Service

Workshop Manual
SpaceFox, Space Cross, Suran, Suran
Cross, Sportvan 2006 ➤
Running gear, axles, steering
Edition 05.2011

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Service Department. Technical Information

 Service
List of Workshop Manual Repair GroupsList of Workshop Manual
Repair GroupsList of Workshop Manual Repair Groups

Repair Group
00 - Technical data
40 - Front suspension
42 - Rear suspension
44 - Wheels, tires, vehicle measurement
48 - Steering

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Technical information should always be available to the foremen and mechanics, because their
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careful and constant adherence to the instructions is essential to ensure vehicle road-worthiness and
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All rights reserved.
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No reproduction without prior agreement from publisher.

Copyright © 2011 Volkswagen AG, Wolfsburg D3E80312575

 SpaceFox, Space Cross, Suran, Suran Cross, Sportvan 2006 ➤
Running gear, axles, steering - Edition 05.2011

Contents

00 - Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1 Assessment of vehicles involved in accidents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2 Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
2.1 Frame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
2.2 Steering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
2.3 Wheels, tires . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

40 - Front suspension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
1 Front suspension - repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
1.1 Front suspension - assembly overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
1.2 Lift the rear axle in the unladen position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
2 I - Sub-frame, anti-roll bar, and wishbone - assembly overview . . . . . . . . . . . . . . . . . . . . . . 7
2.1 Threads in longitudinal member - repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
2.2 Swivel tip - check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
2.3 Swivel tip - remove and install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
2.4 Swivel joint - installation position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
2.5 Support arm - remove and install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
2.6 Console - remove and install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
2.7 Rubber support bearing for the console - replace . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
2.8 Subframe - position . . . . . . . . . . . . . . . . . . . . . . . . . . e.n.A.G.. V . o. lk. [Link]. n.A.G. . . . . . . . . . . . . . . 20
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2.9 Subframe - remove and install . . . . . . . . . . . . .Vo. . . . . . . . . . . . . . . . . . . . .es. [Link]. g. . . . . . . . .
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2.10 Anti-roll bar for vehicles with power steering ris
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3 II - Wheel roller bearings - repair . . . [Link]. t . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .[Link]. . 27
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3.1 Wheel roller bearing for vehicles without ABS - remove and install . . . . . . . . . . . . . . . . . . 29

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3.2 Front wheel hub with wheel roller bearing for 13" running gear - vehicles with ABS / ESP -
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remove and install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

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3.3 Front wheel hub with wheel roller bearing for 14" and 15" running gears - remove and

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install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41

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4 III - Front suspension pillar - assembly overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
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4.1 Vehicle identification label . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
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4.2 Suspension column - remove and install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47

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4.3 Front suspension spring - repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
5 Drive shafts - repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54

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5.1 Drive shafts - remove and install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
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6 IV - Drive shafts with constant-velocity joints - repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58

42 - Rear suspension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
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1 Rear axle - repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64

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1.1 Rear axle - remove and install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64

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1.2 Rear axle body for drum brakes - assembly overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68

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1.3 Metal and rubber bearing - remove and install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70

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1.4 Spring - remove and install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73

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1.5 Shock absorbers - assembly overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
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1.6 Damper - remove and install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
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2 Wheel bearings for drum brakes (without adjustment) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
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2.1 Wheel bearings - assembly overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
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2.2 Wheel roller bearing/wheel hub set in vehicles with brake drums - remove and install . . . . 79
3 Wheel bearings for drum brakes (with adjustment) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
3.1 Wheel bearings - assembly overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
3.2 Wheel roller bearing - check and adjust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
3.3 Internal/external rear wheel roller bearing - remove and install . . . . . . . . . . . . . . . . . . . . . . 84
3.4 Rear wheel internal roller bearing sealant - remove and install . . . . . . . . . . . . . . . . . . . . . . 86

Contents i
 SpaceFox, Space Cross, Suran, Suran Cross, Sportvan 2006 ➤
Running gear, axles, steering - Edition 05.2011

3.5 Stub axle - check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86

3.6 Axle end - remove and install, . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87

44 - Wheels, tires, vehicle measurement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88

1 Wheel screws . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
1.1 Screws with anti-theft lock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
1.2 Wheel screws - tightening torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
2 Vehicle alignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
2.1 General aspects . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
2.2 Checking conditions: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
2.3 Preparation for measurement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
2.4 Vehicle identification label . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
2.5 Sequence for the alignment of the vehicle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
2.6 Nominal values for vehicle alignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
2.7 Vehicles in “"0" position” of transverse inclination . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
2.8 Camber on front axle - adjust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
2.9 Camber on rear axle - adjust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
2.10 Convergence on rear axle - adjust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
2.11 Convergence on front axle - adjust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
2.12 Steering the wheel to the left and right - check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95

48 - Steering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
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1 Steering wheel . . . . . . . . . . . . . . . . . . . . . . . . . . . [Link].e. . . . . . . . . . . . .[Link]. s. n.o. . . . . . . . 97
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1.1 Horn activator H - remove and install . . . . . . .ed. b.y. . . . . . . . . . . . . . . . . . . . . . . . . .[Link]. ra. . . . . 97
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1.2 Steering wheel and Horn activator H - assembly ut
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overview . . . . . . . . . . . . . . . . . . . . .te.e .o . 98
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1.3 Steering wheel without airbag - remove and ss
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install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .ac 101

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2 Fixed steering column - repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103

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2.1 Support and fixed steering column - assembly overview . . . . . . . . . . . . . . . . . . . . . . . . . . 103

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2.2 Fixed steering column - remove and install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
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3 Steering column with adjustment - repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109

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3.1 Support and steering column with adjustment - assembly overview . . . . . . . . . . . . . . . . . . 109
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3.2 Adjustable steering column - remove and install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
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3.3 Steering column - check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118
4 Power steering box - repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119
4.1 Power steering box - assembly overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119

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4.2 Power steering box - remove and install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120
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4.3 Power steering box - disassemble and assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124

4.4 Steering track rod - remove and install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126
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4.5 Protective caul - assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127

4.6 Clearance, fastening and protective cauls from the steering yoke tips - check . . . . . . . . . . 128
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4.7 Correspondence of the steering yoke tips . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128

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4.8 Gear rack centering - determine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128

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5 Hydraulic pump (power steering) - repair (valid for all engines, except CCRA and CFZA)
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. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129
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5.1 Hydraulic pump with hydraulic piping and hoses - assembly overview . . . . . . . . . . . . . . . . 129
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5.2 Hydraulic pump on the upper part - assembly overview . . . . . . . . . . . . . . . . . . . . . . . . . . 131
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5.3 Hydraulic pump on the lower part - assembly overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132
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5.4 Vehicles with hydraulic pump on the upper part - remove and install . . . . . . . . . . . . . . . . 132
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5.5 Vehicles with hydraulic pump installed on the lower part - remove and install . . . . . . . . . . 134
5.6 Hydraulic pump operation pressure - check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 136
5.7 Power steering oil - fill . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141
6 Hydraulic pump (power steering) - repair (valid for CCRA and CFZA engines) . . . . . . . . . . 142
6.1 Hydraulic pump with hydraulic piping and hoses - assembly overview . . . . . . . . . . . . . . . . 142
6.2 Hydraulic pump - assembly overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144
6.3 Power pump - remove and install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144

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 SpaceFox, Space Cross, Suran, Suran Cross, Sportvan 2006 ➤
Running gear, axles, steering - Edition 05.2011

6.4 Hydraulic pump operation pressure - check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 148

6.5 Power steering oil - fill . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 151
7 Hydraulic power steering (Diesel engines) - repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 152
7.1 Hydraulic power steering fª JTEKT - assembly overview . . . . . . . . . . . . . . . . . . . . . . . . . . 152
7.2 Hydraulic power steering fª TRW - assembly overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . 154
7.3 Electro-hydraulic power steering gear housing - remove and install . . . . . . . . . . . . . . . . . . 155
7.4 Electro-hydraulic . Vpower
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7.5 Hydraulic
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7.6 Hydraulic
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7.7 utho Steering track rod - remove and install . e. [Link]. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 166
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ss Left steering bar length - check and adjust . c. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 167

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7.9 Clearance, fastening and protective cauls from the steering yoke tips - check . . . . . . . . . . 168
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7.10 Correspondence of the steering yoke tips . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 169
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7.11 Gear rack centering - determine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 169

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8 Hydraulic power steering motor/pump set (Diesel engines) . . . . . . . . . . . . . . . . . . . . . . . . 170

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8.1 Motor/pump set; fª JTEKT - assembly overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 170
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8.2 Motor/pump set; fª TRW - assembly overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 172
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8.3 Motor/pump assembly - remove and install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 173

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8.4 Motor/pump set pressure; fª JTEKT - check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 175
8.5 Steering system - bleed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 177

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8.6 Leak-proofness of the steering system - check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 178
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8.7 Oil level - check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 179

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Contents iii
 SpaceFox, Space Cross, Suran, Suran Cross, Sportvan 2006 ➤
Running gear, axles, steering - Edition 05.2011

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hole

spec
es, in part or in w

t to the co
rrectness of i
l purpos

nform
mercia

a
com

tion in
r
te o

thi
s
iva

do
r
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Cop py
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by
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Prote AG.

iv Contents
 SpaceFox, Space Cross, Suran, Suran Cross, Sportvan 2006 ➤
Running gear, axles, steering - Edition 05.2011

00 – Technical data
1 Assessment of vehicles involved in
accidents
During steering and suspension component
gen AG repairs
. Volkswagen AG do on crashed
vehicles, there may exist swa
kunidentified damages on the t frame. Lat‐
l es n
o o
yV gu
er these unidentified sed bdamages may cause serious consequences. ara
n
If the vehicle geometry
ho
ri measurement does not indicate anyteedif‐
ut or
ference related
ss
a to nominal values, this means there is no frame ac
deformation. Regardless of checking the vehicle geometry, the

ce
e
nl

following components are checked on the sequence and as indi‐

pt
du

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cated.
itte

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erm

ab
Visual and operation check of the steering system

ility
ot p

wit
, is n

♦ Check visually for deformities and cracks

h re
hole

spec
♦ Check clearances in the steering bar articulation and in the
es, in part or in w

steering mechanism

t to the co
♦ Check electrical wires, hydraulic system tubes, and flexible
tubes for wear, cuts, or folds

rrectness of i
♦ Check the tightness of hydraulic system tubes, threaded units
l purpos

and steering box

♦ Check the correct seating of the steering box and the tubes

nform
ercia

♦ Check the correct operation of the steering system, making

m

the steering wheel travel all the way, from stop to stop. Apply‐
at
om

io

ing the same force, the steering wheel should turn with no
n
c

in t
r

pressure
o

his
ate

do
riv

Visual check for operation of the frame

p

cum
for

en
g

♦ check all components represented in the assembly scheme

n

t.
yi Co
for deformations, cracks or other damages t. Cop py
rig
gh ht
yri
♦ always replace the damaged components p by
co Vo
by lksw
cted agen
♦ Check vehicle geometry in an equipment certified by “VOLKS‐ Prote AG.
WAGEN”
Visual check of wheel and tire operation
♦ Check for uniformity and any deformations. Refer to: ⇒ Run‐
ning gear, axles, steering; Rep. Gr. 44 ; Wheels, tires, vehicle
measurement
♦ Check the tires for cuts and damage to threads and flanks.
Refer to: ⇒ Running gear, axles, steering; Rep. Gr. 44 ;
Wheels, tires, vehicle measurement
♦ Check tire pressure; see tire pressure tag on fuel cover or on
the manual ⇒ Maintenance ; Booklet
In case of damages to the rim and/or tire, replace the tire. The
same is applicable when crash and damage on the vehicle indi‐
cate rim damage, even though they are invisible.
Another criterion is the age of the tires: tires shall not be older
than 6 years.
In case of doubt:
• If a safety risk cannot be eliminated, the tire(s) must be re‐
placed
Vehicle general condition:
Also check other vehicle systems, such as:

1. Assessment of vehicles involved in accidents 1

 SpaceFox, Space Cross, Suran, Suran Cross, Sportvan 2006 ➤
Running gear, axles, steering - Edition 05.2011

♦ Braking system, including ABS

♦ Exhaust and protection system for passengers through visual
and operation checking
Checking and adjustment values, and notes on the issue are in‐
cluded in the respective Repair Manual/ELSA.
The checking described herein, related to crashed vehicles, re‐
fers only to the chassis and is not intended to be comprehensive
for the entire vehicle.
Electronic vehicle systems:
Safety-relevant systems such as, e.g.: ABS/EDS; wage
n AGairbag;
. Volkswaelec‐
gen AG
does
s
tronically controlled power steering systems;
y Volk electromechanical; not
gu
electrohydraulic steering and other ris
edriver assistance systems
d b ara
nte
must be checked using the Diagnosis,
utho Measurement and Infor‐ eo
ra
mation System -VAS 5052-- sfors a eventual faults. In case there are c
any inconsistencies in the fault memory of these systems, pro‐

ce
e
nl

pt
ceed to repair according to the instructions described in the
du

an
itte

Workshop Manual or ELSA. After finishing the repair, check the

y li
erm

ab
systems for any faults again in order to ensure the correct oper‐

ility
ot p

ation of the related device.

wit
, is n

h re
hole

spec
es, in part or in w

t to the co
rrectness of i
l purpos

nf
ercia

orm
m

atio
om

n in
or c

thi
te

sd
iva

o
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rp

cu
o

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t.
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Cop py
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by
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Prote AG.

2 Rep. Gr.00 - Technical data

 n AG. Volkswagen AG do
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d byV
o
SpaceFox, Space Cross,
ot g
ua Suran, Suran Cross, Sportvan 2006 ➤
ran
o
ir se Running tee gear, axles, steering - Edition 05.2011
th or
au ac
ss

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2 Technical data
nl

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itte

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ility
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2.1 Frame

wit
, is n

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hole

Model

spec
All
es, in part or in w

t to the co
Distance between axles mm 2464
Unloaded axle bore mm 1418 front
1408 rear

rrectness of i
Vehicle turning radius: m
l purpos

Power steering box 11,25

nf
ercia

orm
m

atio
2.2 Steering
om

n in
or c

thi
e

Model All
t

sd
iva

o
r
rp

cu
Steering wheel turns from stopper to stopper 2,90
o

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t.
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Cop py
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2.3 Wheels, tires
cop Vo
by lksw
cted agen
Prote AG.
General information on wheel/tire sets, winter tires, snow chains
or other recommended types of tires can be found in chapter
Wheels, tires, vehicle measurement.

2. Technical data 3
 SpaceFox, Space Cross, Suran, Suran Cross, Sportvan 2006 ➤
Running gear, axles, steering - Edition 05.2011

40 – Front suspension
1 Front suspension - repair

Note

When replacing components with metal and rubber supports, or

when screws/nuts have been removed from such components,
you must lift the unloaded axle before tightening ⇒ page 5 .
AG. Volkswagen AG d
agen
1.1 Front suspension - assemblyeoverview
o
ksw s no
Vol t gu
by a
ed ran
oris tee
th or
l - Sub-frame,ss anti-roll bar and au ac
wishbone - assembly overview

ce
le
un

pt
⇒ page 7

an
d
itte

y li
ll - Wheel roller bearings - re‐
rm

ab
pe

ility
pair ⇒ page 27
ot

wit
, is n

lll - Front suspension strut - as‐

h re
hole

sembly overview ⇒ page 46

spec
es, in part or in w

lV - Drive shafts with constant-

velocity joints - repair t to the co
⇒ page 58 rrectness of i
l purpos

nform
mercia

a
com

tion in
r
te o

thi
s
iva

do
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cum
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t.
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Cop py
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by c lksw
cted agen
Prote AG.

4 Rep. Gr.40 - Front suspension

 SpaceFox, Space Cross, Suran, Suran Cross, Sportvan 2006 ➤
Running gear, axles, steering - Edition 05.2011

1.2 Lift the rear axle in the unladen position

Special tools and workshop

equipment required
n AG. Volkswagen AG do
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♦ Engine and gearbox olks jack + es n
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yV
gearbox or sEQ d 7081 -VAG
b ua
ran
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1383A- th o tee
or
au ac
♦ Tension belt -T 10038-
ss

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pt
♦ Support -T 10149-

an
d
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ility
ot

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spec
es, in part or in w

t to the co
rrectness of i
l purpos

nform
mercia

a
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tion in
r
te o

thi
s
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do
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cum
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t.
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Cop py
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Prote AG.

