert intermediate steering shaft. olksw not
byV gu
ara
d
– Fit universal joint of intermediate steering shaft
oris to steering
e nte
eo
h
pinion. aut ra
c
ss
– Tighten eccentric bolt -2- with nut -3- by hand.
ce
e
nl
pt
du
an
itte
– Tighten securing bolts ⇒ Item 12 (page 210) .

y li
erm
ab
ility
ot p
wit
, is n
Note h re
hole
spec
Ensure that the guides of the cover plate for the intermediate
es, in part or in w
steering shaft sit exactly in the holes in the body.

t to the co
– Tighten universal joint.

rrectness of i
– To do this, turn eccentric bolt -2- in anti-clockwise direction

l purpos
onto stop -arrow-, and hold eccentric bolt in this position.

nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
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Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

agen oes
Volksw not
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by ara
ed
ris ntee
– Pushut protective sleeve -1- with clamp -2- onto steering
ho or rack
-3-
ss a as far as it will go. ac
ce
le
Ensure that marking -arrow A- on protective sleeve and marking

un
pt
an
d
-arrow B- on steering rack align.

itte
y li
erm
ab
In left-hand drive vehicles, the mark "LHD" on protective sleeve
ility
ot p
-arrow A- and mark on steering rack -arrow B- must align.
wit
is n
h re
ole,
In right-hand drive vehicles, the mark "RHD" on protective sleeve
spec
t to the co
– Secure clamp -2- of protective sleeve -1- on steering rack
-3-.
rrectne
– If applicable, fit cover -1- in area of wheel housing liner.
ss
– Mount front left wheel.
o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
va
satelettronica
i
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
– Position intermediate steering shaft -2- in such a way that the
rubber lugs -arrows- are properly aligned.
– Tighten bolts -1-.
– Fit floor covering.
– Fit universal joint of steering column to intermediate steering

shaft.
»onto stop« -arrow- and hold eccentric bolt in this position.
– Fold protective sleeve -1- downwards.
Note
After fitting intermediate steering shaft, test drive the vehicle to

ensure that the centre position of the steering wheel is correct.
Specified torques

2.6 Removing and installing protective

sleeve for intermediate steering shaft
Removing
– Wheels in straight-ahead position.
satelettronica
– Remove front left wheel. n AG. Volkswagen AG do
lkswage es n
o ot g
– If fitted, remove cover -1- in area of wheel housingd byV liner. ua
ran
ir se tee
– Remove both clamps from protective sleeve. utho
or
ac
a
ss
ce
le
un
pt
an
d
itte
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erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co

rrectne

s

s o

cial p
f inform
mer
– Remove eccentric bolt -2- from universal joint.

atio
m

o
n
c
shaft.
or
n thi
te
sd
va
– Pull off protective sleeve -1- from intermediate steering shaft.

i
o
pr
cum
r
fo
Installing
en
ng
t.
yi Co
op py
Install in the reverse order of removal, observing the following: t. C rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

– Align recesses in protective sleeve -arrows A- with detents on

intermediate steering shaft -arrows B-.
– Carefully push protective sleeve -3- with upper clamp -2- onto
intermediate steering shaft -1- as far as it will go.
Note
Ensure that lugs -arrow B- on intermediate steering shaft -1- en‐

gage correctly in recesses in protective sleeve -arrows A-.
– Secure protective sleeve -3- with clamp -2- on intermediate

steering shaft -1-.
– Fit universal joint onto steering pinion.

– Insert eccentric bolt -2- in universal joint.
»onto stop« -arrow- and hold eccentric bolt in this position.
satelettronica
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
s c
– Push protective sleeve -1- with clamp -2- onto steering rack
s
ce
le
-3- as far as it will go.

un
pt
an
d
itte
y li

erm
ab

ility
ot p
wit
is n

h re

ole,
spec

t to the co

– Secure protective sleeve -1- with clamp -2- on steering rack
rrectne
-3-.
ss
– If applicable, fit cover -1- in area of wheel housing liner.

o
cial p
f inform
– Mount front left wheel.

mer
atio
Specified torques
om
n
c
i
or

thi
te
sd
va

i
o
pr
cum
r
fo
en
ng
t.
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Cop py
t. rig
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pyri by
Vo
o
by c lksw
cted agen
Prote AG.