All screws on running gear's components with metal rubber bear‐

ings must always be tightened with the vehicle in unladen posi‐
tion.
The metal-rubber bearings must have limited torsion area. There‐
fore, the axle components with metal-rubber bearings must be
placed in running position before tightening (unladen vehicle).
Otherwise, the metal-rubber bearings would become deformed
and, consequently, their work life would be reduced.
We can simulate this suspension position in the lift with the aid of
the Tray for engine jack EQ 7081 -VAG 1359/2- and Support -
T10149- .

1. Front suspension - repair 5

 AG. Volkswagen AG d
agen oes
olksw not
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d by ara
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r
SpaceFox, Space Cross, Suran, Suran Cross, uSportvan
tho 2006 ➤ eo
ra
a
Running gear, axles, steering - Edition 05.2011
ss c

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nl

pt
du

an
Before servicing it, the distance shall be measured using a meas‐

itte

y li
uring tape

erm

ab
-nd- from the wheel centre to the wheel housing lower edge shall

ility
ot p
be measured using a measure tape.

wit
, is n

h re
hole

spec
Note

es, in part or in w

t to the co
♦ The measurement must be performed with the vehicle unla‐
den).

rrectness of i
♦ Take notes on the measured value. This will be required for

l purpos
tightening the screws/nuts.

nform
Before lifting the vehicle, you must fasten it to the supporting arms ercia
in the lift with the help of the Tension belt -T 10038-
m

at
om

io
If the vehicle is not fastened, there is a danger of it shifting from

n
c

in t
r

the lift
o

his
ate

do
riv

– Turn the wheel until one of its screw hole is at upper position.
p

cum
for

en
g

– Fasten the Support -T10149- with the wheel screw.

n

t.
yi Co
op py
The required screws and nuts tightening should only be done
t. C rig
gh ht
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when the distance -nd- between the wheel hub centre and the p by
o Vo
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wheel housing lower edge is the same measurement as the pre‐
lksw
cted agen
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vious one
AG.

– Lift the rear axle with the hydraulic jack until the dimension
-nd- has been reached.

WARNING

♦ Do not lift or lower the vehicle if the engine jack is placed

under the vehicle.
♦ Do not leave the hydraulic jack below the vehicle longer
than necessary.

– Tighten the necessary screws and nuts.

– Remove the engine jack.
– Remove the Support -T10149- .

6 Rep. Gr.40 - Front suspension

 SpaceFox, Space Cross, Suran, Suran Cross, Sportvan 2006 ➤
Running gear, axles, steering - Edition 05.2011

2 I - Sub-frame, anti-roll bar, and wish‐

bone - assembly overview

WARNING

Always replace self-locking nuts and screws which were sub‐

jected to angular torque.

Note

♦ Soldering and straightening works are not permitted in sup‐

porting components from the suspension or in components
located on the wheels
♦ Always replace corroded screws/nuts

1 - Subframe
❑ different versions
❑ Refer to: ⇒ Electronic
Parts Catalogue (ETKA)
❑ Remove and install
⇒ page 22
2 - Hexagon nut
❑ 40 Nm
3 - Anti-roll bar wage
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❑ The subframe must be d byV ua
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lowered to remove and o
ir se tee
install auth or
ac
ss
4 - Rubber support ce
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5 - Clamp
itte

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erm

ab
6 - Hexagon nut
ility
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wit
❑ only vehicles with power
, is n

h re

steering
hole

spec

❑ 40 Nm
es, in part or in w

t to the co

7 - Coupling rod
❑ only vehicles with power
steering
rrectness of i

❑ Between the stabilizer

l purpos

and suspension pillar

8 - Subframe console
nf
ercia

or

❑ Remove and install

m
m

atio

⇒ page 16
om

n in
or c

If the console thread is dam‐

thi
e

aged, it can be repaired with a

t

sd
iva

Heli-Coil thread insert

r
rp

cu
o

m
f

en
ng

❑ To do so, drill the hole

t.
yi Co
op
with a ∅ 12 mm drill bit. C py
t. rig
gh ht
pyri by
Vo
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Prote AG.

2. I - Sub-frame, anti-roll bar, and wishbone - assembly overview 7

 AG. Volkswagen AG d
agen oes
olksw not
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d by ara
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SpaceFox,thoSpace Cross, Suran, Suran Cross, Sportvan
ris
e o2006 ➤
u
Running
ss agear, axles, steering - Edition 05.2011 ra
c

ce
le
un

pt
an
d
itte
WARNING

y li
erm

ab
When
♦ drilling, make sure

ility
ot p

to not perform an inclined

wit
is n

h re
hole drilling
ole,

spec
urposes, in part or in wh

Should
♦ the hole be drilled
in oblique angle, the con‐

t to the co
sole shall be replaced

rrectne
Should the hole was drilled correctly, proceed with the operation according to the procedure described in the
VAS thread repair set ⇒ page 9

ss o
9 - Support
cial p

f inform
10 - Hexagon screw
mer

atio
m

❑ 20 Nm + 90°
o

n
c

i
❑ Replace after each removal
or

n thi
te

sd
va

If the soldered nut thread is damaged, it can be repaired with a Heli-Coil thread insert
i

o
pr

cum
r
fo

en
ng

Servicing thread in longitudinal member ⇒ page 9

t.
yi Co
Cop py
t. rig
11 - Hexagon screw opyri
gh by
Vo
ht

❑ 70 Nm + 90° by c lksw
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Prote AG.
❑ Replace after each removal
If the soldered nut thread is damaged, it can be repaired with a Heli-Coil thread insert

Servicing thread in longitudinal member ⇒ page 9

12 - Rubber support bearing for the console

❑ Remove and install ⇒ page 19
13 - ?Support arm
❑ Remove and install ⇒ page 14
14 - Plate with nuts
15 - Self-locking nut
❑ 20 Nm + 90°
❑ Replace after each removal
16 - Swivel tip
❑ Check ⇒ page 10
❑ Remove and install ⇒ page 11
❑ Installation position ⇒ page 14
17 - Hexagon screw
❑ 20 Nm + 90°
❑ Replace after each removal
18 - Air deflector plate
❑ Only on vehicles with 13" running gear
19 - Spreader rivet
❑ Only on vehicles with 13" running gear
20 - Hexagon screw
❑ 20 Nm + 90°
❑ Replace after each removal
21 - Hexagon screw
❑ ⇒ Item 16 (page 154)

8 Rep. Gr.40 - Front suspension

 SpaceFox, Space Cross, Suran, Suran Cross, Sportvan 2006 ➤
Running gear, axles, steering - Edition 05.2011
❑ Replace after each removal
❑ follow the sequence for installing and tightening the screws:
❑ First, screw the hex head screw ⇒ Item 23 (page 9) -, but do not tighten it definitively. Then, also screw
the hex head screw ⇒ Item 21 (page 8) -, but do not tighten it definitively
❑ Then, tighten the hex head screws alternately
22 - Hexagon screw agen
AG. Volkswagen AG d
oes
olksw not
❑ 30 Nm + 90° d by V gu
ara
ise nte
❑ Replace afterthoeach removal
r eo
au ra
c
23 - Hexagon screw
ss

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nl

❑ 70 Nm + 90°

pt
du

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itte

y li
❑ Replace after each removal
erm

ab
ility
❑ follow the sequence for installing and tightening the screws:
ot p

wit
, is n

❑ First, screw the hex head screw ⇒ Item 23 (page 9) -, but do not tighten it definitively. Then, also screw

h re
the hex head screw ⇒ Item 21 (page 8) -, but do not tighten it definitively
hole

spec
❑ Then, tighten the hex head screws alternately
es, in part or in w

t to the co
24 - Hexagon screw
❑ 40 Nm + 90°

rrectness of i
❑ Replace after each removal
l purpos

25 - Pendulum support

nform
ercia

2.1 Threads in longitudinal member - repair

m

at
om

ion
c

It is possible to repair the welded nut threads in the longitudinal in t

or

his
e

member depending on certain conditions:

at

do
priv

♦ The repair must only be performed once in each thread

um
for

en
ng

t.
yi
♦ If a second repair is necessary, the soldered nut must be re‐
Co
Cop py
placed
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pyri by
Vo
o
♦ Follow the work instructions in the VAS repair set
c by lksw
cted agen
Prote AG.

Caution

When drilling, it is mandatory to wear safety goggles.

♦ Make your supervisor or immediate superior check the thread

repair
♦ Rectify any damage to the underbody sealant layer ⇒ Body -
Repairs; General notes; Anti-corrosion protection measures
♦ Use only the repair sets listed on the table for the repair works

2.1.1 VAS thread repair set

Thread VAS number
M8 6022
M10 6024
M12×1.5 6026

2. I - Sub-frame, anti-roll bar, and wishbone - assembly overview 9

 SpaceFox, Space Cross, Suran, Suran Cross, Sportvan 2006 ➤
Running gear, axles, steering - Edition 05.2011

2.2 Swivel tip - check

Check axial clearance:
– Pull the wishbone -towards the arrow- vigorously down and
press it up again.
Check radial clearance:

AG. Volkswagen AG d
agen oes
lksw not
– Press lower part of wheel forcefully outwards and inwards.
d byV
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h
aut ra
Note ss c

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nl

pt
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♦ No visible or noticeable clearance, when performing both tests
itte

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erm

ab
♦ Observe the swivel tip during the check

ility
ot p

wit
, is n

♦ Consider an eventual “play” in the wheel roller bearing or in

h re
the upper support of the suspension column
hole

spec
es, in part or in w

♦ Check the rubber bellows for damages, replace the swivel tip,

t to the co
if necessary

rrectness of i
l purpos

nform
mercia

at
om

ion
c

in t
or

his
ate

do
priv

cum
for

en
ng

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

10 Rep. Gr.40 - Front suspension

 AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
SpaceFox, Space ris Cross, Suran, Suran Cross, Sportvan 2006
ed
nte ➤
o eo
ut Running gear, axles, steering - Edition 05.2011
h
a ra
ss c

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e
2.3 Swivel tip - remove and install

nl

pt
du

an
itte

y li
erm

ab
ility
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Special tools and workshop

wit
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equipment required

h re
hole
♦ Extractor -3287A-

spec
es, in part or in w

t to the co
♦ "Torquemeter - 40 to 200
Nm (socket 1/2")" -VAG
1332-

rrectness of i
♦ Engine and gearbox jack +
gearbox or EQ 7081 -VAG
l purpos
1383A-
♦ Torque wrench 20 - 100 Nm

nf
ercia

o
-VAG 1756-

rm
m

atio
m

♦ ?Star socket 36mm or Ge‐

o

n in
c

dore Ref. D32-36 -T 10125-

or

thi
te

sd
iva

♦ Extractor -3283-

o
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rp

cu
o

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f

en
ng

t.
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Cop py
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rig ht
py by
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by lksw
cted agen
Prote AG.

2.3.1 Removal
– Lift the vehicle until the front axle is without any load.
– Loosen the grooved nut -arrow- with the ?Star socket 36mm
or Gedore Ref. D32-36 -T 10125- or the 30-mm star socket.
– Remove the wheel.

2. I - Sub-frame, anti-roll bar, and wishbone - assembly overview 11

 SpaceFox, Space Cross, Suran, Suran Cross, Sportvan 2006 ➤
Running gear, axles, steering - Edition 05.2011

– Loosen the fastening nut -1- from the yoke.

– Separate the steering yoke tip -2- from the wheel roller bearing
case, by using the Extractor -3287 A- .
– Mark the position for the swivel tip screws on the wishbone.

– Remove the attaching screws -arrows-.

– Move the suspension column together with the swivel joint on
the wishbone.

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– Remove the hexagon nuts -1- from sboth
s au
sides of the coupling ac
rod -3-.

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– Remove the coupling rod -3- from the anti-roll bar -2-.
itte

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erm

ab
ility
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wit
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h re
hole

spec
es, in part or in w

t to the co
rrectness of i
l purpos

– Press the drive axle shaft out of the roller bearing case. To do
this, install the Extractor -3283- as shown in the illustration.
nform
mercia

at

Note
om

ion
c

in t
or

While pressing the drive axle shaft outwards, make sure you have
his
ate

do

enough free space.

priv

cum
for

en
ng

t.
– Remove the wheel roller bearing case with the shaft articula‐
yi Co
op py
tion out of the transverse arm. t. C rig
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Prote AG.

12 Rep. Gr.40 - Front suspension

 SpaceFox, Space Cross, Suran, Suran Cross, Sportvan 2006 ➤
Running gear, axles, steering - Edition 05.2011

– Turn the suspension outward and support, for example, with

a wooden block -1- , and simultaneously remove the drive axle
shaft from the wheel roller bearing.
– Fasten the drive axle shaft to the body with a wire.

AG. Volkswagen AG d
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Vo lksw Note oes
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The drive axle shaftthor
must not be pressed downwards. Otherwise, eo
the internal articulation
ss au
will be damaged due to excessive tilting. ra
c

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le
un

pt
an
d
itte

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rm

ab
pe

ility
– Position the Extractor -3287A- as indicated in illustration and
ot

wit
press the swivel joint.
, is n

h re
hole

spec
es, in part or in w

Note

t to the co
In order to protect the swivel joint, leave the nut threaded a few
turns.

rrectness of i
l purpos

nform
mercia

a
com

tio
2.3.2 Installation n in
r
te o

thi
s
iva

do
r
rp

WARNING
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fo

en
ng

t.
yi Co
Always replace self-locking nuts and screws which were sub‐ Cop py
t. rig
jected to angular torque. opyri
gh by
Vo
ht
c by lksw
cted agen
Prote AG.
Install by inverting the removal sequence, paying attention to the
following:
– Screw on self-locking nuts, counter-holding with T40 Torx key.
Tightening torque ⇒ Item 15 (page 8) .
– Install the drive shaft in the wheel roller bearing.

Note

Check if the gaiters are not damaged or twisted.

– Fasten the swivel tip to the wishbone (screws on old marks).

Tightening torque ⇒ Item 17 (page 8) .
– Install the wheels and tighten the screws ⇒ page 88 .

2. I - Sub-frame, anti-roll bar, and wishbone - assembly overview 13

 SpaceFox, Space Cross, Suran, Suran Cross, Sportvan 2006 ➤
Running gear, axles, steering - Edition 05.2011

– Tighten the splined nut -arrow -.

- Vehicles with ABS brakes ⇒ Item 14 (page 28) .
- Vehicles without ABS brakes ⇒ Item 13 (page 28) .

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2.4 Swivel joint - installation position rm

ab
pe

ility
ot

Left swivel tip

wit
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h re
The arrow marked with “L4” points to the vehicle traveling direc‐
hole

spec
tion for the 14" running gear
es, in part or in w

t to the co
rrectness of i
l purpos

nform
mercia

a
com

tion in
Right swivel tip
r
te o

thi
s
iva

The arrow marked with “R4” points to the vehicle traveling direc‐

do
r
rp

c
tion for the 14" running gear

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t.
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Note gh ht
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If the installation position is incorrect, the caster will be wrong. Prote AG.

2.5 Support arm - remove and install

Special tools and workshop equipment required
♦ "Torquemeter - 40 to 200 Nm (socket 1/2")" -VAG 1332-

14 Rep. Gr.40 - Front suspension

 SpaceFox, Space Cross, Suran, Suran Cross, Sportvan 2006 ➤
Running gear, axles, steering - Edition 05.2011

♦ Bushing and bearing extractor -VW 771-

2.5.1 Removal
– Lift the vehicle until the front axle is without any load.
– Remove the wheel.
If it is not necessary to replace the wishbone:
♦ Mark the installation position of the screws -arrows- from the
the swivel tip -1- to supporting arm -2-.
– Remove screws -arrows-.
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– Remove the wheel roller bearing case and the axle articulation
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2. I - Sub-frame, anti-roll bar, and wishbone - assembly overview 15

 SpaceFox, Space Cross, Suran, Suran Cross, Sportvan 2006 ➤
Running gear, axles, steering - Edition 05.2011

2.5.2 Installation

Caution

♦ While installing, watch the installation position of the sup‐

port arm in relation to the console. The wishbone hexag‐
onal end must match the one from the metal-rubber
support in the console.
♦ The wishbone must be at the same level as the subframe.
♦ If the assembly position is not followed, the console metal-
rubber bearing may be damaged, consequently reducing
its durability.

– Install the wishbone to the console with the help of a rubber

hammer if necessary.
– Install screw -arrow- and tighten it. Tightening torque
⇒ Item 23 (page 9) .
– Insert the swivel tip in the wishbone.
– If the wishbone is not replaced, tighten the swivel tip screws
firmly on the previous marking ⇒ Item 17 (page 8) .
If the wishbone is replaced:

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– Position supporting arm -1- and the swivel joint -2- so that theVol
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– The remaining installation steps are carried out in reverse or‐
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2.6 Console - remove and install

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2.6.1 Removal
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– Remove supporting arm ⇒ page 14 .