3 Steering rack
⇒ “3.1 Assembly overview - steering rack”, page 222
⇒ “3.2 Removing and installing steering rack”, page 224
⇒ “3.3 Removing and installing track rod”, page 228
⇒ “3.4 Repairing steering rack”, page 230
3.1 Assembly overview - steering rack
1 - Bolt
❑ 6 Nm
AG. Volkswagen AG d
2 - Reservoir wage
n oes
Volks not
gu
❑ Hook reservoir into elock db
y ara
nte
carrier, clip in and
thorise‐
s
eo
cure with bolt s au ra
c
⇒ Item 1 (page 222)
s
ce
le
un
pt
3 - Connection hose
an
d
itte
y li
satelettronica
rm
❑ Clip connecting hose in‐
ab
pe
ility
to reservoir (only 4-cyl.
ot
wit
diesel engines)
, is n
h re
❑ Fit connection on cool‐
hole
spec
ing pipe with clip in 9
es, in part or in w
o'clock position
t to the co
❑ Fit connection on reser‐
voir, with clip on colour rrectness of i
identification flush with
push-on limit
l purpos
4 - Spring-type clip
❑ Pay attention to installa‐
nform
ercia
tion notes/colour identi‐

m
fications on hoses for

a
com
tio
installation
n in
r
te o
thi
5 - Coolant pipe
s
iva
do
r
❑ Cools power steering oil

rp
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in return to reservoir
en
ng
t.
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op
6 - Holder
C py
ht. rig
rig ht
❑ Fit bracket for cooling py by
co Vo
lksw
pipe on radiator on left in
by
cted agen
Prote
driving direction
AG.
7 - Return line
❑ Fit return line to cooling pipe, connection on cooling pipe with clip in 9 o'clock position
❑ For installation notes/installation position, see ⇒ page 224
❑ 32 Nm
8 - Bracket
❑ Retainer of return line on longitudinal member
❑ For intermediate steering shaft.
10 - Eccentric bolt
❑ Observe fitting instructions ⇒ page 216

11 - Universal joint
12 - Nut
❑ 20 Nm +90°
13 - Clip
Volkswagen AG
14 - Seal agen
AG. does
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❑ Renew after
ed
byremoval
V gu
ara
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15 - Bolt autho eo
ra
ss c
❑ Securing bolt for pressure line on power steering box
ce
le
un
pt
❑ 9 Nm
an
d
itte
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16 - Pressure line
erm
ab
ility
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wit
is n
❑ For installation notes/installation position, see ⇒ page 224
h re
ole,
spec
❑ 32 Nm
t to the co
17 - Bolt
satelettronica
rrectne
18 - Servotronic solenoid valve - N119-
❑ Mode of operation: Force of power-assisted steering declines as vehicle speed increases.
ss
❑ Cannot be renewed individually.
o
cial p
f in
19 - Nut
form
mer
❑ Self-locking, always renew after removing

atio
om
❑ 60 Nm +90°
c
i
or
n thi
te
20 - Nut
sd
iva
o
pr
❑ Self-locking, always renew after removing

um
r
fo
en
ng
❑ 33 Nm +90°
t.
yi Co
Cop py
. rig
21 - Power steering rack
ht ht
rig by
opy Vo
❑ Removing and installing ⇒ page 224 by c lksw
cted agen
Prote AG.
❑ Repairing ⇒ page 230
22 - Vane pump
❑ Altered version ⇒ Varioserv version from model year 2010 ►
❑ Vane pump adapts displacement to actual requirement for delivery volume, used with all 4-cyl. diesel
engines only
❑ Removing and installing, 4-cylinder diesel engine ⇒ page 252
❑ Removing and installing, 4-cylinder petrol engine ⇒ page 241
23 - Holder
❑ Retainer of suction hose on longitudinal member
24 - Suction hose
❑ From reservoir to vane pump
25 - Holder
❑ Bracket for cooling pipe mounted on radiator on right in driving direction
3. Steering rack 223

Installation note/installation position of pressure line:
Note
During installation/tightening of pressure line, make sure that lo‐

cating mechanism of pressure line -2- is in contact with housing
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Installation note/installation position of return line:
ab
ility
ot p
wit
, is n
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Note
hole
spec
es, in part or in w
During installation/tightening of return line, make sure that locat‐
t to the co
ing mechanism of return line -2- is in contact with housing -1-.
satelettronica
rrectness of i
l purpos
nform
mercia
at
3.2 Removing and installing steering rack
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.


equipment required
satelettronica
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
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or eo
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ss c
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an
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t to the co
♦ Hose clamps to 25 mm - 3094- rrectne

ss o
cial p

inform
mer

atio
om
Removing
n
c
i
or
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– Turn steering to straight-ahead position and engage steering

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lock.
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– Remove wheel. Prote AG.
– Clamp off suction hose at reservoir.

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– Loosen nut -1- on track rod ball joint but do not remove com‐orise nte
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– Press track rod off wheel bearing housing using ball joint puller
spec
- T10187- -2-.
t to the co
rrectne
– Open clip on protective sleeve -1-.
s
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f inform
– Unbolt universal joint from steering pinion.
mer
atio
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– Remove anti-roll bar ⇒ page 22 .

o
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– Depending on engine version, unbolt the respective pressure
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line from steering rack.
iv
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– Catch escaping hydraulic fluid.
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For vehicles with Servotronic:
C py
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– Separate electrical connector -2- on Servotronic solenoid
AG.
valve - N119- -1-.

Continuation for all vehicles:
– Remove rear engine mounting ⇒ Rep. gr. 10 ; Assembly
mountings; Removing and installing engine mounting .