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16 Rep. Gr.40 - Front suspension

 SpaceFox, Space Cross, Suran, Suran Cross, Sportvan 2006 ➤
Running gear, axles, steering - Edition 05.2011

– Remove the hexagon nuts -1- from the connecting rod.

– Remove the coupling rod -3- of stabilizer -2- to both sides.

– Remove screws -arrows-.

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– Remove screws -arrows-. s

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2.6.2 Installation
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2. I - Sub-frame, anti-roll bar, and wishbone - assembly overview 17

 SpaceFox, Space Cross, Suran, Suran Cross, Sportvan 2006 ➤
Running gear, axles, steering - Edition 05.2011

– Install the anti-roll bar on the console -arrows-.

– Install the coupling rod -3- to stabilizer -2- to both sides.

– Install supporting arm ⇒ page 14 .
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Console to body 70 Nm + 90°

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⇒ Item 21 (page 8)
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Anti-roll bar to console 20 Nm + 90°
⇒ Item 20 (page 8) 1)
Coupling rod to anti-roll bar 40 Nm rrectness of i
⇒ Item 2 (page 7) 1)
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1) Use new screws/nuts

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18 Rep. Gr.40 - Front suspension

 AG. Volkswagen AG d
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SpaceFox, SpaceseCross,
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2.7 Rubber support bearing for the console - replace

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♦ Pressure Disc -3062-

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♦ Mounting device -3253-

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♦ Fitting tool -3346-
♦ Extractor -T10037-

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♦ Extractor / Fitting tool -T
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40023-

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– Remove supporting arm ⇒ page 14 .

– Partially remove the noise insulation. ⇒ General body repairs,
external; Rep. Gr. 50 ; Body - front section .

2.7.1 Remove bonded rubber bush

– Press the noise insulation down and position the Fitting tool
-3346/2- and Extractor / Fitting tool -T 40023- behind the sup‐
port.
– Using the Fitting tool -3346/2- , screw the thread on the con‐
sole -arrow- until the tool Extractor / Fitting tool -T 40023- seat
on support.
– Remove the metal and rubber bearing.

2. I - Sub-frame, anti-roll bar, and wishbone - assembly overview 19

 SpaceFox, Space Cross, Suran, Suran Cross, Sportvan 2006 ➤
Running gear, axles, steering - Edition 05.2011

2.7.2 Install the metal-rubber bearing on the

console
Installation position of the metal and rubber bearing on the con‐
sole:
The pin on the metal-rubber bearing -arrow A- must be aligned
with the console marking -arrow B-.
– Draw a perpendicular line to the bearing with a pen, for ex‐
ample, to easy the installation.
– Apply a thin coat of tire mounting paste onto the metal-rubber
bearing.

– Install bonded rubber mounting -1- to the console -2-.

– Fasten the noise insulation.⇒ General
gen AG
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2.8 Subframe - position

t to the co

Special tools and workshop equipment required

rrectness of i

♦ Location pins -T 10096-

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♦ Engine and gearbox jack + gearbox or EQ 7081 -VAG 1383A-
agen
Prote AG.

20 Rep. Gr.40 - Front suspension

 SpaceFox, Space Cross, Suran, Suran Cross, Sportvan 2006 ➤
Running gear, axles, steering - Edition 05.2011

2.8.1 Removal
– Loosen and remove screws -1- and -2- from gearbox pendu‐
lum support.
– Remove the front exhaust tube ⇒ Engine; Rep. Gr. 26 ; Ex‐
haust system .
– Install the Engine and gearbox jack + gearbox or EQ 7081 -
VAG 1383A- under the subframe.
– Clean the fastening device threads with the Location pins -T
10096- .
In the following work phases, it is mandatory to follow the se‐
quence:
– Remove the screws of the rear support.

– Remove fixing screws -arrow A- from the subframe and screw

the Location pins -T 10096- -1- with 20 Nm.
– Remove fixing screws -arrow B- from the subframe and screw
the Location pins -T 10096- -2- with 20 Nm. AG. Volkswagen AG d
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The Location pins -T 10096- must only be tightened up to 20 Nm.

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– Remove the next screw and tighten again the Location pins -
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– The subframe fastening will be concluded when all 4 screws
hole

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– Lower the subframe about 4 cm.

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2.8.2 Installation
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following:

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– Always remove one fastening device at a time and replace it
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with a new screw -arrow-.

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– Tighten this screw to the specified torque ⇒ page 22 .

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test drive. If the steering wheel is not in the straight forward po‐
sition, the axle geometry must be checked.

2. I - Sub-frame, anti-roll bar, and wishbone - assembly overview 21

 SpaceFox, Space Cross, Suran, Suran Cross, Sportvan 2006 ➤
Running gear, axles, steering - Edition 05.2011

2.8.3 Tightening torque

Tightening torque Nm
Subframe to body 70 Nm + 90°
Support to body 20 Nm + 90°
Pendulum support to gearbox 30 Nm + 90°

2.9 Subframe - remove and install

Special tools and workshop

equipment required
♦ "Torque wrench - 5 to 50
Nm ( socket 1/2")" -VAG
1331-
♦ "Torquemeter - 40 to 200
Nm (socket 1/2")" -VAG
1332-
♦ ?Star socket 36mm or Ge‐
dore Ref. D32-36 -T 10125-

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2.9.1 Removal
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– Lift the vehicle until the front axle is without any load.
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22 Rep. Gr.40 - Front suspension

 SpaceFox, Space Cross, Suran, Suran Cross, Sportvan 2006 ➤
n AG. Volkswagen AG do
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o ot g
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– Loosen the grooved
thoris
nut -arrow- with the ?Star socket 36mm
tee
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u D32-36 -T 10125- or the 30-mm star socket.r ac
s

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– Remove the wheel. le
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– Loosen the fastening nut -1- from the yoke.

ss
– Separate the steering yoke tip -2- from the wheel roller bearing

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case, by using the Extractor -3287 A- .

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– Mark the position for the swivel tip screws on the wishbone.

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– Remove the attaching screws -arrows-.
Prote AG.

– Move the suspension column together with the swivel joint on

the wishbone.

– Remove the hexagon nuts -1- from both sides of the coupling
rod -3-.
– Remove the coupling rod -3- from the anti-roll bar -2-.
Continuation for all vehicles:

2. I - Sub-frame, anti-roll bar, and wishbone - assembly overview 23

 SpaceFox, Space Cross, Suran, Suran Cross, Sportvan 2006 ➤
Running gear, axles, steering - Edition 05.2011

– Press the drive axle shaft out of the roller bearing case. To do
this, install the Extractor -3283- as shown in the illustration.

Note

While pressing the drive axle shaft outwards, make sure you have
enough free space.

– Remove the wheel roller bearing case with the shaft articula‐
tion out of the transverse arm.

– Turn the suspension outward and support, for example, with

a wooden block -1- , and simultaneously remove the drive axle
shaft from the wheel roller bearing.
– Fasten the drive axle shaft to the body with a wire.

Note

The drive axle shaft must not be pressed downwards. Otherwise,

the internal articulation will be damaged due to excessive tilting.

– Loosen the fastening screws -1- from the steering box to sub‐
frame and fasten it to the body (for example, with
agena wire).
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– Position the subframe ⇒ page 20 . ed by ara
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Lower the subframe using the Engine and gearbox jack + eo
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2.9.2 Installation
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WARNING
s

Always replace self-locking nuts and screws which were sub‐

s o
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jected to angular torque.

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mer

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Install by inverting the removal sequence, paying attention to the

o

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following:
or

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– Position the subframe ⇒ page 20 .

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– Fasten the steering box to the subframe. Tightening torque

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⇒ Item 16 (page 154) .
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– Install the drive shaft in the wheel roller bearing.
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Note

Check if the bellows are not damaged or twisted

24 Rep. Gr.40 - Front suspension

 AG. Volkswagen AG d
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SpaceFox, Space Cross, Suran, gu Suran Cross, Sportvan 2006 ➤
ara
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e o steering - Edition 05.2011
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– Fasten the swivel tip to the wishbone (screws on old marks).

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Tightening torque ⇒ Item 17 (page 8) .

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– Install the wheels and tighten the screws ⇒ page 88 .

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– Tighten the splined nut -arrow-. ot p

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- Vehicles with ABS brakes ⇒ Item 14 (page 28) .
hole

spec
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- Vehicles without ABS brakes ⇒ Item 13 (page 28) .

t to the co
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2.10 Anti-roll bar for vehicles with power steering - remove and install
or

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Special tools and workshop
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♦ "Torque wrench - 5 to 50
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♦ "Torquemeter - 40 to 200
Nm (socket 1/2")" -VAG
1332-
♦ Engine and gearbox jack +
gearbox or EQ 7081 -VAG
1383A-

2.10.1 Removal
– Remove the wheel.

2. I - Sub-frame, anti-roll bar, and wishbone - assembly overview 25

 SpaceFox, Space Cross, Suran, Suran Cross, Sportvan 2006 ➤
Running gear, axles, steering - Edition 05.2011 AG. Volkswagen n AG do
wage es n
olks ot g
– Remove the noise insulation. ⇒ General body repairs,eexter‐
db
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– Remove screws -arrows-. ss

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– Remove the hexagon nuts -1- from both sides of the coupling
rod -3-.

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ercia

– Remove the coupling rod -3- from the anti-roll bar -2-.
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– Loosen the fastening screws -1- from the steering box to sub‐
frame and fasten it to the body (for example, with a wire).
– Position the subframe ⇒ page 20 .
– Lower the subframe with the help of the Engine and gearbox
jack + gearbox or EQ 7081 -VAG 1383A- .
– Remove the anti-roll bar laterally.

2.10.2 Installation
Install by inverting the removal sequence, paying attention to the
following:
– Install the anti-roll bar and fasten it to the console with the
clamps ⇒ Item 20 (page 8) .
– Position the subframe ⇒ page 20 .
– Fasten the steering box to the subframe. Tightening torque
⇒ Item 16 (page 154) .
– Install the wheels and tighten the screws ⇒ page 88 .

26 Rep. Gr.40 - Front suspension

 SpaceFox, Space Cross, Suran, Suran Cross, Sportvan 2006 ➤
Running gear, axles, steering - Edition 05.2011

3 II - Wheel roller bearings - repair

AG. Volkswagen AG d
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Always replace self-locking
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Note

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♦ Soldering and straightening works are not permitted in sup‐

spec
urposes, in part or in wh

porting components from the suspension or in components

t to the co
located on the wheels
♦ Always replace corroded screws/nuts

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1 - Drive shaft

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2 - Suspension pillar

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❑ remove and install

atio
⇒ page 47
om

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3 - Internally ??splined bolt

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❑ the tip on the hex head

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❑ 8 Nm cted agen
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5 - Speed sensor
❑ before installing the
sensor, you must clean
the internal surface of
the hole and apply Tem‐
perature-resistant
grease -G 000 650- .
Refer to the ⇒ Chemical
material manual
6 - Self-locking nut
❑ 20 Nm + 90°
❑ replace after each re‐
moval
7 - Self-locking nut
❑ 60 Nm + 90°
❑ replace after each re‐
moval
8 - Wheel roller bearing case
❑ for FS II and FS III brake
calipers
❑ different versions for 13"
and 14" running gears
❑ Refer to: ⇒ Electronic Parts Catalogue (ETKA)
9 - Wheel roller bearing case
❑ for C54 brake calipers
❑ different versions for 15" running gear.

3. II - Wheel roller bearings - repair 27

 SpaceFox, Space Cross, Suran, Suran Cross, Sportvan 2006 ➤
Running gear, axles, steering - Edition 05.2011
❑ Refer to: ⇒ Electronic Parts Catalogue (ETKA)
10 - Track rod ball joint
11 - Splash plate
12 - Hexagon screw
❑ 10 Nm
13 - Self-locking nut
for vehicles without ABS
❑ Refer to: ⇒ Electronic Parts Catalogue (ETKA)
❑ first tighten to 200 + 50Nm and loosen (going back) 180º, then tighten further to 50 Nm + 50º
❑ apply first White lubricating grease -G 052 751 A1- on the grooves and outer thread of the drive semi-
shaft, which must be previously cleaned. Refer to the ⇒ Chemical material manual
❑ replace after each removal
14 - Self-locking nut
for vehicles with ABS
❑ tightening torque for 13” running gear (black nut) = 50 Nm
❑ tightening torque for 14” and 15" running gear (silver nut) = 50 Nm + 45º
❑ replace after each removal
olkswagen AG
en AG. V
– Apply first Adhesive -D 185 400 A2- on the grooves and outer
olks thread of the drive semi-shaft,
wag does
not which must
be previously cleaned. Refer to the ⇒ Chemical material
ed
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WARNING ss

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The torque must be ap‐

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ter inserting the shaft tip

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hours with no strain on
urposes, in part or in wh

the semi-shaft.

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15 - Screw

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❑ 4 Nm

s
16 - Ventilated brake disc
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17 - Wheel hub with wheel bearings
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for vehicles with ABS

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❑ the ABS sensor ring is installed in the wheel hub

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❑ different versions for 13", 14" and 15" running gears

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❑ Refer to: ⇒ Electronic Parts Catalogue (ETKA)

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❑ remove (vehicles with 13" running gear) ⇒ page 35

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❑ remove (vehicles with 14" and 15" running gears) ⇒ page 41
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❑ replace, because it is destroyed when removed co Vo
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❑ install (vehicles with 13" running gear) ⇒ page 35 Prote AG.

❑ install (vehicles with 14" and 15" running gears) ⇒ page 41

18 - Wheel hub without roller bearing
for vehicles without ABS
❑ Refer to: ⇒ Electronic Parts Catalogue (ETKA)
❑ remove and install ⇒ page 29

28 Rep. Gr.40 - Front suspension

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SpaceFox, Space thCross, Suran, Suran Cross, Sportvan 2006 t➤
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or
u
ss Running gear, axles, steering - Edition 05.2011 c
a a

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un

pt
19 - Safety ring

an
d
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ab
for vehicles without ABS

pe

ility
ot

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❑ 72 X 2.5

, is n

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❑ Refer to: ⇒ Electronic Parts Catalogue (ETKA)

hole

spec
❑ remove and install ⇒ page 29

es, in part or in w

t to the co
20 - Double ball bearing
for vehicles without ABS

rrectness of i
❑ Refer to: ⇒ Electronic Parts Catalogue (ETKA)

l purpos
❑ remove and install ⇒ page 29

nform
3.1 mercia
Wheel roller bearing for vehicles without ABS - remove and install

a
com

tion in
r
te o

thi
s
iva
Special tools and workshop

do
r
rp

c
equipment required

um
fo

en
ng
t.
yi
♦ Mounting device -3253-
Co
Cop py
t. rig
♦ Fixed wrench 50mm -3254-
gh ht
pyri by
Vo
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by
♦ ?Star socket 36mm or Ge‐ cted agen
Prote AG.
dore Ref. D32-36 -T 10125-
♦ Device -T10030-
♦ Extractor and Fitting tool
KUKKO 20/10 -VW 045Z-
and Grip -VW 045Z/1-
♦ Basis -VW 295A-

3. II - Wheel roller bearings - repair 29

 SpaceFox, Space Cross, Suran, Suran Cross, Sportvan 2006 ➤
Running gear, axles, steering - Edition 05.2011

Special tools and workshop

equipment required
♦ Torque wrench - 5 to 50 Nm
(socket 1/2") -VAG 1331-
♦ Torquemeter - 40 to 200
Nm (socket 1/2") -VAG
1332-
♦ Similar - EQ 7081 - Engine
and gearbox jack + gearbox
-VAG 1383A-
♦ Thrust pad -VW 472/1-
♦ Pressure tube -VW 418A-
♦ Thrust pad -VW 442-
♦ Pulling device -VW 202K-
♦ Torque wrench - 4 to 20 Nm
(socket 3/8") -VAG 1410-

AG. Volkswagen AG d
agen oes
olksw not
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d by ara
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h
aut ra
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nl

pt
du

an
itte

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erm

ab
ility
ot p

wit
, is n

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hole

spec
es, in part or in w

t to the co

3.1.1 Removal
rrectness of i

– Lift the vehicle until the front axle is without any load.
l purpos

– Loosen the grooved nut -arrow- with the ?Star socket 36mm
or Gedore Ref. D32-36 -T 10125- or the 30-mm star socket.
nform
ercia

– Remove the wheel.

m

at
om

ion
c

in t
or

his
ate

do
priv

cum
for

en
ng

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

30 Rep. Gr.40 - Front suspension

 SpaceFox, Space Cross, Suran, Suran Cross, Sportvan 2006 ➤
Running gear, axles, steering - Edition 05.2011

– Loosen the fastening nut -1- from the yoke.