– Push steering rack to left, turning it at the same time until
steering pinion faces downwards.
– Remove steering rack to left.
Installing
– Insert steering rack from left and lay on subframe.
– Insert anti-roll bar from left and lay on subframe.

– Install steering rack to subframe, and tighten nuts -arrows-.

– Install rear engine mounting ⇒ Rep. gr. 10 ; Assembly mount‐
ings; Removing and installing engine mounting .
– Attach anti-roll bar to subframe and tighten bolts.
– Fit nut and eccentric bolt.
– To tighten universal joint on steering pinion, turn eccentric bolt

-2- left »to stop« -arrow- and hold.
satelettronica
AG. Volkswagen AG d
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Cop py
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Prote AG.

– Pull protective sleeve -1- down to stop.

– Secure protective sleeve -1- with new O-type clip -2- on steer‐
ing rack -3-. To do this, use locking pliers for Phaeton steering
rack - VAS 6199- .
– Attach coupling rods to anti-roll bar and tighten nuts
⇒ Item 7 (page 13) .
– Tighten return line on power steering box. While doing this,
observe assembly instructions/installation position of return
line ⇒ page 224 .
– Tighten pressure line on power steering box. While doing so,
observe assembly instructions/installation position ofApressure
agen
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– Fill up with hydraulic fluid and bleedhorsteering
is system tee
⇒ page 237 . au
t or
ac
ss
– Check fluid level of power steering ⇒ Maintenance ; Booklet
ce
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nl
pt
du
20.1 ; Descriptions of work; Power steering: checking fluid lev‐
an
itte
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el .
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– Install track rods ⇒ page 228 and check tracking; adjust if
wit
necessary ⇒ page 187 .
, is n
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es, in part or in w
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Specified torques
rrectness of i
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♦ Rear engine mounting ⇒ Rep. gr. 10 ; Assembly mountings;

or
Removing and installing engine mounting

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3.3 Removing and installing track rod

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

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♦ Insert tool - V.A.G 1332/9-

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

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– Clean steering rack in area of boot. cted agen
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Running gear, axles, steering - Edition 02.2019 ss c
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– Use ball joint puller - T10187- to press track rod ball joint -1-
itte
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off wheel bearing housing steering arm.
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– Detach clamp -3- and pull off boot -4- from steering rack -5-.
ot
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– Using open-end spanner attachment - V.A.G 1923- (AF 38),
hole
spec
unscrew track rod -2- from rack of steering gear. Counterhold‐
es, in part or in w
ing at steering rack is not necessary.
t to the co
Note
rrectness of i
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If the steering rack shows signs of corrosion, damage or wear,
renew the complete steering rack.
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Installing
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The steering rack steering rack must be greased before installing
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Grease designation ⇒ Electronic Parts Catalogue “ETKA” .
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Never use any other grease.
C py
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rig
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– To grease, turn steering to full lock on both sides.
cop Vo
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Prote AG.
– Grease toothed rack on tooth and thrust piece side.
– Turn steering to straight-ahead position.
– Screw track rod -2- into toothed rack of steering gear -5-.
– Tighten track rod -2- with open-end spanner attachment -
V.A.G 1923- (AF 38). Counterholding at steering rack is not
necessary.
– Secure boot -4- to steering rack -5- onto stop using new clamp
-3-.
– To do this, use locking pliers for Phaeton steering rack - VAS
6199- or hose clip pliers - V.A.G 1275 A- .
– Make sure that the boot is not twisted.
– Bolt track rod ball joint -1- to wheel bearing housing steering
arm using a new nut.
– Perform wheel alignment ⇒ page 187 .
Specified torques
♦ ⇒ “3.4 Repairing steering rack”, page 230
3.4 Repairing steering rack

1 - Right track rod ball joint

❑ Check that dust caps
are undamaged and
correctly seated.
❑ If a track rod ball joint
was renewed, or re‐
moved and installed,
wheels must be aligned
⇒ page 187 .
2 - Nut
❑ When loosening and AG. Volkswagen AG d
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tightening nut, a 24 mm Volksw
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spanner must be used d by ara
to counterhold on track rise nte
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rod ball joint contact sur‐ s au ra
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nl
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❑ 60 Nm
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3 - Track rod
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⇒ page 228
h re
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spec
es, in part or in w
t to the co
❑ As a spare part, is sup‐
plied only with track rod
ball joint
rrectness of i
⇒ Item 1 (page 231) or
l purpos
and nut
⇒ Item 2 (page 231) .
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❑ 100 Nm
m
at
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5 - Boot
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❑ Check for damage

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❑ Must not be twisted after toe setting has been adjusted.

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6 - Clip C py
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❑ Renew after removal yri
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❑ Install new O-type clip with locking pliers for Phaeton steering rack - VAS 6199- or with hose clip pliers cted agen
Prote AG.
- V.A.G 1275- .
7 - O-ring
8 - Servotronic solenoid valve - N119-
❑ Mode of operation: Force of power-assisted steering declines as vehicle speed increases.
❑ Cannot be renewed individually.
9 - Rubber mounting
❑ Check for damage
10 - Steering rack
11 - Left track rod ball joint
❑ Check that dust caps are undamaged and correctly seated.
❑ If a track rod ball joint was renewed, or removed and installed, wheels must be aligned ⇒ page 187 .

satelettronica
AG. Volkswagen AG d
agen oes
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4 Hydraulic power steering

⇒ “4.1 Assembly overview - vane pump”, page 233
⇒ “4.2 Checking hydraulic fluid level of power steering”,
page 237
⇒ “4.3 Bleeding steering system after repairs”, page 237
⇒ “4.4 Check steering for leaks”, page 237
⇒ “4.5 Checking delivery pressure of vane pump”, page 238
⇒ “4.6 Removing and installing vane pump”, page 241
4.1 Assembly overview - vane pump

⇒ “4.1.1 Assembly overview - vane pump, 4-cylinder petrol en‐
gine”, page 233
⇒ “4.1.2 Assembly overview - vane pump, 4-cylinder diesel en‐
gine”, page 235
4.1.1 Assembly overview - vane pump, 4-cyl‐

inder petrol engine
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Note oris eo
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♦ If reservoir fluid level is low, always check steering system for
ce
le
un
pt
leaks ⇒ page 237 .
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♦ Never reuse hydraulic that has escaped; always dispose of it

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in an ecologically responsible manner.

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♦ Vane pumps from the parts stock are supplied dry (without
h re
ole,
fluid). Before installing the vane pump, fill it with hydraulic fluid
spec
and turn pump by hand. Otherwise, the pump may be noisy or

t to the co
even be damaged during operation.

♦ Use only the specified sort of fluid: hydraulic fluid, allocation
⇒ Electronic Parts Catalogue “ETKA”
rrectne
♦ The volume of fluid in the system is 0.7-0.9 litres.

ss o
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4. Hydraulic power steering 233

1 - Console
2 - Spacer
❑ Press back before in‐
stalling vane pump
3 - Bolt
❑ Securing bolt of vane
pump on bracket
❑ 25 Nm
4 - Suction hose
❑ From reservoir to vane
pump
❑ Observe installation po‐
sition on vane pump,
see
❑ Fit spring-type clip on
colour identification us‐
ing hose clip pliers -
satelettronica
V.A.G 1921-
6 - Suction hose marking
❑ Suction hose marking
must line up with mark‐
ing on vane pump pipe
when installed
7 - Marking on vane pump pipe
❑ Marking on vane pump
pipe must line up with
suction hose marking
⇒ Item 6 (page 234) agen
AG. Volkswagen AG d
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8 - Vane pump rise nte
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9 - Pulley
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❑ Use counter-hold tool - T10172- to install/remove.

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10 - Bolts
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❑ Securing bolts of pulley on vane pump

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❑ 25 Nm
spec
es, in part or in w
t to the co
11 - Seal
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12 - Bolts
❑ Securing bolts for block connection of pressure line
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❑ 9 Nm
nf
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13 - Pressure line
orm
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Caution
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pletely when installing.

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14 - Bolt Cop py
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❑ Securing bolt of vane pump on bracket
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Prote AG.

❑ 25 Nm
4.1.2 Assembly overview - vane pump, 4-cyl‐

inder diesel engine
Note
♦ Always check steering system for leaks if fluid level in reservoir

is low ⇒ page 237 .
♦ Never reuse hydraulic that has escaped; always dispose of it
in an ecologically responsible manner.
♦ Vane pumps from the parts stock are supplied dry (without
fluid). Before installing the vane pump, fill it with hydraulic fluid
and turn pump by hand. Otherwise, the pump may be noisy or
even be damaged during operation.
♦ Use only the specified sort of fluid: hydraulic fluid, allocation
⇒ Electronic Parts Catalogue “ETKA”
♦ The quantity of fluid in the system is 0.7-0.9 litres.
satelettronica
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 no fault is found, the vane pump unit must be re‐ G. Volkswage
newed. lksw
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Cop py
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Prote AG.

1 - Console
2 - Spacer
❑ Press back before in‐
stalling vane pump
3 - Bolt
❑ Securing bolt of vane
pump on bracket
❑ 25 Nm
4 - Suction hose
❑ From reservoir to vane
pump
❑ Pay attention of installa‐
tion position on vane
pump, see
⇒ Item 6 (page 236) or
⇒ Item 7 (page 236) wagen AG. Volkswagen AG doe
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5 - Spring-type clip ed by ara
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❑ Fit spring-type
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6 - Suction hose marking
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❑ Suction hose marking

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must line up with mark‐

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when installed
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7 - Marking on vane pump pipe

❑ Marking on vane pump
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pipe must line up with

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suction hose marking

when installed
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8 - Vane pump
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❑ Vane pump adapts displacement to actual requirement; used with all 4-cyl. diesel engines only
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9 - Pulley
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10 - Bolts py by
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❑ Securing bolts of pulley on vane pump
agen
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❑ 25 Nm
11 - Seal
12 - Bolts
❑ Securing bolts for block connection of pressure line
❑ 9 Nm
13 - Pressure line
Caution
Insert pressure line com‐
pletely when installing.