– Separate the steering yoke tip -2- from the wheel roller bearing
case, by using the Extractor -3287 A- .
– Mark the position for the swivel tip screws on the wishbone.

– Remove the attaching screws -arrows-.

– Move the suspension column together with the swivel joint on
the wishbone.
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ir se tee
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ss

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pt
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itte

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rm

ab
pe

ility
ot

wit
, is n

h re
– Remove the hexagon nuts -1- from both sides of the coupling
hole

spec
rod -3-.
es, in part or in w

t to the co
– Remove the coupling rod -3- from the anti-roll bar -2-.
rrectness of i
l purpos

nform
mercia

a
com

tion in
r
te o

thi
s
iva

– Press the drive axle shaft out of the roller bearing case. To do
do
r
rp

this, install the Extractor -3283- as shown in the illustration.

um
fo

en
ng

t.
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Cop py
. rig
Note
t
gh ht
pyri by
Vo
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cted
While pressing the drive axle shaft outwards, make sure you have
agen
Prote AG.
enough free space.

– Remove the wheel roller bearing case with the shaft articula‐
tion out of the transverse arm.

3. II - Wheel roller bearings - repair 31

 SpaceFox, Space Cross, Suran, Suran Cross, Sportvan 2006
. Volk➤
swagen AG
gen AG does
Running gear, axles, steering - Edition 05.2011Volkswa not
y gu
db ara
ise nte
– Turn the suspension outward and support, with for
thoexample,
r eo
a wooden block -1- , and simultaneously remove
s the drive axle au ra
c
s
shaft from the wheel roller bearing.

ce
e
nl

pt
du

an
– Fasten the drive axle shaft to the body with a wire.

itte

y li
erm

ab
ility
ot p

wit
Note

, is n

h re
hole

spec
The drive axle shaft must not be pressed downwards. Otherwise,
the internal articulation will be damaged due to excessive tilting. es, in part or in w

t to the co
– Remove disc brake caliper and tie it to body with wire ⇒ Brake
system; Rep. Gr. 46 ; Brakes - Mechanical systems .

rrectness of i
– Remove the Phillips screw from the brake disc and remove the
l purpos

brake disc.
– Remove the cover plate.

nform
mercia

at
om

ion
Note
c

in t
or

his
ate

Position the Engine and gearbox jack + gearbox or EQ 7081 -VAG

do
priv

c
1383A- underneath (danger of accident from falling parts when

um
for

en
g

extracting the wheel hub and the wheel roller bearing)

n

t.
yi Co
Cop py
t. rig
gh ht
pyri by
3.1.2 Remove the wheel roller bearing hub
o Vo
by c lksw
cted agen
Prote AG.
Install the removal device
1- Mounting device -3253/3-
2- Pressure tube -VW 418A-
3- Mounting device -3253/6-
4- Mounting device -3253/2-
5- Mounting device -3253/1-
6- Open-end spanner, 50 mm -3254-

Remove the circlip -A- with pliers

32 Rep. Gr.40 - Front suspension

 AG. Volkswagen AG d
agen oes
ksw not
SpaceFox,
by Vol
Space Cross, Suran, Suran guCross, Sportvan 2006 ➤
ara
d
o rise Running gear, axles, steering
nte
eo
- Edition 05.2011
th
au ra
ss c
Remove the wheel bearing inner track

ce
e
nl

pt
du
1- Basis -VW 295A-

an
itte

y li
erm

ab
2- Pulling device -VW 202K-

ility
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wit
3- Extractor and Fitting tool KUKKO 20/10 -VW 045Z/1-

, is n

h re
hole
4- Extractor and Fitting tool KUKKO 20/10 -VW 045Z-

spec
es, in part or in w

t to the co
rrectness of i
l purpos

Remove the wheel roller bearing by removing it from the wheel

roller bearing case

nf
ercia

orm
1- Mounting device -3253/5-
m

atio
om

2- Mounting device -3253/2-

n in
or c

thi
e

3- Mounting device -3253/1-

t

sd
iva

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cu
4- Open-end spanner, 50 mm -3254-
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en
ng

t.
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5- Mounting device -3253/6- t. Cop py
rig
gh ht
6- Mounting device -3253/3- yri
p by
co Vo
by lksw
cted agen
Prote AG.

3.1.3 Installation
– Clean the residues from the wheel roller bearing housing in
the wheel roller bearing case.
– Lubricate the surface of wheel bearing case with Molybdenum
grease -G 052 723 A2- . Refer to the ⇒ Chemical material
manual .

Install the wheel roller bearing in the wheel roller bearing case
1- Thrust pad -VW 442-
2- Wheel bearing
3- Assembly device -T 10064/4-
4- Device -T 10030/3-

Note

Pay attention to the correct alignment of the roller bearing in re‐

lation to the roller bearing case

– Install the lock ring on the wheel bearing case.

3. II - Wheel roller bearings - repair 33

 SpaceFox, Space Cross, Suran, Suran Cross, Sportvan 2006 ➤
Running gear, axles, steering - Edition 05.2011

Install the wheel hub in the wheel roller bearing

1- Thrust pad -VW 442-
2- Wheel hub
3- Thrust pad -VW 472/1-
4- Device -T 10030/3-
– Clean the surfaces from the thread and the toothed area.

– Lubricate the toothed area -1- and the thread -2- with Molyb‐
denum Paste -G 052 751 A1- . Refer to the ⇒ Chemical
material manual .
– Install the drive shaft in the wheel roller bearing.

Note

Check if the gaiters are not damaged or twisted.

– Fasten the swivel tip to the wishbone (screws on old marks).

Tightening torque ⇒ Item 17 (page 8) .

WARNING
n AG. Volkswagen AG do
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o o
Always replace self-locking nuts by Vand screws which were sub‐ t gua
ed ran
jected to angular torque. horis tee
ut or
a ac
ss
ce
e
nl

– Install the disc protector, the brake disc and the disc brake
pt
du

an

caliper ⇒ Brake systems; Rep. Gr. 46 ; Front brakes - repair .

itte

y li
erm

ab

– Install the coupling rod.

ility
ot p

wit
, is n

– Install the wheels and tighten the screws ⇒ page 88 .

h re
hole

spec

– Tighten the splined nut -arrow-.

es, in part or in w

t to the co

- Vehicles with ABS brakes ⇒ Item 14 (page 28) .

- Vehicles without ABS brakes ⇒ Item 13 (page 28) .
rrectness of i
l purpos

nf
ercia

orm
m

atio
om

n in
or c

thi
te

sd
iva

o
r
rp

cu
o

m
f

en
ng

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

34 Rep. Gr.40 - Front suspension

 SpaceFox, Space Cross, Suran, Suran Cross, Sportvan 2006 ➤
Running gear, axles, steering - Edition 05.2011

3.2 Front wheel hub with wheel roller bearing for 13" running gear - vehicles
with ABS / ESP - remove and install

Special tools and workshop

equipment required
♦ Mounting device -3253-
♦ Assembly device -T10064-
♦ "Torque wrench - 5 to 50
Nm ( socket 1/2")" -VAG
1331-
♦ "Torquemeter - 40 to 200
Nm (socket 1/2")" -VAG
1332-
AG. Volkswagen AG d
♦ Engine and gearbox jack + agen oes
olksw not
gearbox or EQ 7081 -VAG ed by
V gu
ara
1383A- and Tray for engine horis nte
eo
jack EQ 7081 -VAG aut ra
c
1359/2- ss

ce
le
un

pt
♦ Torque wrench - 4 to 20 Nm

an
d
itte

y li
(socket 3/8") -VAG 1410-
rm

ab
pe

ility
ot

wit
, is n

h re
hole

spec
es, in part or in w

t to the co
rrectness of i
l purpos

nform
mercia

a
com

tion in
r
te o

thi
s
iva

do
r
rp

cum
fo

en
ng

t.
yi Co
Cop py
t. rig
♦ Open-end spanner, 50 mm -3254-
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.

3. II - Wheel roller bearings - repair 35

 SpaceFox, Space Cross, Suran, Suran Cross, Sportvan 2006 ➤
Running gear, axles, steering - Edition 05.2011

♦ Similar - Gedore Ref. D32-36 - Star socket 36mm -T10125-

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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
3.2.1 Removal
– Lift the vehicle until the front axle is without any load.

rrectness of i
– Loosen the grooved nut -arrow- with the ?Star socket 36mm
l purpos

or Gedore Ref. D32-36 -T 10125- or the 30-mm star socket.

– Remove the wheel.

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
– Loosen the fastening nut -1- from the yoke.
cted agen
Prote AG.

– Separate the steering yoke tip -2- from the wheel roller bearing
case, by using the Extractor -3287 A- .
– Mark the position for the swivel tip screws on the wishbone.

– Remove the attaching screws -arrows-.

– Move the suspension column together with the swivel joint on
the wishbone.

36 Rep. Gr.40 - Front suspension

 AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
ise nte
thor SpaceFox, Space Cross, Suran, Suran Cross,
eo Sportvan 2006 ➤
u ra
ss a Running gear, axles, steeringc - Edition 05.2011

ce
e
nl

pt
du
– Remove the hexagon nuts -1- from both sides of the coupling

an
itte

y li
rod -3-.

erm

ab
ility
ot p
– Remove the coupling rod -3- from the anti-roll bar -2-.

wit
, is n

h re
hole

spec
es, in part or in w

t to the co
rrectness of i
l purpos

nf
ercia

– Press the drive axle shaft out of the roller bearing case. To do

orm
this, install the Extractor -3283- as shown in the illustration.
m

atio
om

n in
or c

thi
e

Note
t

sd
iva

o
r
rp

cu
o

While pressing the drive axle shaft outwards, make sure you have

m
f

en
ng

t.
enough free space.
yi Co
Cop py
t. rig
gh ht
yri
– Remove the wheel roller bearing case with the shaft articula‐
p by
co Vo
by lksw
tion out of the transverse arm. Prote
cted AG.
agen

– Turn the suspension outward and support, for example, with

a wooden block -1- , and simultaneously remove the drive axle
shaft from the wheel roller bearing.
– Fasten the drive axle shaft to the body with a wire.

Note

The drive axle shaft must not be pressed downwards. Otherwise,

the internal articulation will be damaged due to excessive tilting.

– Remove disc brake caliper and tie it to body with wire ⇒ Brake
system; Rep. Gr. 46 ; Brakes - Mechanical systems .
– Remove the Phillips screw from the brake disc and remove the
brake disc.
– Remove the cover plate.
– Remove the speed sensor from the wheel bearing case.

Note

Position the Engine and gearbox jack + gearbox or EQ 7081 -VAG

1383A- underneath (danger of accident from falling parts when
extracting the wheel hub and the wheel roller bearing)

3. II - Wheel roller bearings - repair 37

 SpaceFox, Space Cross, Suran, Suran Cross, Sportvan 2006 ➤
Running gear, axles, steering - Edition 05.2011

3.2.2 Wheel hub with roller bearing - remove

– Install the detachment device -1- between the wheel roller
bearing case and the wheel hub, and pre-tension it.
Installation position: Flat sides of plates face to wheel hub side
– Hold the device and remove the wheel hub with the wheel roll‐
er bearing
1 - Mounting device -3253/3-
2 - Mounting device -3253/5-
3 - Mounting device -3253/2-
4 - Mounting device -3253/1-
5 - Mounting device -3253/6-
6 - Open-end spanner, 50 mm -3254-

3.2.3 Wheel hub with roller bearing - install

– Remove residues from the drilling retaining washer and the
wheel roller bearing case groove.
– Clean the suspension column hole.
– Lubricate the wheel roller bearing housing surface with the
Molybdenum grease -G 052 723 A2- . Refer to the ⇒ Chemical
material manual . agen
AG. Volkswagen AG d
oes
olksw not
V gu
Use the Molybdenum grease -G 052 723 A2- . Refer to the ⇒ ed by ara
nte
Chemical material manual . horis
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

– Install the claws from the Installation device -T10064/5- on the

t to the co
wheel hub with wheel roller bearing.
1 - Wheel hub with wheel bearing
2 - Wheel screws rrectness of i
l purpos

3 - Assembly device -T 10064/5-

Screws from wheel -2- must not protrude from the back of claw of
nform
ercia

the Assembly device -T 10064/5- .

m

at
om

ion
c

in t
or

his
ate

do
priv

cum
for

en
ng

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

38 Rep. Gr.40 - Front suspension

 SpaceFox, Space Cross, Suran, Suran Cross, Sportvan 2006 ➤
Running gear, axles, steering - Edition 05.2011

– Install the wheel hub with wheel roller bearing in the wheel
roller bearing case.

Note

When installing, do not tilt the wheel hub with wheel roller bearing

– Install the wheel hub with wheel bearing until the retaining
washer fits with an audible click.
1 - Mounting device -3253/5-
2 - Mounting device -3253/3-
3 - Assembly device -T 10064/1-
4 - Assembly device -T10064/5-
5 - Assembly device -T10064/4-

– Loosen the claws from the Assembly device -T10064/5- wheel

hub with wheel bearing.
1 - Wheel hub with wheel bearing
2 - Wheel screws

AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
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aut ra
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ce
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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

nform
mercia

a
com

tion in
r
te o

thi
s
iva

do
r
rp

cum
fo

en
ng

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

3. II - Wheel roller bearings - repair 39

 n AG. Volkswagen AG do
lkswage es n
o ot g
byV ua
d ran
ir se
SpaceFox, Space Cross, Suran, th Suran Cross, Sportvan 2006 ➤
o tee
or
u
Running gear, axles, steering
ss - Edition 05.2011
a ac

ce
le
un

pt
Install the drive shaft in the wheel roller bearing as detailed below:

an
d
itte

y li
erm

ab
– Apply the Adhesive -D 185 400 A2- to the stub axle threads

ility
ot p
-A- or to the nut thread. Refer to the ⇒ Chemical material

wit
is n
manual .

h re
ole,
– Apply 2g of Adhesive -D 185 400 A2- to area -B-. Refer to the

spec
⇒ Chemical material manual . urposes, in part or in wh

t to the co
– The areas where the Adhesive -D 185 400 A2- should be free
from grease, oil, water or any other type of material. Refer to
the ⇒ Chemical material manual .

rrectne
– Tighten the nut with 50 Nm.

ss o
cial p

f i
WARNING

nform
mer

atio
The torque must be applied within 2 minutes after inserting the
om

n
shaft tip into the wheel hub. After the torque, the vehicle must
c

i
or

n
remain at least 1.5 hours with no strain on the semi-shaft.

thi
te

sd
iva

o
pr

cum
r
fo

en
ng

– Fasten the swivel tip to the wishbone (screws on old marks).

t.
yi Co
op
Tightening torque ⇒ Item 17 (page 8) . C py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted
Note
agen
Prote AG.

Check if the bellows are not damaged or twisted

– Install the disc protector, brake disc and disc brake caliper.
Please refer to manual ⇒ Brake system; Rep. Gr. 46 ; Brakes
- Mechanical systems .
– Install the wheels and tighten the screws ⇒ page 88 .