14 - Bolt
❑ Securing bolt of vane pump on bracket
❑ 25 Nm
4.2 Checking hydraulic fluid level of power

steering
⇒ Maintenance ; Booklet 20.1 ; Descriptions of work; Power
steering: checking fluid level
4.3 Bleeding steering system after repairs

– Check hydraulic fluid level and top up if necessary.
– Raise vehicle until front wheels are free.
– With engine switched off, turn steering wheel 10 times from
lock to lock.
– Check hydraulic fluid level and top up if necessary.
– Lower vehicle.
satelettronica
– Start engine.
– Turn steering wheel 10 times from lock to lock.
swage es n
– Check level of hydraulic fluid and top up if necessary ⇒ y VMain‐
olk ot g
ua
tenance ; Booklet 20.1 ; Descriptions of work; Power ir se steering:
d b ran
tee
checking fluid level . utho
or
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ss
Any air remaining in steering system will dissipate by itself over
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nl
the next 10 … 20 km driven.
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4.4 Check steering for leaks
erm
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ility
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Note
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spec
es, in part or in w
If hydraulic fluid level in reservoir is low after repairs are comple‐
t to the co
ted, steering system must be checked for leaks.
rrectness of i
– Start engine.
l purpos
– Turn steering wheel left and right to lock and hold briefly.
This develops the maximum possible pressure.
nf
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In this position, the following components must be checked for

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♦ Pinion seal on steering rack valve housing

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♦ All pipe connections

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♦ Rack seals ⇒ page 237

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Checking rack seals
C py
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– Open clip on bellows.
cop Vo
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Prote AG.
– Push boot back.
Note
If hydraulic fluid is visible in steering rack housing or in boot,

steering rack must be replaced.

4.5 Checking delivery pressure of vane

pump
♦ Hose clamp to 25 mm - 3094-
♦ Power steering tester - V.A.G 1402-
satelettronica
AG. Volkswagen AG d
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♦ Adapter set - V.A.G 1402/6-

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es, in part or in w
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or
♦ Adapter set - V.A.G 1402/19–1+2-

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– Clamp off suction and return hoses at reservoir using hose
AG. Volkswagen AG d
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clamp, up to 25 mm - 3094- . Volksw
oes
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– If fitted, remove noise insulation ⇒ Generalris body repairs, ex‐
e
tee
ho
terior; Rep. gr. 66 ; Noise insulation;auAssembly overview -
t or
ac
noise insulation . ss
ce
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nl
pt
– Position suitable drip tray underneath to collect hydraulic fluid.
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– Unscrew pressure line -2- from steering rack -1-.
ab
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satelettronica
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– Fit special tools as shown in illustration.
om
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1 - Power steering tester - V.A.G 1402-

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2 - Hose from adapter set - V.A.G 1402/6-

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3 - Adapter - V.A.G 1402/19–1-
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4 - Seal
C py
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5 - Connection of pressure line co Vo
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6 - Pressure line vane pump/steering rack
7 - Adapter - V.A.G 1402/19-2-
8 - Seal
– Remove hose clamp, up to 25 mm - 3094- from return suction
hose.

Lever on power steering tester - V.A.G 1402- must be in position

-2-.
– Start engine.
– Turn steering wheel approx. 10 times from lock to lock.
– Turn off engine and check hydraulic fluid level, replenish as
necessary ⇒ Maintenance ; Booklet 20.1 ; Descriptions of
work; Power steering: checking oil level .
– Check delivery pressure
Prerequisites for testing:
• System must be free of leaks
• Hoses and lines are not kinked or restricted.
• Poly V-belt tension OK.
Caution
Ensure that the shut-off valve is not closed in position -1- for
more than 5 seconds to avoid damage to the vane pump.
satelettronica
Take pump pressure reading immediately after shut-off valve
closes. Employ the aid of a second mechanic if necessary.
– Start engine. Set shut-off valve to closing position -1- with en‐
gine idling.
AG. Volkswagen AG d
agen oes
– Read pressure from power steering
Vol tester - V.A.G 1402- .
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Specification for delivery pressure:
rise nte
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110 to 120 bar ss c
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If the specification is not attained, renew the vane pump.

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– Switch off engine.

rm
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ility
– Clamp off suction and return hoses at reservoir using hose

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clamp, up to 25 mm - 3094- .
h re
hole
spec
– Remove pressure gauge and adapter.

es, in part or in w
t to the co
rrectness of i
l purpos
nform
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tion in
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Cop py
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AG. Volkswagen AG d
agen oes
olksw not
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d by ara
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eo Transporter 2016 ➤
ut
ss a Running gear, axles, steering
ra
c - Edition 02.2019
ce
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nl
pt
– Install pressure line leading to steering rack.
du
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itte
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erm
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ility
ot p
Note
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When tightening pressure line, ensure that locating mechanism
spec
of pressure line -2- is in contact with housing -1-.
es, in part or in w
t to the co
– Remove hose clamp, up to 25 mm - 3094- from return suction
hose.
rrectness of i
– Bleed steering system ⇒ page 237 .
l purpos
– Check hydraulic fluid level, replenish as necessary ⇒ Mainte‐

nance ; Booklet 20.1 ; Descriptions of work; Power steering:
nform
ercia
checking fluid level .

m
at
– Check steering system for leaks ⇒ page 237 .
om
ion
c
in t
r
– If present, install noise insulation ⇒ General body repairs, ex‐

o
his
te
terior; Rep. gr. 66 ; Noise insulation; Assembly overview -

a
do
riv
noise insulation .
p
cum
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4.6 Removing and installing vane pump
op
satelettronica
C py
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⇒ “4.6.1 Removing and installing vane pump, 4-cylinder petrol
op Vo
by c lksw
cted
engine”, page 241
agen
Prote AG.
⇒ “4.6.2 Removing and installing vane pump, 4-cylinder diesel

engine, EA189”, page 246
⇒ “4.6.3 Removing and installing vane pump, 4-cylinder diesel
engine, EA288”, page 252
4.6.1 Removing and installing vane pump, 4-cylinder petrol engine


equipment required
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♦ Drip tray for workshop hoist - VAS 6208-

atio
om
n
c
♦ Hose clamp pliers - V.A.G 1921-

or
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♦ Retainer - T10172-
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♦ Engine bung set - VAS 6122-

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♦ Hose clamps to 25 mm - 3094- cop Vo
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– If fitted, remove noise insulation ⇒ General body repairs, ex‐
noise insulation .
– Remove poly V-belt ⇒ Rep. gr. 13 ; Cylinder block, pulley end;
Removing and installing poly V-belt .
Note
Before removing poly V-belt, mark running direction. A used belt

can break if it runs in the opposite direction. When installing belt,
ensure that it is correctly seated in pulleys.

Vehicles with air conditioning system

– Remove air conditioner compressor ⇒ Heating, air condition‐
ing; Rep. gr. 87 ; Air conditioner compressor; Removing and wagen AG. Volkswagen AG does
installing air conditioner compressor . olks not
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– Remove poly V-belt pulley -1-. When loosening bolts
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with counter-hold - T10172- .
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vane pump.
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– Clamp off suction hose -1- at vane pump with hose clamps,
, is n
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up to 25 mm - 3094- -2-.
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
satelettronica
nf
ercia
orm
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or c
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– Loosen clip -3- using hose clip pliers - V.A.G 1921- . Detach
o
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hose -1- from nozzle -4-. yi

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yri
VAS 6122- . p by
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– Unscrew bolts of pressure line -1- and remove pressure line Prote AG.
from vane pump -2-.
– Seal pressure line with a suitable plug from engine plug set -
VAS 6122- .

– Unscrew bolt -3-.

– Unscrew bolts -1- of vane pump -2-.
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– Remove vane pump -2- from bracket -3-.
h re
satelettronica
hole
– Remove vane pump between subframe and engine.
spec
es, in part or in w
t to the co
rrectness of i
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nf
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orm
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or c
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Cop py
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– To prepare for installation, press spacer -1- back until flush
Prote AG.
with bracket -2-.

Installing

Note
♦ Always remove seals and oil seals.

♦ Before installing a new vane pump, fill with hydraulic oil on suction side. Turn vane pump by hand until
hydraulic oil exits from pressure side.
– Insert vane pump -7- into bracket -1-. Fit bolts by hand.
Pay attention to tightening sequence of securing bolts:
– First tighten vane pump bolts -8-.
– Then tighten vane pump bolts -3-.
– Fit pressure line -2- with new seal ⇒ Item 11 (page 234) .
satelettronica
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cial p
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mer
atio
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Cop py
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co
Note
by lksw
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Make sure that pressure line -2- is pressed fully into block connection of vane pump.
– Fit suction hose -5- to connection of vane pump -6-. When

installing, make sure that markings -arrow- align.