40 Rep. Gr.40 - Front suspension

 AG. Volkswagen AG d
agen oes
olksw not
V
SpaceFox, Space d b Cross, Suran, Suran Cross, Sportvan
y gu
ara 2006 ➤
ise nte
thor Running gear, axles, steering - Edition 05.2011
eo
au ra
ss c
3.3 Front wheel hub with wheel roller bearing for 14" and 15" running gears -

ce
le
un

pt
an
d
remove and install

itte

y li
rm

ab
pe

ility
ot

wit
Special tools and workshop

, is n

h re
equipment required

hole

spec
♦ Mounting device -3253-

es, in part or in w

t to the co
♦ Assembly device -T 10064-
♦ "Torque wrench - 5 to 50

rrectness of i
Nm ( socket 1/2")" -VAG
1331- l purpos

♦ "Torquemeter - 40 to 200
Nm (socket 1/2")" -VAG

nform
ercia

1332-
m

a
com

ti
♦ Engine and gearbox jack +

on in
gearbox or EQ 7081 -VAG
r
te o

thi
1383A- and Tray for engine

s
iva

do
jack EQ 7081 -VAG
r
rp

cum
1359/2-
fo

en
ng

t.
yi Co
♦ Torque wrench - 4 to 20 Nm t. Cop py
(socket 3/8") -VAG 1410-
rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

♦ ?Star socket 36mm or Gedore Ref. D32-36 -T 10125-

3. II - Wheel roller bearings - repair 41

 SpaceFox, Space Cross, Suran, Suran Cross, Sportvan 2006 ➤
Running gear, axles, steering - Edition 05.2011

♦ Open-end spanner, 50 mm -3254-

3.3.1 Removal
– Lift the vehicle until the front axle is without any load.
– Loosen the grooved nut -arrow- with the ?Star socket 36mm
or Gedore Ref. D32-36 -T 10125- or the 30-mm star socket.
– Remove the wheel.
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
– Loosen the fastening nut -1- from the yoke.
ole,

spec
urposes, in part or in wh

– Separate the steering yoke tip -2- from the wheel roller bearing t to the co
case, by using the Extractor -3287 A- .
– Mark the position for the swivel tip screws on the wishbone.
rrectness o
cial p

f inform
mer

atio
om

n
c

i
or

n thi
te

– Remove the attaching screws -arrows-.

sd
iva

o
pr

cum
r

– Move the suspension column together with the swivel joint on

fo

en
ng

the wishbone.
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

42 Rep. Gr.40 - Front suspension

 SpaceFox, Space Cross, Suran, Suran Cross, Sportvan 2006 ➤
Running gear, axles, steering - Edition 05.2011

– Remove the hexagon nuts -1- from both sides of the coupling
rod -3-.
– Remove the coupling rod -3- from the anti-roll bar -2-.

– Press the drive axle shaft out of the roller bearing case. To do
this, install the Extractor -3283- as shown in the illustration.

Note

While pressing the drive axle shaft outwards, make sure you have
enough free space.

– Remove the wheel roller bearing case with the shaft articula‐
tion out of the transverse arm.

– Turn the suspension outward and support, for example, with

a wooden block -1- , and simultaneously remove the drive axle
shaft from the wheel roller bearing.
– Fasten the drive axle shaft to the body with a wire.

n AG. Volkswagen AG do
lkswage Note es n
o ot g
byV ua
ed ran
The drive axlehorshaft must not be pressed downwards. Otherwise,
is tee
the internals auarticulation will be damaged due to excessive tilting.
t or
ac
s
ce
e
nl

pt

– Remove the break support with the disc break caliper, or only
du

an
itte

the disc break caliper, and fasten to the body with a wire ⇒
y li
erm

ab

Brake system; Rep. Gr. 46 ; Brakes - Mechanical systems .

ility
ot p

– Remove the Phillips screw from the brake disc and remove the
wit
, is n

h re

brake disc.
hole

spec

– Remove the cover plate.

es, in part or in w

t to the co

– Remove the speed sensor from the wheel bearing case.

rrectness of i

Note
l purpos

Position the Engine and gearbox jack + gearbox or EQ 7081 -VAG

1383A- underneath (danger of accident from falling parts when
nform
ercia

extracting the wheel hub and the wheel roller bearing).

m

at
om

ion
c

in t
or

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ate

do
priv

cum
for

en
ng

t.
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Cop py
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pyri by
Vo
co lksw
by
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Prote AG.

3. II - Wheel roller bearings - repair 43

 n AG. Volkswagen AG do
lkswage es n
SpaceFox, Space byV
o
Cross, Suran, Suran Cross, Sportvan
ot g
ua 2006 ➤
ed ra
Runninghogear,
ris axles, steering - Edition 05.2011 ntee
t or
au ac
ss
3.3.2 Hub with wheel bearing - remove

ce
e
nl

pt
du

an
itte

– Install the detachment device -1- between the wheel bearing

y li
erm

ab
case and the wheel hub and pretension it.

ility
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Installation position: Flat plate surfaces to the wheel hub side.

wit
, is n

h re
hole

– ?Firmly ??hold the device and remove the wheel hub with the

spec
wheel bearing.
es, in part or in w

t to the co
1 - Mounting device -3253/3-
2 - Mounting device -3253/5-

rrectness of i
3 - Mounting device -3253/2-
l purpos

4 - Mounting device -3253/1-

5 - Mounting device -3253/6-

nform
mercia

6 - Open-end spanner, 50 mm -3254-

at
om

ion
c

in t
or

3.3.3 Wheel hub with wheel bearing - install

his
ate

do
priv

c
– Remove residues from the drilling retaining washer and the

um
for

en
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wheel roller bearing case groove.

n

t.
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op py
– Clean the suspension column hole.
t. C rig
gh ht
pyri by
Vo
– Lubricate the wheel roller bearing housing surface with the
co lksw
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cted agen
Molybdenum grease -G 052 723 A2- . See the ⇒ Chemical Prote AG.
material manual .
Use the Molybdenum grease -G 052 723 A2- . Refer to the ⇒
Chemical material manual .
Use the grease from the repair kit.

– Install the claws from the Installation device -T10064/6A- on

the wheel hub with wheel roller bearing.
1 - Wheel hub with wheel bearing
2 - Wheel screws
3 - Assembly device -T10064/6A-
Screws from wheel -2- must not protrude from the back of claw of
the Assembly device -T10064/6A- .

44 Rep. Gr.40 - Front suspension

 SpaceFox, Space Cross, Suran, Suran Cross, Sportvan 2006 ➤
Running gear, axles, steering - Edition 05.2011

– Install the wheel hub with the wheel bearing on the wheel
bearing case.

Note

When installing, do not tilt the wheel hub with wheel roller bearing

– Install the wheel hub with wheel bearing until the retaining
washer fits with an audible click.
1 - Mounting device -3253/5-
2 - Mounting device -3253/3-
3 - Assembly device -T 10064/1- agen
AG. Volkswagen AG d
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4 - Assembly device -T10064/6A- d byV gu
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r
5 - Assembly device -T10064/4- ut
ho eo
ra
s a c
s

ce
le

– Loosen the claws from the Installation device -T10064/6A-

un

pt
an
wheel hub with wheel bearing.
d
itte

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rm

ab
1 - Wheel hub with wheel bearing
pe

ility
ot

wit
2 - Wheel screws
, is n

h re
hole

– Install the drive shaft in the wheel roller bearing.

spec
es, in part or in w

t to the co
Note

rrectness of i
Check if the gaiters are not damaged or twisted.
l purpos

– Fasten the swivel tip to the wishbone (screws on old marks).

Tightening torque ⇒ Item 17 (page 8) .

nform
ercia

– Install the disc protector, the brake disc and the brake support
m

a
com

with the disc brake caliper, or only the disc brake caliper.

tion in
Please refer to manual ⇒ Brake system; Rep. Gr. 46 ; Brakes
r
te o

thi
- Mechanical systems .
s
iva

do
r

– Install the wheels and tighten the screws ⇒ page 88 .

rp

cum
fo

en
ng

t.
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– Tighten the splined nut -arrow -. Cop py
ht. rig
rig ht
- Vehicles with ABS brakes ⇒ Item 14 (page 28) . py by
co Vo
by lksw
cted agen
- Vehicles without ABS brakes ⇒ Item 13 (page 28) . Prote AG.

3. II - Wheel roller bearings - repair 45

 SpaceFox, Space Cross, Suran, Suran Cross, Sportvan 2006 ➤
Running gear, axles, steering - Edition 05.2011

4 III - Front suspension pillar - assem‐

bly overview AG. Volkswagen AG d
agen oes
olksw not
V gu
by
WARNING rised ara
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aut ra
At a same vehicle, only shock absorbers from the
ss same brand c
must be used.

ce
le
un

pt
an
d
itte

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rm

ab
pe

ility
ot

wit
1 - Damper
, is n

h re
❑ Refer to: ⇒ Electronic
hole

spec
Parts Catalogue (ETKA)
es, in part or in w

t to the co
WARNING
At a same vehicle, only

rrectness of i
shock absorbers from
l purpos

the same brand must be

used.

nform
ercia

2 - Stopper
m

a
com

tion in
3 - Damper dust boot
r
te o

thi
s
4 - Coil spring
iva

do
r
rp

c
❑ remove and install

um
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en
g

⇒ page 52
n

t.
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op
❑ observe the color cod‐
C py
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ing
ht
pyri by
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by c lksw
❑ Refer to: ⇒ Electronic Prote
cted AG.
agen
Parts Catalogue (ETKA)
Spring allocation via PR num‐
ber

These numbers are indicated

on the vehicle data plate

Example ⇒ page 47
❑ the external spring sur‐
face must not be dam‐
aged
5 - Axial ball bearing
6 - Suspension pillar support
7 - Self-locking hexagon nut
❑ 60 Nm
❑ replace after each removal
8 - Suspension pillar turret
9 - Hexagon screw
❑ 15 Nm + 90°
❑ replace after each removal
10 - Cover

46 Rep. Gr.40 - Front suspension

 SpaceFox, Space Cross, Suran, Suran Cross, Sportvan 2006 ➤
Running gear, axles, steering - Edition 05.2011

4.1 Vehicle identification label

The vehicle ID label is located in the spare wheel housing and in
the Maintenance and Warranty book.
Numbers -1. . . 4- give information on the coil springs and shock
absorbers installed in the respective vehicle.
The corresponding spring installed in the vehicle is indicated on
the vehicle identification label, documented by the respective PR
number of the weight class.
Based on this PR number, the matching between the respective
spring and the vehicle can be made from the Replacement Parts
Catalogue/ETKA.

AG. Volkswagen AG d
agen oes
olksw not
y V gu
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au ra
ss c

ce
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un

pt
an
d
itte

4.2 Suspension column - remove and install

y li
erm

ab
ility
ot p

wit
is n

Special tools and workshop

h re
ole,

equipment required

spec
urposes, in part or in wh

♦ "Torque wrench - 5 to 50

t to the co
Nm ( socket 1/2")" -VAG
1331-
♦ "Torquemeter - 40 to rrectne
200Nm (socket 1/2")" -VAG
1332-
ss o
cial p

♦ Tray for engine jack EQ

inform

7081 -VAG 1359/2- and

mer

Engine and gearbox jack +

atio
m

gearbox or EQ 7081 -VAG

o

n
c

1383A-
i
or

n thi
te

sd
a

♦ Spreader -3424-
iv

o
pr

cum
r
fo

♦ ?Star socket 36mm or Ge‐

en
ng

t.
yi
dore Ref. D32-36 -T 10125-
Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

4. III - Front suspension pillar - assembly overview 47

 SpaceFox, Space Cross, Suran, Suran Cross, Sportvan 2006 ➤
Running gear, axles, steering - Edition 05.2011

4.2.1 Removal
– Lift the vehicle until the front axle is without any load.
– Loosen the grooved nut -arrow- with the Star socket 36mm or
Gedore Ref. D32-36 -T 10125- or the 30 mm star socket.
– Remove the wheel.
– Release upper hexagon nut from the coupling rod -arrow B-
from the suspension pillar.
olkswagen AG
en AG. V
– Release the speed sensor cable from the suspensionocolumn.
lksw
ag does
not
byV gu
ara
– Mark the position for the swivel tip screws on theris wishbone.
ed
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

– Remove screws -arrows-.

t to the co
– Move the suspension column together with the swivel joint on
the wishbone.

rrectness of i
l purpos

nform
mercia

at
om

ion
c

in t
or

his
ate

do
priv

cum
or

– Press the drive axle shaft out of the roller bearing case. To do
f

en
ng

t.
yi
this, install the Extractor -3283- as shown in the illustration.
Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
Note
by
cted agen
Prote AG.

While pressing the drive axle shaft outwards, make sure you have
enough free space.

– Remove the wheel roller bearing case with the shaft articula‐
tion out of the transverse arm.

48 Rep. Gr.40 - Front suspension

 SpaceFox, Space Cross, Suran, Suran Cross, Sportvan 2006 ➤
Running gear, axles, steering - Edition 05.2011

– Turn the suspension outward and support, for example, with

a wooden block -1- , and simultaneously remove the drive axle
shaft from the wheel roller bearing.
– Fasten the drive axle shaft to the body with a wire.

Note

The drive shaft shall not hang, once the inner articulation can be
damaged due to excessive tilting

– Release the swivel joint from the support arm.

– Position the Engine and gearbox jack + gearbox or EQ 7081
-VAG 1383A- under the wheel bearing case.

– Loosen the nut that connects the wheel roller bearing case to
the suspension column -arrow-.

AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
– Install the Spreader -3424-
aut in the slot. ra
c
ss
– Turn the ratchet 90° and remove it from the Spreader -3424- .
ce
e
nl

pt
du

an
itte

– Press the brake disc toward the suspension column manually.

y li
erm

ab

– Otherwise, the shock absorber tube could incline into the hole
ility
ot p

in the wheel roller bearing case.

wit
, is n

h re
hole

– Remove the wheel bearing case from under the shock ab‐
spec

sorber tube and lower it, with the Engine and gearbox jack +
es, in part or in w

gearbox or EQ 7081 -VAG 1383A- until the shock absorber

t to the co

tube can be freely moved.

– Fasten the wheel roller bearing case on the console/subframe
rrectness of i

by using a wire.
l purpos

– Remove the Engine and gearbox jack + gearbox or EQ 7081

-VAG 1383A- in the wheel roller bearing case.
nf
ercia

or

Remove hexagon screws -arrows- from upper fastening of shock

m
m

atio

absorber and remove the suspension pillar.

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.

4.2.2 Installation
– Install the suspension pillar.

4. III - Front suspension pillar - assembly overview 49

 SpaceFox, Space Cross, Suran, Suran Cross, Sportvan 2006 ➤
Running gear, axles, steering - Edition 05.2011

Remove the hex head screws -arrows- from the shock absorber
upper fastening ⇒ Item 9 (page 46) .
– Position the Engine and gearbox jack + gearbox or EQ 7081
-VAG 1383A- under the wheel bearing case.
. Volkswage n AG n AG d
wage oe
– Place the suspension pillar
yV
olks on wheel bearing case. s not g
u b ara
ed
– Removing the wire
ho from the wheel bearing case.
ris nte
e
t or
au ac
– Using the and gearbox jack + gearbox or EQ 7081 - Engine
ss
VAG 1383A- , lift the wheel roller bearing case carefully until

ce
le
un

pt
you are able to install the screws for the suspension column/

an
d
itte

y li
wheel bearing case.
erm

ab
ility
ot p

– While lifting the support, press the brake disc toward the sus‐

wit
is n

pension column manually.

h re
ole,

– Otherwise, the shock absorber tube could incline into the hole

spec
urposes, in part or in wh

in the wheel roller bearing case.

t to the co
– Remove the Spreader -3424- .

rrectne
– Tighten the nut -arrow- from the screwed connection of the
wheel roller bearing case/suspension column
⇒ Item 7 (page 27) .

ss o
cial p

f
– Install the wheel roller bearing case with the swivel tip in the

inform
wishbone.
mer

atio
m

Only for vehicles without ABS

o

n
c

i
or

n
Clean threaded and indented surfaces. The cleaned areas must
thi
te

sd
a

be free of oil and grease.

iv

o
pr

cum
r
fo

en
ng

t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co
– Apply to the splines-1- (bead diameter 2mm) and the thread
by lksw
cted agen
Prote
-2- (and all around) Adhesive -D 185 400 A2- as indicated in
AG.

the illustration. Refer to the ⇒ Chemical material manual .

Only for vehicles with 13" running gear with ABS/ESP

50 Rep. Gr.40 - Front suspension

 SpaceFox, Space Cross, Suran, Suran Cross, Sportvan 2006 ➤
Running gear, axles, steering - Edition 05.2011

Install the articulated shaft on the wheel bearing as follows:

– Apply the Adhesive -D 185 400 A2- to the stub axle threads
-A- or to the nut thread. Refer to the ⇒ Chemical material
manual .
– Apply 2g of Adhesive -D 185 400 A2- to area -B-. Refer to the
⇒ Chemical material manual .
– The areas where the Adhesive -D 185 400 A2- should be free
from grease, oil, water or any other type of material. Refer to
the ⇒ Chemical material manual .
– Tighten the nut with 50 Nm.

WARNING

The torque must be applied within 2 minutes after inserting the

shaft tip into the wheel hub. After the torque, the vehicle must
remain at least 1,5 hours with no strain on the semi-shaft.

Continuation for all vehicles:

– Install the screws -arrows- in the previous made markings.

Tightening torque ⇒ Item 17 (page 8) .

Note

♦ Use new screws!

♦ Check if the bellows are not damaged or twisted

Install by inverting the removal

AG. Volksequence.
swagen A
gen G do
swa es
– Fit wheel and
by
Votighten
lk screws ⇒ page 88 . not gu
d ara
se nte
– Tighten
tho the grooved nut:
ri e or
au ac
- Vehicles
ss with ABS brakes ⇒ Item 14 (page 28) .
ce
e
nl

pt
du

- Vehicles without ABS brakes. ⇒ Item 13 (page 28) .

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
o
by c lksw
cted agen
Prote AG.

4. III - Front suspension pillar - assembly overview 51

 AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
SpaceFox, Space ris Cross, Suran, Suran Cross, Sportvan 2006
ed
nte ➤
o eo
Running gear,aut axles, steering - Edition 05.2011
h
ra
ss c

ce
le
4.3 Front suspension spring - repair

un

pt
an
d
itte

y li
rm

ab
pe

ility
Special tools and workshop
ot

wit
, is n

equipment required

h re
hole

♦ "Torquemeter - 40 to 200

spec
es, in part or in w

Nm (socket 1/2")" -VAG

t to the co
1332-
♦ Compression device or VW
5340 -VAG 1752/1- and

rrectness of i
Spring support -VAG
l purpos

1752/4-
♦ Keys -T 10001-

nform
mercia

a
com

tion in
r
te o

thi
s
iva

do
r
rp

cum
fo

en
ng

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

4.3.1 Coil spring - remove

– Remove suspension pillar ⇒ page 47 .

52 Rep. Gr.40 - Front suspension

 SpaceFox, Space Cross, Suran, Suran Cross, Sportvan 2006 ➤
Running gear, axles, steering - Edition 05.2011

– Compress the coil spring, using the Compression device or

VW 5340 -VAG 1752/1- until upper portion of axial ball bearing
is free.
– Remove the hexagon nut from the damper rod.
– Remove individual parts of suspension strut and coil spring
with Compression device or VW 5340 -VAG 1752/1- .
1 - "Torquemeter - 40 to 200Nm (socket 1/2")" -VAG 1332-
2 - Keys -T10001/8-
3 - Keys -T10001/11-
4 - Keys -T10001/5-
5 - Compression device or VW 5340 -VAG 1752/1-
6 - Spring support -VAG 1752/4-

WARNING

Initially, tension the spring until the upper spring plate pressure
is relieved.

– Ensure coil spring is correctly fit in Spring support -VAG

1752/4- -arrow-.

AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
ut
4.3.2 Coil spring - install a ra
ss c
ce
e
nl

pt

– Fit coil spring into lower spring support with Compression de‐
du

an
itte

vice or VW 5340 -VAG 1752/1- .

y li
erm

ab
ility

– The end of the coil spring must touch the stop -arrow-.
ot p

wit
, is n

– Tighten new hexagonal nut on the shock absorber rod

h re
hole

⇒ Item 7 (page 46) .

spec
es, in part or in w

– Release the Compression device or VW 5340 -VAG 1752/1-

t to the co

and remove it from coil spring.

– Install suspension pillar ⇒ page 47 .
rrectness of i
l purpos

nform
mercia

at
om

ion
c

in t
or

his
ate

do
priv

cum
for

en
ng

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

4. III - Front suspension pillar - assembly overview 53

 SpaceFox, Space Cross, Suran, Suran Cross, Sportvan 2006 ➤
Running gear, axles, steering - Edition 05.2011

5 Drive shafts - repair

WARNING

Always replace self-locking nuts and screws which were sub‐

jected to angular torque.

AG. Volkswagen AG d
Note lksw
agen oes
not
o
byV gu
ara
ed
The only operations authorized thorisby Volkswagen engineering divi‐ nte
eo
sion are the replacement ofs au(external or internal) drive shafts and ra
c
replacement of the respective
s cauls.

ce
e
nl

pt
du

an
itte

5.1 Drive shafts - remove and install

y li
erm

ab
ility
ot p

Special tools and workshop equipment required

wit
, is n

h re
♦ "Torquemeter - 40 to 200 Nm (socket 1/2")" -VAG 1332-
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

♦ Star socket 36mm or Gedore Ref. D32-36 -T 10125-

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.

5.1.1 Removal
– Lift the vehicle until the front axle is without any load.

54 Rep. Gr.40 - Front suspension

 SpaceFox, Space Cross, Suran, Suran Cross, Sportvan 2006 ➤
Running gear, axles, steering - Edition 05.2011

– Loosen the grooved nut -arrow- with the Star socket 36mm or
Gedore Ref. D32-36 -T 10125- or the 30-mm star socket.
– Remove the wheel.

– Loosen the fastening nut -1- from the yoke.

– Separate the steering yoke tip -2- from the wheel roller bearing
case, by using the Extractor -3287 A- .
– Mark the position for the swivel tip screws on the wishbone.

– Remove the attaching screws -arrows-.

– Move the suspension column together with the swivel joint on
the wishbone.

AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
ss c
ce
e
nl

pt
du

– Remove the hexagon nuts -1- from both sides of the coupling
an
itte

rod -3-.
y li
erm

ab
ility

– Remove the coupling rod -3- from the anti-roll bar -2-.
ot p

wit
, is n

h re
hole

spec
es, in part or in w

t to the co
rrectness of i
l purpos

nf
ercia

orm
m

atio
om

n in
or c

thi
te

sd
iva

o
r
rp

cu
o

m
f

en
ng

t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw

55
cted agen
Prote AG.
5. Drive shafts - repair
 SpaceFox, Space Cross, Suran, Suran Cross, Sportvan 2006 ➤
Running gear, axles, steering - Edition 05.2011

– Press the drive axle shaft out of the roller bearing case. To do
this, install the Extractor -3283- as shown in the illustration.

Note

While pressing the drive axle shaft outwards, make sure you have
enough free space.

– Remove the wheel roller bearing case with the shaft articula‐
tion out of the transverse arm.
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
– Turn the suspension outward and support, for oris example, with
e nte
a wooden block -1- , and simultaneously remove
aut
h the drive axle eo
ra
shaft from the wheel roller bearing. ss c

ce
e
nl

pt
– Fasten the drive axle shaft to the body with a wire.
du

an
itte

y li
erm

ab
ility
ot p

Note

wit
, is n

h re
hole

The drive axle shaft must not be pressed downwards. Otherwise,

spec
the internal articulation will be damaged due to excessive tilting.
es, in part or in w

t to the co
rrectness of i
5.1.2 Installation
l purpos

Remove any paint residue and/or corrosion on threads/splines of

outer homokinetic articulation.

nform
ercia

Only for vehicles without ABS

m

at
om

io
– Clean threaded and indented surfaces.

n
c

in t
or

his
e

– Lubricate the toothed area -1- and the thread -2- with Molyb‐
at

do
riv

denum Paste -G 052 751 A1- . Refer to the ⇒ Chemical

p

cum
or

material manual .
f

en
ng

t.
yi Co
op
Only for vehicles with 13" running gear with ABS/ESP C py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.

56 Rep. Gr.40 - Front suspension

 SpaceFox, Space Cross, Suran, Suran Cross, Sportvan 2006 ➤
Running gear, axles, steering - Edition 05.2011

Install the drive shaft in the wheel roller bearing as detailed below:
– Apply the Adhesive -D 185 400 A2- to the stub axle threads
-A- or to the nut thread. Refer to the ⇒ Chemical material
manual .
– Apply 2g of Adhesive -D 185 400 A2- to area -B-. Refer to the
⇒ Chemical material manual .
– The areas where the Adhesive -D 185 400 A2- should be free
from grease, oil, water or any other type of material.
– Tighten the nut with 50 Nm.

WARNING

The torque must be applied within 2 minutes after inserting the

shaft tip into the wheel hub. After the torque, the vehicle must
remain at least 1.5 hours with no strain on the semi-shaft.

Continued for all vehicles

– Install the drive shaft in the wheel roller bearing.

Note

Check if the bellows are not damaged or twisted

– Fit the outer homokinetic articulation into the wheel hub

splines as far as possible.
– Fasten the swivel tip to the wishbone (screws on old marks).
Tightening torque ⇒ Item 17 (page 8) .
AG. Volkswagen AG d
agen oes
lksw not
WARNING d by
Vo gu
ara
ise nte
or eo
h
Always replace self-lockings autnuts and screws which were sub‐ ra
c
jected to angular torque. s
ce
le
un

pt
an
d
itte

y li
erm

– Install the inner homokinetic articulation and firstly tighten the

ab
ility

bolts crosswise with 10 Nm.

ot p

wit
is n

– Tighten the internal grooved screws in a cross pattern, to the

h re
ole,

torque specified ⇒ Item 12 (page 61) .

spec
urposes, in part or in wh

– Install the wheels and tighten the screws ⇒ page 88 .

t to the co

– Tighten the splined nut -arrow-.

rrectne

- Vehicles with ABS brakes ⇒ Item 14 (page 28) .

s

- Vehicles without ABS brakes ⇒ Item 13 (page 28) .

s o
cial p

f inform
mer

atio
om

n
c

i
or

n thi
te

sd
iva

o
pr

cum
r
fo

en
ng

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

5. Drive shafts - repair 57

 SpaceFox, Space Cross, Suran, Suran Cross, Sportvan 2006 ➤
Running gear, axles, steering - Edition 05.2011

6 IV - Drive shafts with constant-veloc‐

ity joints - repair

WARNING

• Always replace self-locking nuts and screws which were

subjected to angular torque.
• The only operations authorized by Volkswagen engineer‐
ing division are the replacement of (external or internal)
drive shafts and replacement of the respective cauls.

Special tools and workshop

equipment required
♦ Pressure plate -VW 401-
♦ Pressure plate -VW 402-
♦ Pressure pin -VW 408 A-
♦ Pressure pin -VW 411-
♦ Pressure tube -VW 416 B-
AG. Volkswagen AG d
agen oes
♦ Thrust pad -VW 447 H- Volksw not
gu
by ara
d
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

t to the co
rrectness of i
l purpos

nform
mercia

a
com

tion in
r
te o

thi
s
iva

do
r
rp

cum
fo

en
ng

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

58 Rep. Gr.40 - Front suspension

 SpaceFox, Space Cross, Suran, Suran Cross, Sportvan 2006 ➤
Running gear, axles, steering - Edition 05.2011

Special tools and workshop

equipment required
♦ Pliers or VW 5161A -VW
161A-
♦ "Torque wrench - 5 to 50
Nm ( socket 1/2")" -VAG
1331-
♦ "Torquemeter - 40 to 200
Nm (socket 1/2")" -VAG
1332- AG. Volkswagen AG d
agen oes
lksw not
♦ Clamp device -VAG 1682- d by V o gu
ara
ise nte
r
♦ Mounting device -T10065-
ut
ho eo
ra
s a 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

t to the co
rrectness of i
l purpos

nf
ercia

orm
m

atio
om

n in
or c

thi
te

sd
iva

o
r
rp

cu
o

m
f

en
ng

t.
yi Co
Cop py
t. rig
gh ht
yri by
Grease quantity and types:
op Vo
by c lksw
cted agen
Prote AG.
The constant-velocity joints are stored with Grease -G 000 603- .
Refer to the ⇒ Chemical material manual .
Grease of total for
Outer homoki‐ Total quantity Articulation Protection cov‐
netic articulation ers
∅ mm [g] [g] [g]
85 80 40 40

Grease of total for

Inner homokinet‐ Total quantity Articulation Protection cov‐
ic articulation ers
∅ mm [g] [g] [g]
90 80 40 40
Lubricate the joint with grease, if necessary, when replacing the
protective cauls.

6. IV - Drive shafts with constant-velocity joints - repair 59

 AG. Volkswagen AG d
agen o
SpaceFox, Space Cross,VoSuran,
lksw Suran Cross, Sportvan
es n
ot g2006 ➤
by ua
Running gear, axles,
risesteering
d - Edition 05.2011 ran
t ee
ho
ut or
ac
1 - Self-locking sa
splined snut

ce
e
nl
for vehicles without ABS

pt
du

an
itte

y li
❑ Refer to: ⇒ Electronic
erm

ab
Parts Catalogue (ETKA)

ility
ot p

wit
, is n

❑ first tighten to 200 +

h re
50Nm and loosen (go‐
hole

spec
ing back) 180º, then
es, in part or in w

tighten further to 50 Nm

t to the co
+ 50º
❑ apply first White lubri‐
cating grease -G 052

rrectness of i
751 A1- on the grooves
l purpos

and outer thread of the

drive shaft, which must
be previously cleaned.

nform
ercia

Refer to the ⇒ Chemical

material manual
m

at
om

io
❑ replace after each re‐

n
c

in t
or

moval

his
ate

do
riv

for vehicles with ABS

p

cum
for

en
g

❑ tightening torque for 13”

n

t.
yi Co
running gear (black nut) Cop py
t. rig
= 50 Nm opyri
gh by
Vo
ht
c lksw
apply first Adhesive -D 185 400
by
cted agen
Prote
A2- on the grooves and outer
AG.

thread of the drive shaft, which

must be previously cleaned.
Refer to the ⇒ Chemical ma‐
terial manual
❑ tightening torque for 14”
and 15" running gear
(silver nut) = 50 Nm +
45º
❑ replace after each re‐
moval
2 - Deflector ring
3 - Outer homokinetic articulation
❑ full replacement only
❑ remove ⇒ page 61
❑ drive onto shaft on to stop with plastic hammer
4 - Lock ring
❑ replace after each removal
❑ install in the shaft groove
5 - Retainer
6 - Dished washer
❑ ∅ outer diameter (concave side) in contact with the retainer
7 - Clamp
❑ replace after each removal
❑ fasten ⇒ page 63
8 - Dust cover of the inner homokinetic articulation
❑ check for cracks and wear
9 - Clamp
❑ replace after each removal
❑ fasten ⇒ page 63

60 Rep. Gr.40 - Front suspension

 SpaceFox, Space Cross, Suran, Suran Cross, Sportvan 2006 ➤
Running gear, axles, steering - Edition 05.2011

10 - Left drive shaft (solid shaft)

11 - Left drive shaft (solid shaft)
12 - Internally splined bolt
❑ tighten in cross pattern to 10 Nm
❑ 20Nm + 180°
❑ replace after each removal
13 - Thrust plate
14 - Clamp
❑ replace after each removal
❑ fasten ⇒ page 63
15 - Dust cover of the homokinetic articulation
❑ check for cracks and wear
16 - Dished washer
❑ ∅ grooved inner diameter
❑ Installing position: outer diameter (concave side) in contact with the articulation
17 - Inner homokinetic articulation
❑ only replace complete
❑ remove ⇒ page 62 . Volkswagen AG
gen AG does
❑ install ⇒ page 62 Volkswa not
y gu
db a
18 - Gasket ris
e ran
tee
tho or
❑ replace, sremoving
au the protective film, and paste to the joint. ac
s
ce
e

19 - Lock ring
nl

pt
du

an

❑ replace after each removal

itte

y li
erm

ab

❑ remove and install with the Pliers or VW 5161A -VW 161A-

ility
ot p

wit
, is n

h re
hole

spec

Remove the external constant-velocity joint

es, in part or in w

t to the co

– Remove from the drive shaft through vigorously pounding with

an aluminum hammer.
rrectness of i
l purpos

nf
ercia

orm
m

atio
om

n in
or c

thi
te

sd
iva

o
r
rp

cu
o

m
f

en
ng

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

6. IV - Drive shafts with constant-velocity joints - repair 61

 SpaceFox, Space Cross, Suran, Suran Cross, Sportvan 2006 ➤
Running gear, axles, steering - Edition 05.2011

Remove the internal constant-velocity joint

Note

First, remove the protective caul from the joint with the help of a
drift.

AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
o
Install the internal constant-velocity joint auth eo
ra
ss c
– Press on the articulation to stopper.

ce
e
nl

pt
du

an
– Insert the lock ring.
itte

y li
erm

ab
ility
ot p

wit
Note
, is n

h re
hole

spec
The ball hub internal diameter chamfer (splined) must face the
es, in part or in w

the drive shaft shoulder.

t to the co
rrectness of i
l purpos

nf
ercia

orm
m

atio
om

n in
or c

thi
te

sd
iva

o
r
rp

cu
o

m
f

en
ng

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

62 Rep. Gr.40 - Front suspension

 SpaceFox, Space Cross, Suran, Suran Cross, Sportvan 2006 ➤
Running gear, axles, steering - Edition 05.2011

Install brace on outer joint

– Install the Clamp device -VAG 1682- as displayed in the illus‐
tration. While doing it, make sure that the pliers claws fit the
ends -arrow B- of clamp.
– Tight the clamp by turning the bolt with a torque wrench (do
not tilt the pliers).