– Fit spring-type clip ⇒ Item 5 (page 234) using hose clip pliers
- V.A.G 1921- in marked area.
– Loosen hose clamps, up ton25
wage
AG.mm
Volks-w3094-
agen AGon suction hose
does
-5-. yV
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– Install poly V-belt
ris pulley -1- and tighten bolts -2-. Whenndoing
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this, brace
s auusing counter-hold - T10172- . or
ac
s
– Install poly V-belt for vane pump ⇒ Rep. gr. 13 ; Cylinder
ce
le
un
pt
block, pulley end; Removing and installing poly V-belt .
an
d
itte
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– Top up hydraulic fluid if necessary. Allocation ⇒ Electronic
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– Bleed steering system and check for leaks ⇒ page 237 .
ole,
spec
– Check fluid level of steering system and top up if necessary
t to the co
steering: checking fluid level .
Specified torques
rrectne
♦ ⇒ “4.1.1 Assembly overview - vane pump, 4-cylinder petrol
engine”, page 233
ss o
cial p
f
♦ Noise insulation ⇒ General body repairs, exterior; Rep. gr.
satelettronica
nform
66 ; Noise insulation; Assembly overview - noise insulation
mer
atio
m
♦ Air conditioner compressor ⇒ Heating, air conditioning sys‐

o
n
c
tem; Rep. gr. 87 ; Air conditioning compressor; Removing and

i
or
n thi
installing air conditioning compressor on bracket

te
sd
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4.6.2 Removing and installing vane pump, 4-

en
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cylinder diesel engine, EA189
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Only applies for vehicles with engine codes CAAA, CAAB, CAAC, co Vo
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CAAD, CAAE, CCHA, CCHB and CFCA
agen
Prote AG.


equipment required
satelettronica
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♦ Retainer - T10172- t to the co

rrectne

♦ Hose clamps to 25 mm - 3094-
ss o
cial p
inform
mer

atio
m

o
n
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noise insulation .
i
or
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te
sd
– Remove poly V-belt ⇒ Rep. gr. 13 ; Cylinder block, pulley end;

iva
o
r
Removing and installing poly V-belt .

p
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t.
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Note
t. rig
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co lksw
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Prote AG.


ing; Rep. gr. 87 ; Air conditioner compressor; Removing and
installing air conditioner compressor .
– Remove poly V-belt pulley -1-. When loosening bolts -2- brace
vane pump.
up to 25 mm - 3094- -2-.
satelettronica
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– Seal suction hose with a suitable plug from engine plug
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VAS 6122- . utho eo
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ss
– Unscrew bolts of pressure line -1- and remove pressure line
ce
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from vane pump -2-.
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VAS 6122- .
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satelettronica
– Unscrew bolt of bumper cover -3-.
– Remove coolant hose -1- from plastic bracket -2- and pull
coolant hose away to side.
AG. Volkswagen AG d
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– Swing vane pump -4- out forwards over cross-member. Pull

ility
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bumper cover -5- forwards slightly as you do so.

wit
is n
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spec
t to the co
rrectness o
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mer
atio
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i
or
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with bracket -2-.
Installing
AG. Volkswagen AG d
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spec
– Swing vane pump in from below over front cross-member.
es, in part or in w
t to the co
rrectness of i
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nf
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Prote AG.
Note

– Loosen hose clamps, up to 25 mm - 3094- on suction hose
-5-.

– Install poly V-belt pulley -1- and tighten bolts -2-. When doing
this, brace using counter-hold - T10172- .
Specified torques n AG. Volkswagen AG do
lkswage es n
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♦ ⇒ “4.1.2 Assembly overview - vane pump, 4-cylinder diesel d byV ua
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♦ Noise insulation ⇒ General body repairs, exterior;ssRep. gr.
ce
le
un
pt
an
d
itte
♦ Air conditioner compressor; Assembly overview - drive unit for
y li
rm
ab
air conditioner compressor ⇒ Heating, air conditioning; Rep.
pe
ility
gr. 87 ; Air conditioner compressor; Assembly overview - drive
ot
wit
satelettronica
unit for air conditioner compressor
, is n
h re
hole
spec
4.6.3 Removing and installing vane pump, 4-cylinder diesel engine, EA288
es, in part or in w
t to the co
rrectness of i
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nform
mercia
a
com
tion in
r
te o
thi
s
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fo
en
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t.
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Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

equipment required

♦ Retainer - T10172-
♦ Hose clamps to 25 mm - 3094-
noise insulation .
– Remove poly V-belt ⇒ Rep. gr. 13 ; CylinderAGblock,
. Volkswpulley
agen AGend;
Removing and installing poly V-belts.
w agen does
olk no t gu
yV
db ara
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tho eo
Note
satelettronica
s au ra
c
s
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
ing; Rep. gr. 87 ; Air conditioner compressor; Removing and
t to the co
installing air conditioner compressor .
– Remove poly V-belt pulley -1-. When loosening bolts -2- brace rrectness of i
l purpos

nform
ercia
vane pump.
m
at
om
io
up to 25 mm - 3094- -2-.
n
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

– Loosen clip -3- using hose clip pliers - V.A.G 1921- . Detach
hose -1- from nozzle -4-.
– Seal suction hose with a suitable plug from engine plug set -
VAS 6122- .
– Unscrew bolts of pressure line -1- and remove pressure line
from vane pump -2-.
VAS 6122- .
satelettronica
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c
ce
e

nl
pt
du
an
itte
y li
– Unscrew bolt of bumper cover -3-.