Note

♦ The hardness of the material from the constant-velocity joint

protective caul (when compared with rubber) makes neces‐
sary to use a stainless steel clamp, and it can only be tightened
with the help from the Clamp device -VAG 1682-
♦ Tightening torque: 25 Nm
♦ Use "Torque wrench - 5 to 50 Nm ( socket 1/2")" -VAG 1331-
-C-
♦ Ensure the spindle -A- is not blocked.
gen AG
Ifaneeded,
. Volksw gen AG grease with
Lubricating grease MoS2Vol
ksw. Refer to the ⇒ Chemical
a d oes material
not
manual ed by gu
ara
is nte
or
♦ If the thread ais
ut tight e.g. dirty, the required tensioning force for
h eo
ra
the brace will
ss not be achieved in spite of correct tightening c
torque settings ce
le
un

pt
an
d
itte

y li
rm

ab
Install the clamp on the inner articulation protection cover (smaller
pe

ility
ot

diameter) wit
, is n

h re
hole

spec
es, in part or in w

t to the co
rrectness of i
l purpos

nform
mercia

a
com

tion in
r
te o

thi
s
iva

do
r
rp

cum
fo

en
ng

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

6. IV - Drive shafts with constant-velocity joints - repair 63

 SpaceFox, Space Cross, Suran, Suran Cross, Sportvan 2006 ➤
Running gear, axles, steering - Edition 05.2011

42 – Rear suspension
1 Rear axle - repair

WARNING

Always replace self-locking nuts and screws which were sub‐

jected to angular torque.

1.1 Rear axle - remove and install

Special tools and workshop

equipment required
♦ "Torquemeter - 40 to 200
Nm (socket 1/2")" -VAG
1332-
♦ Engine and gearbox jack +
gearbox or EQ 7081 -VAG
1383A- and Tray for engine
jack EQ 7081 -VAG
1359/2-
♦ Suspension pillar device -
VAG 1752-
♦ Brake pedal compression
device -VAG 1869/2-

n AG. Volkswagen AG do
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

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.

64 Rep. Gr.42 - Rear suspension

 SpaceFox, Space Cross, Suran, Suran Cross, Sportvan 2006 ➤
Running gear, axles, steering - Edition 05.2011

♦ Tension belt -T 10038-

1.1.1 Removal
– Measure distance from wheel housing
n AG. Voto
lkswheel
wagen Acentre
G do
⇒ page 6 . wage es n
olks o V t gu
by a
– Remove the centre rconsole
ise
d
⇒ Body - internal mountings; Rep.
ran
tee
Gr. 68 ; Internalautequipment
ho . or
a
ss c
– Release the parking brake.
ce
e
nl

pt
du

an

– Loosen adjusting nut -arrow- so that the handbrake cables can

itte

y li

be removed from the equalizer.

erm

ab
ility
ot p

– Install the Brake pedal compression device -VAG 1869/2- .

wit
, is n

h re

This will prevent the brake fluid from draining from the brake pipes
hole

spec

and the ABS hydraulic unit!

es, in part or in w

t to the co

– Lift the vehicle to a suitable work height.

Fasten the vehicle to the lift
rrectness of i

The vehicle must be fastened to the support arms of the lift before
the rear axle is removed.
l purpos

Caution
nf
ercia

orm
m

atio

If the vehicle is not fastened to the lift, the vehicle may slide off
om

n in

the lift.
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.

1. Rear axle - repair 65

 SpaceFox, Space Cross, Suran, Suran Cross, Sportvan 2006 ➤
Running gear, axles, steering - Edition 05.2011

– Remove the plugs from the longitudinal member -3- and pass
the fastening belt through the holes.
1 - Elevator arm
2 - Tension belt -T 10038- n AG. Volkswagen AG do
lkswage es n
– The vehicle must be fastened on by V the right and left sides with
o ot g
ua
the help of the fastening belts.
ir se
d ran
tee
tho
u or
– Remove the wheels. ss a ac

ce
e

– Disconnect the connector from the speed sensor.

nl

pt
du

an
itte

y li
erm

ab
ility
ot p

wit
, is n

– Remove the cable -1- from the speed sensor by removing it

h re
from the clips -arrows-.
hole

spec
es, in part or in w

– Lower rear muffler ⇒ Engine; Rep. Gr. 26 ; Exhaust system .

t to the co
rrectness of i
l purpos

nform
mercia

at
om

ion
c

in t
or

– Install spring tensioner -1-.

his
ate

do
riv

1 - Compression device or VW 5340 -VAG 1752/1-

p

cum
for

en
ng

2 - Spring support -VAG 1752/3-

t.
yi Co
Cop py
. rig
– Tension the coil spring until it is possible to remove it.
t
gh ht
pyri by
Vo
co
– Remove the spring.
by lksw
cted agen
Prote AG.
Vehicles without ABS

– Remove the screw -arrow-.

Continuation for all vehicles:

66 Rep. Gr.42 - Rear suspension

 SpaceFox, Space Cross, Suran, Suran Cross, Sportvan 2006 ➤
Running gear, axles, steering - Edition 05.2011

– Disconnect the brake pipes -arrow A- and remove the clip.

– Remove the left brake hose from the support -2-. n AG. Volkswagen AG do
lkswage es n
– Remove the right hose from rear axle beam. d byV
o ot g
ua
ran
ir se tee
– Remove parking brake cables of supports -arrow
utho B-. or
a ac
ss
– Remove the guide tubes from the parking brake cables.

ce
e
nl

pt
du
– Position the Engine and gearbox jack + gearbox or EQ 7081

an
itte

y li
-VAG 1383A- .

erm

ab
ility
ot p
– Fasten the rear axle with the belt or a similar device when

wit
, is n
lowering and removing.

h re
hole

spec
– Remove screws -1- from rear axle beam.
es, in part or in w

t to the co
– Loose rear axle from shock absorbers -arrows-.
– Lower rear axle using Engine and gearbox jack + gearbox or

rrectness of i
EQ 7081 -VAG 1383A- .
l purpos

nf
ercia

orm
m

atio
om

n in
or c

thi
te

sd
iva

o
r
rp

cu
o

m
f

en
ng

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

1.1.2 Installation
Before installing the rear axle, lubricate the metal-rubber bearings
cavities with Assembly Grease -G 052 150 A2-
. Refer to the ⇒ Chemical material manual . If the rear axle is
installed without lubrication, there may be noises while driving the
vehicle.
– Fasten the axle correctly and unladen ⇒ page 5 .
The rest of the installation is processed in the reverse order from
removal.
– Bleed the brake system. Refer to the ⇒ Brake system; Rep.
Gr. 47 ; Brakes - Hydraulic system, servo brake .
– Fit wheel and tighten screws ⇒ page 88 .
Tightening torque:
Rear axle to its support ⇒ Item 22 (page 69) .
Shock absorber to rear axle ⇒ Item 8 (page 69) .
Braking pressure adjustment to rear axle. Refer to the ⇒ Brake
system; Rep. Gr. 47 ; Brakes - Hydraulic system, servo brake .

1. Rear axle - repair 67

 SpaceFox, Space Cross, Suran, Suran Cross, Sportvan 2006 ➤
Running gear, axles, steering - Edition 05.2011

1.2 Rear axle body for drum brakes - as‐

sembly overview

WARNING

♦ At a same vehicle, only shock absorbers from the same

brand must be used.
♦ Welding and straightening on the rear axle and stub axle
is not allowed. AG. Volkswagen A n G do
wage es n
Volks ot g
by ua
ed ran
oris tee
th or
1 - Axle beam au ac
ss
❑ the shaft tip contact sur‐

ce
le
un

pt
face and threaded holes

an
d
itte

y li
must be free from paint
erm

ab
and dirt

ility
ot p

wit
2 - Lower spring plate
is n

h re
ole,

❑ check the plates for

spec
urposes, in part or in wh

damage

t to the co
3 - Coil spring
❑ observe the color cod‐
ing

rrectne
❑ Refer to: ⇒ Electronic
Parts Catalogue (ETKA)

ss o
cial p

f
Spring correspondence
inform
through the PR number
mer

atio
m

These numbers are indicated

o

n
c

on the vehicle data plate

or

n thi
te

sd
a

❑ Outer surface of the

iv

o
pr

springs shall not be

um
r
fo

en
ng

damaged
t.
yi Co
op py
4 - Spring seat
t. C rig
gh ht
pyri by
Vo
o
5 - Hexagon screw
c by lksw
cted agen
Prote AG.
❑ 30 Nm + 90°
❑ replace after each re‐
moval
If the soldered nut thread in the
longitudinal member is dam‐
aged, the thread can be re‐
paired with a Heli-Coil thread
insert

Servicing thread in longitudinal

member

6 - Damper
❑ Refer to: ⇒ Electronic Parts Catalogue (ETKA)

WARNING
At a same vehicle, only
shock absorbers from
the same brand must be
used.

68 Rep. Gr.42 - Rear suspension

 SpaceFox, Space Cross, Suran, Suran Cross, Sportvan 2006 ➤
Running gear, axles, steering - Edition 05.2011

7 - Hexagon screw
❑ replace after each removal
8 - Self-locking nut
❑ 40 Nm + 90°
❑ when tightening, check the installation angle of the rear axle in relation to the shock absorber
⇒ page 70
❑ replace after each removal
9 - ABS speed sensor
❑ before installing the sensor, you must clean the internal surface of the hole and apply Grease -G 000
650- . Refer to the ⇒ Chemical material manual
10 - Hexagon socket head screw
❑ 8 Nm
11 - Stub axle
❑ straightening operations are not permitted
❑ reworking the thread is not permitted
12 - Brake drum
13 - Screw
❑ 4 Nm
Volkswagen AG
14 - Protection cover against dust agen
AG. does
olksw not
❑ replace after each removal db
yV gu
ara
ise nte
❑ remove and install ⇒uthpage
or
79 eo
ra
sa c
A perfect seal is only achieved
s by using a new dust protection cover ce
le
un

pt
an
d

This is the only way to ensure optimal operation and high durability of the roller bearing
itte

y li
rm

ab
pe

15 - Self-locking splined nut

ility
ot

wit
, is n

❑ 70 Nm + 30°
h re
hole

❑ replace after each removal

spec
es, in part or in w

16 - Wheel hub with wheel bearings

t to the co

❑ the ABS sensor ring is installed in the wheel hub

❑ remove and install ⇒ page 79
rrectness of i

The wheel roller bearing and the wheel hub are installed together in a housing
l purpos

This wheel bearing/hub set is free of maintenance and adjustment. Adjustment and repair works are not pos‐
sible.
nform
mercia

17 - Hexagon screw
a
com

tion in

❑ 30 Nm + 90°
r
te o

thi

❑ replace after each removal

s
iva

do
r

❑ with dished spring

rp

cum
fo

en
ng

18 - Rear brake plate with brake shoes

t.
yi Co
Cop py
❑ repair. Please refer to manual ⇒ Brake system; Rep. Gr. 46 ; Brakes - Mechanical systems
ht. rig
rig ht
py by
o Vo
19 - Parking brake cable bracket by c lksw
cted agen
Prote AG.
20 - Screw
❑ install from outside
❑ replace after each removal
21 - Metal and rubber bearing
❑ remove and install ⇒ page 70
22 - Self-locking nut
❑ 45 Nm + 90°

1. Rear axle - repair 69

 SpaceFox, Space Cross, Suran, Suran Cross, Sportvan 2006 ➤
Running gear, axles, steering - Edition 05.2011
❑ replace after each removal
❑ See notes ⇒ page 67

Volkswagen AG
Installation angle of the rear axle/shock absorber swagen AG. does
k not
Vol gu
1 - Damper d by ara
e nte
ris
nd - approximately 95° utho eo
ra
a c
ss

ce
le
un

pt
an
d
itte

y li
rm

ab
pe

ility
ot

wit
, is n

h re
hole

spec
es, in part or in w

t to the co
1.3 Metal and rubber bearing - remove and install

rrectness of i
l purpos

Special tools and workshop

equipment required

nform
ercia

♦ Mounting device -3416/2-

m

a
♦ Brake pedal compression
com

tio
device -VAG 1869/2-

n in
r
te o

thi
♦ "Torquemeter - 40 to

s
iva

do
200Nm (socket 1/2")" -VAG
r
rp

cum
fo

1332-

en
ng

t.
yi Co
op
♦ Hydraulic press cylinder - C py
t. rig
VAS 6178- gh ht
pyri by
Vo
co lksw
by
♦ Hydraulic pump -VAS Prote
cted AG.
agen
6179-
♦ Mounting device -VAS
6180-

70 Rep. Gr.42 - Rear suspension

 SpaceFox, Space Cross, Suran, Suran Cross, Sportvan 2006 ➤
Running gear, axles, steering - Edition 05.2011

♦ Engine and gearbox jack +

gearbox or EQ 7081 -VAG
1383A-

1.3.1 Removal
– Measure distance from wheel housing to wheel centre
⇒ page 6 . wage
n AG. Volkswagen AG do
e ks s no
Vol t gu
– Release the parking brake.
ed
by ara
is nte
or
– Install the Brake pedal
au compression device -VAG
th 1869/2- . eo
ra
ss c
– Lift the vehicle to a suitable work height.
ce
e
nl

pt
du

an

– Remove the wheels.

itte

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erm

ab

– Disconnect the connector from the speed sensor.

ility
ot p

wit
, is n

– Remove the cable -1- from the speed sensor by removing it

h re

from the clips -arrows-.

hole

spec
es, in part or in w

t to the co
rrectness of i
l purpos

nform
mercia

at
om

ion
c

in t
or

his
ate

do
priv

cum
for

en
ng

t.
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Cop py
t. rig
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pyri by
Vo
co lksw
by
cted agen
Prote AG.

1. Rear axle - repair 71

 SpaceFox, Space Cross, Suran, Suran Cross, Sportvan 2006 ➤
Running gear, axles, steering - Edition 05.2011

– Remove the bolts from the wheel housing liners -arrows- to

both sides.
Vehicles without ABS

– Loosen the screw -arrow-.

Continued for all vehicles

– Disconnect the brake pipes -arrow A- and remove the clip.

– Remove the left brake hose from the support -2-.
– Remove the right hose from rear axle beam.
– Remove parking brake cables of supports -arrow B-.
– Remove the handbrake cables from the guide tubes.
G. Volkswagen AG d
– Position the Engine and gearbox jack + gearbox or EQ 7081 lkswagen A oes
not
-VAG 1383A- below. by
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ris
– Remove the fastening screws/nuts from the rear axleutbody
ho eo
ra
-1-. ss a c
ce
e

– Lower the rear axle with the help of the Engine and gearbox
nl

pt
du

an

jack + gearbox or EQ 7081 -VAG 1383A- .

itte

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erm

ab
ility
ot p

– Remove the metal and rubber bearing.

wit
, is n

h re

1 - Hydraulic pump -VAS 6179-

hole

spec

2 - Mounting device -VAS 6180/1-

es, in part or in w

t to the co

3 - Mounting device -VAS 6180/4-

4 - Mounting device -VAS 6180/3-
rrectness of i

5 - Mounting device -3416/2-

l purpos

6 - Mounting device -VAS 6180/2-

nf
ercia

orm
m

atio
om

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or c

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te

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ng

t.
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Cop py
t. rig
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pyri by
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by
cted agen
Prote
72
AG.
Rep. Gr.42 - Rear suspension
 SpaceFox, Space Cross, Suran, Suran Cross, Sportvan 2006 ➤
Running gear, axles, steering - Edition 05.2011

1.3.2 Installation
The metal and rubber bearing has marks -1- on frontal face.
. Volkswage n AG n AG d
wage oe
These marks must align
yV
olkswith the edge -arrow- of ssupporting
not
gu arm
-2-. ised b ara
n r tee
ho
– Identify sthe
au position of such marks -1- on the bonded rubber
t or
ac
bush cylindrical
s surface.