erm
ab
ility
ot p
– Remove coolant hose -1- from plastic bracket -2- and pull
wit
, is n
coolant hose away to side.

h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
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rp
cu
o
m
f
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ng
t.
yi Co
Cop py
t. rig
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254
cop Vo
by lksw
Rep. gr.48 - Steering Prote
cted AG.
agen
– Swing vane pump -4- out forwards over cross-member. Pull

bumper cover -5- forwards slightly as you do so.
satelettronica
with bracket -2-.
Installing
AG. Volkswagen AG d
agen oes
olksw not
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ed
ris nte
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un
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pe
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ot
wit
, is n
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es, in part or in w
Note
t to the co

rrectness of i
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– Swing vane pump in from below over front cross-member.

nform
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m
a
com
tio

n in
r
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thi

s
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rp

um
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Cop py
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satelettronica
AG. Volkswagen AG d
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es, in part or in w
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Note
rrectness of i
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m
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tio

n in
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thi
– Loosen hose clamps, up to 25 mm - 3094- on suction hose

s
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rp
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Prote AG.

wage es n
yV
olks ot g Transporter 2016 ➤
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d Running gear, ran axles,
tee steering - Edition 02.2019
tho
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– Install poly V-beltss pulley -1- and tighten bolts -2-. When doing
this, brace using counter-hold - T10172- .
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
rrectne
Specified torques
ss
♦ ⇒ “4.1.2 Assembly overview - vane pump, 4-cylinder diesel
o
cial p
f
engine”, page 235
inform
mer
♦ Noise insulation ⇒ General body repairs, exterior; Rep. gr.
atio
m

o
n
c
i
or
n
♦ Air conditioner compressor ⇒ Heating, air conditioning sys‐
thi
te
sd
a
tem; Rep. gr. 87 ; Air conditioning compressor; Removing and

iv
o
pr
c
installing air conditioning compressor on bracket
um
r
fo
satelettronica
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
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co lksw
by
cted agen
Prote AG.

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Service

Service Department. Technical Information

All rights reserved.

Copyright © 2019 Volkswagen AG, Wolfsburg D4B80565308

2.1 Assembly overview - subframe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

2.2 Removing and installing subframe without steering rack . . . . . . . . . . . . . . . . . . . . . . . . . . 14

2.3 Repairing subframe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

2.4 Removing and installing anti-roll bar . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

3.1 Assembly overview - suspension strut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37 f inform

3.3 Repairing suspension strut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48

4 Lower suspension link, swivel joint . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52

4.1 Assembly overview - lower suspension link, swivel joint . . . . . . . . . . . . . . . . . . . . . . . . . . 52

4.2 Removing and installing lower suspension link . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53

4.3 Checking swivel joint . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55

6.7 Checking inner constant velocity joint . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119

42 - Rear suspension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123

3.3 Renewing bonded rubber bush for suspension link . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132

4.2 Removing and installing shock absorbers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139

5.2 Removing and installing wheel bearing unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144

6.1 Assembly overview - drive shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149

6.3 Dismantling and assembling drive shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 156

6.4 Loosening and tightening threaded connections of drive shaft . . . . . . . . . . . . . . . . . . . . . . 163

6.5 Checking inner constant velocity joint . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 164

43 - Self-levelling suspension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 167

44 - Wheels, tyres, vehicle geometry . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 178

3.3 Test preparations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 188

1.1 Safety measures when working on ve‐

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

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

guiding components of the suspension.

♦ Always renew corroded nuts and bolts.

♦ Bonded rubber bushes can be twisted only to a limited extent.

Therefore, tighten the bolted connections of components with

bonded rubber bushes only when the wheel bearing housing

has been raised (unladen state) ⇒ page 4 .

2.1 Leaks at shock absorbers

is visible, but the fluid is dull and possibly dried by dust.

there is no case for complaint. The replacement was not justified.

2 Rep. gr.00 - Technical data

2.3 Checking shock absorbers when re‐

Shock absorbers are maintenance-free; shock absorber fluid can‐

After removal, a shock absorber can be checked by hand as fol‐

Note n AG. Volkswagen AG do

damping effect as long as there has been no major loss of fluid.

However, it may produce more noise.

2.4 Steering rack

To achieve the desired results when performing repairs on the

steering rack it is important to work with the greatest possible care

A series of generally valid instructions for individual repairs are

summarised here. They are also repeated at numerous places in

♦ Thoroughly clean all unions and the adjacent areas before

♦ Place removed parts on a clean surface and cover them to

this purpose. Use lint-free cloths only.

2.5 Gaskets and seals

♦ Completely remove all residue from liquid sealants from the

♦ Avoid canting sensitive parts, such as servo motor with control

something metallic. This is due to the electrostatic charge of the

object, such as a water pipe or a lifting platform. Do not directly

touch connector contacts.

2.8 Raising suspension to unladen position

4 Rep. gr.00 - Technical data

Special tools and workshop

All bolts on running gear components with bonded rubber