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
– Install the metal and rubber bearing and special tools onto the
rear axle.

rrectness of i
1 - Mounting device -VAS 6180/1-
l purpos

2 - Mounting device -VAS 6180/6-

3 - Mounting device -VAS 6180/7-

nform
ercia

4 - Metal and rubber bearing

m

at
om

io
5 - Mounting device -VAS 6180/8-

n
c

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or

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ate

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for

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ng

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– Before fitting bonded rubber bush, assure marking -arrow A- Cop py
t. rig
is aligned with the supporting arm edge -arrow B-. opyri
gh by
Vo
ht
c
– Install the metal and rubber bearing.
by lksw
cted agen
Prote AG.
– Check the position of the metal-rubber bearing after the in‐
stallation.
– Lubricate the kidney-shaped cavities of the metal-rubber bear‐
ing with the Assembly Grease -G 052 150 A2- before installing
the rear axle. Refer to the ⇒ Chemical material manual .
If the rear axle is installed without lubrication, there may be noises
while driving the vehicle
– Fasten the axle correctly and unladen ⇒ page 5 .
The rest of the installation is processed in the reverse order from
removal.
– Bleed the brake system. Please refer to manual ⇒ Brake sys‐
tem; Rep. Gr. 47 ; Brakes - Hydraulic system, servo brake .
Tightening torque:
Rear axle to bearing bracket ⇒ Item 22 (page 69) .
Braking force adjustment to rear axle. Please refer to manual ⇒
Brake system; Rep. Gr. 47 ; Brakes - Hydraulic system, servo
brake .

1.4 Spring - remove and install

Special tools and workshop equipment required

1. Rear axle - repair 73

 SpaceFox, Space Cross, Suran, Suran Cross, Sportvan 2006 ➤
Running gear, axles, steering - Edition 05.2011

♦ Suspension pillar device -VAG 1752-

AG. Volkswagen AG d
agen oes
olksw not
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d by ara
ise nte
or eo
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ss c

ce
le

1.4.1 Removal
un

pt
an
d
itte

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erm

– In order to remover the left spring, the rear muffler must be

ab
ility
lowered. Please refer to manual ⇒ Engine; Rep. Gr. 26 ; Ex‐
ot p

wit
haust system .
is n

h re
ole,

– Install the spring tensioning element -1-.

spec
urposes, in part or in wh

1 - Compression device or VW 5340 -VAG 1752/1-

t to the co
2 - Spring support -VAG 1752/3-

rrectne
– Tension the coil spring until it is possible to remove it.
– Remove the spring.

ss o
cial p

f inform
mer

atio
om

n
c

i
or

n thi
te

sd
va

1.4.2 Installation
i

o
pr

cum
r
fo

en
ng

t.
– Make sure that the lower spring plate is not damaged. If nec‐
yi Co
op py
essary, replace it. t. C rig
gh ht
pyri by
– Install spring along with the spring plate.
o Vo
by c lksw
cted agen
Prote AG.
– The end of the spiral must touch the upper stop -arrow-.
– Release the spring and remove the Compression device or
VW 5340 -VAG 1752/1- (do not damage the superficial spring
protection).
– After installing the left spring, the rear muffler must be fas‐
tened. In order to remover the left spring, the rear muffler must
be lowered. Please refer to manual ⇒ Engine; Rep. Gr. 26 ;
Exhaust system .

74 Rep. Gr.42 - Rear suspension

 SpaceFox, Space Cross, Suran, Suran Cross, Sportvan 2006 ➤
Running gear, axles, steering - Edition 05.2011

1.5 Shock absorbers - assembly overview

1 - Gas-filled shock absorbers

❑ Refer to: ⇒ Electronic
Parts Catalogue (ETKA)

WARNING
At a same vehicle, only
shock absorbers from
the same brand must be
used.

Check the operation

Compress the shock absorber

manually. By doing this, the
AG. Volkswagen AG d
shock absorber rod l
must
ksw
agenmove oes
not
throughout its blength
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ara
and with the
ris same force.
ed
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Whenssthe shock absorber has c
sufficient pressure, the shock
ce
e
nl

pt
du

absorber rod will return to its

an
itte

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initial position.
erm

ab
ility
ot p

If the shock absorber rod does

wit
, is n

not return to its initial position

h re

and there is no oil leak, the

hole

spec

shock absorber may still be ok.

es, in part or in w

t to the co

2 - Protection cover
3 - Damper dust boot
rrectness of i

4 - Stopper
l purpos

5 - Shock absorber support

nf
ercia

6 - Hexagon nut
orm

❑ Self-locking
m

atio
om

❑ 25 Nm
n in
or c

thi

❑ replace after each removal

te

sd
iva

❑ remove ⇒ page 76
r
rp

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o

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f

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ng

7 - Cover
t.
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Prote AG.

1. Rear axle - repair 75

 SpaceFox, Space Cross, Suran, Suran Cross, Sportvan 2006 ➤
AG. Volkswagen AG d
Running gear, axles, steering - Edition 05.2011
ksw
agen oes
n
ol ot g
yV ua
db ran
Remove the hexagonal nut from the shock ris absorber
e
tee
ho
ut or
1 - Commercially available ratchetss a ac

ce
e
nl
2- Keys -T 10001/9-

pt
du

an
itte

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3- Keys -T10001/11-

erm

ab
ility
ot p
4- Keys -T10001/1-

wit
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hole

spec
es, in part or in w

t to the co
rrectness of i
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nf
ercia

orm
m

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or c

thi
1.6 Damper - remove and install
te

sd
iva

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cu
Special tools and workshop equipment required
o

m
f

en
ng

t.
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♦ "Torque wrench - 5 to 50 Nm ( socket 1/2")" -VAG 1331- . Cop py
rig
ht ht
rig by
copy Vo
by lksw
cted agen
Prote AG.

♦ "Torquemeter - 40 to 200 Nm (socket 1/2")" -VAG 1332-

76 Rep. Gr.42 - Rear suspension

 AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
ise nte
thor SpaceFox, Space Cross, Suran,
eo Suran Cross, Sportvan 2006 ➤
u ra
ss a Running gear,c axles, steering - Edition 05.2011

ce
e
nl

pt
du
1.6.1 Removal

an
itte

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erm

ab
– Remove the screws. Remove screws -1-.

ility
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wit
, is n

– Lift the vehicle to a suitable work height.

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

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t.
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Cop py
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– Loosen nut -1- and the hexagon screw -2- of shock absorber cop Vo
by lksw
-3- of rear axle. cted agen
Prote AG.

– Remove the shock absorber.

1.6.2 Installation
– Installing the damper.
– Fix shock absorber -3- with a new hexagon screw -2- and the
new nut -1- on rear axle ⇒ Item 8 (page 69) .
– Fasten the shock absorber to the body ⇒ Item 5 (page 68) .
Installation position ⇒ page 70

1. Rear axle - repair 77

 SpaceFox, Space Cross, Suran, Suran Cross, Sportvan 2006 ➤
Running gear, axles, steering - Edition 05.2011
n AG. Volkswagen AG do
swage es n
2 Wheel bearings for drum brakes olk ot g
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ir se
(without adjustment) autho tee
or
ac
ss

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WARNING

pt
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d
itte

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erm

ab
Always replace self-locking nuts and screws which were sub‐

ility
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jected to angular torque.

wit
is n

h re
ole,

spec
urposes, in part or in wh

2.1 Wheel bearings - assembly overview

t to the co
1 - Crosshead screw

rrectne
❑ 4 Nm
2 - Brake drum

ss o
cial p

f
3 - Dust protection cover

inform
mer

❑ replace after each re‐

atio
moval
om

n
c

❑ remove and install

i
or

n thi
e

⇒ page 79
t

sd
iva

o
pr

c
A perfect seal is only achieved

um
r
fo

en
when using a new protection
ng

t.
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cover against dust. t. Cop py
rig
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This is the only way to ensure cop Vo
by lksw
optimal operation and high du‐ cted agen
Prote AG.
rability of the roller bearing

4 - Rifled nut
❑ self-locking
❑ 70 Nm + 30°
❑ replace after each re‐
moval
5 - Wheel hub with wheel bear‐
ings
❑ the ABS sensor ring is
installed in the wheel
hub
❑ remove and install
⇒ page 79
The wheel roller bearing and
the wheel hub are installed to‐
gether in a housing

This wheel bearing/hub set is

free of maintenance and ad‐
justment. Adjustment and re‐
pair works are not possible!

6 - Axle beam
7 - Rear brake plate with brake shoes
❑ repair. Please refer to manual ⇒ Brake system; Rep. Gr. 46 ; Brakes - mechanical systems
8 - Hexagon screw
❑ 30 Nm + 90°
❑ replace after each removal

78 Rep. Gr.42 - Rear suspension

 SpaceFox, Space Cross, Suran, Suran Cross, Sportvan 2006 ➤
Running gear, axles, steering - Edition 05.2011

9 - Stub axle
❑ straightening operations are not permitted
❑ reworking the thread is not permitted

2.2 Wheel roller bearing/wheel hub set in vehicles with brake drums - remove
and install

Special tools and workshop

equipment required
♦ Extractor for hub nut pro‐
tectors -VW 637/2-
♦ Fitting sleeve -3241/4-
♦ "Torquemeter - 40 to
200Nm (socket 1/2")" -VAG
1332-
♦ Torque wrench - 4 to 20Nm AG. Volkswagen AG d
agen oes
ksw
(socket 3/8") -VAG 1410- byV
ol not
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ara
ed
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aut ra
ss c

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le
un

pt
an
d
itte

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rm

ab
pe

ility
ot

wit
, is n

h re
hole

spec
es, in part or in w

t to the co
rrectness of i
l purpos

nform
mercia

a
com

tion in
r
te o

thi
s
iva

do
r
rp

cum
fo

en
ng

t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
2.2.1 Removal
cted agen
Prote AG.

– Lift the vehicle.

– Remove the wheel.

2. Wheel bearings for drum brakes (without adjustment) 79

 SpaceFox, Space Cross, Suran, Suran Cross, Sportvan 2006 ➤
Running gear, axles, steering - Edition 05.2011

– Put the brake away.

– Insert a screwdriver through the brake drum hole and press
the wedge upwards.
– Remove the brake drum screw and remove the brake drum.

n AG. Volkswagen AG do
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
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a ac
ss
Remove the dust protection cover from its housing by tapping

ce
le
un

lightly on the drift claw with the Extractor for hub nut protectors -

pt
an
d
itte

VW 637/2- .

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

nform
mercia

a
com

tion in
r
te o

thi
s
iva

do
r
rp

cum
fo

– Remove the protection cover. en

ng

t.
yi Co
op
– Remove the splined nut. C py
t. rig
gh ht
yri
– Remove the wheel hub/bearing set from the stub axle.
p by
co Vo
by lksw
cted agen
Prote AG.

2.2.2 Installation
– Carefully install the wheel hub/bearing set on the stub axle.
Make sure that the wheel hub/bearing set is not tilted.
– Use a new splined nut and tighten it ⇒ Item 4 (page 78) .

80 Rep. Gr.42 - Rear suspension

 SpaceFox, Space Cross, Suran, Suran Cross, Sportvan 2006 ➤
Running gear, axles, steering - Edition 05.2011

– Install the dust protection cover with the Fitting sleeve

-3241/4- .

Note

♦ Always replace the dust protection covers

♦ Damaged dust protection covers allow humidity to enter,
therefore always use the indicated tool.

– Fit wheel and tighten screws ⇒ page 88 .

AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
ss c

ce
e
nl

pt
du

an
itte

y li
erm

ab
ility
ot p

wit
, is n

h re
hole

spec
es, in part or in w

t to the co
rrectness of i
l purpos

nform
mercia

at
om

ion
c

in t
or

his
ate

do
priv

cum
for

en
ng

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

2. Wheel bearings for drum brakes (without adjustment) 81

 SpaceFox, Space Cross, Suran, Suran Cross, Sportvan 2006 ➤
Running gear, axles, steering - Edition 05.2011

3 Wheel bearings for drum brakes (with

adjustment)

WARNING

Always replace self-locking nuts and screws which were sub‐

jected to angular torque.

3.1 Wheel bearings - assembly overview

1 - Axle beam
2 - Rear brake plate with brake
shoes
❑ repair. Please refer to
manual ⇒ Brake sys‐
tem; Rep. Gr. 46 ;
Brakes - Mechanical
systems
3 - Hexagon screw
❑ 30 Nm + 90°
❑ replace after each re‐
moval
4 - Stub axle
❑ straightening opera‐ AG. Volkswagen AG d
tions are not permitted agen oes
olksw not
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❑ reworking the thread is d by ara
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not permitted hor eo
aut ra
s c
5 - Thrust washer s
ce
le
un

pt

6 - Nut
an
d
itte

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ab

7 - Locking cover
pe

ility
ot

8 - Wheel hub cover

wit
, is n

h re

❑ At each removal, re‐

hole

spec

place it
es, in part or in w

t to the co

9 - Cotter pin
10 - Rear wheel external roller
rrectness of i

bearing
❑ Adjust ⇒ page 82
l purpos

❑ Remove and install

⇒ page 84
nform
ercia

11 - Brake drum
m

a
com

tio

12 - Rear wheel internal roller bearing

n in
r
te o

thi

❑ Adjust ⇒ page 82
s
iva

do

❑ Remove and install ⇒ page 84

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fo

en
g

13 - Rear wheel internal roller bearing sealant

n

t.
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op
❑ Remove and install ⇒ page 86
C py
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pyri by
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cted agen
Prote AG.
3.2 Wheel roller bearing - check and adjust
Special tools and workshop equipment required

82 Rep. Gr.42 - Rear suspension

 SpaceFox, Space Cross, Suran, Suran Cross, Sportvan 2006 ➤
Running gear, axles, steering - Edition 05.2011

♦ Support tube -40-21-

♦ Extractor for hub nut protectors -VW

en AG. V
olksw637/2-
agen AG.
ag does
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b ara
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th
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ss

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nl

pt
du

an
itte

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erm

ab
ility
ot p

wit
, is n

h re
hole

spec
es, in part or in w

Check bearing clearance t to the co

rrectness of i
– Remove the wheel.
l purpos

– Remove the wheel hub protector, with the Extractor for hub
nut protectors -VW 637/2- .
nf
ercia

The clearance adjustment will be correct when it is possible to

orm

move the thrust washer only in the radial direction, and when
m

atio
m

moving the brake's drum in the axial direction, it does not have an
o

n in
c

apparent clearance.
or

thi
te

sd
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o
r

Caution
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en
ng

t.
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The washer must present a radial movement exactly in ac‐ Cop py
cordance with the following procedure.
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
Procedure for checking bearing clearance adjustment.
1. Place a screwdriver between the washer and the brake
drum hub, so that the screwdriver is perpendicular to the
washer.

1. Move the washer in the radial direction with a light pressure

of the forefinger-arrow- applied to the end of the screwdriv‐
er.

3. Wheel bearings for drum brakes (with adjustment) 83

 SpaceFox, Space Cross, Suran, Suran Cross, Sportvan 2006 ➤
Running gear, axles, steering - Edition 05.2011

1. Never turn -arrows- or leverage the screwdriver.

2. If the washer does not move it is necessary to adjust the
roller bearing clearance ⇒ page 84 .

WARNING

The screwdriver should touch only the washer and never the
external wheel roller bearing.
Never turn or leverage the screwdriver, thus ensuring that the
screwdriver does not touch the brake drum hub under no cir‐
cumstances. agen
AG. Volkswagen AG d
oes
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V
If the notes above are not strictly followed, the adjustment of ed by gu
ara
the roller bearing clearance will be jeopardized (it can leadthto
oris nte
eo
noises and breakage of roller bearings). s au ra
c
s

ce
le
un

pt
an
d
itte
Adjust the roller bearing play

y li
erm

ab
.

ility
ot p

– Unlock and remove the locknut and the lock washer.

wit
is n

h re
ole,

– Loosen or tighten the nut, relieving or increasing the pressure

spec
urposes, in part or in wh

on the thrust washer; simultaneously, check its movement in

the radial direction, according to the procedure described

t to the co
above ⇒ page 83 .
– Install the new lock washer and the locknut; tighten it to 70 Nm.

rrectne
– Check the roller bearing clearance adjustment again. If nec‐
essary, repeat the procedure until the adjustment is correct

ss
⇒ page 84 .

o
cial p

f inform
– The clearance adjustment will be correct when it is possible to
mer

move the thrust washer only in the radial direction, and when

atio
m

moving the brake's drum in the axial direction, it does not have
o

n
c

an apparent clearance.

i
or

n thi
te

sd
a

– Lock the nut and the locknut.

iv

o
pr

cum
r
fo

en
ng

– Install wheel hub lid -1-with the Support tube -40-21- .

t.
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Cop py
. rig
– Fit wheel and tighten screws ⇒ page 88 .
ht ht
rig by
copy Vo
by lksw
cted agen
Prote AG.
Note

The wheel hub cover must be replaced with every removal.

3.3 Internal/external rear wheel roller bear‐

ing - remove and install
Special tools and workshop equipment required

84 Rep. Gr.42 - Rear suspension

 SpaceFox, Space Cross, Suran, Suran Cross, Sportvan 2006 ➤
Running gear, axles, steering - Edition 05.2011

♦ Pressure pin -VW 411-

n AG. Volkswagen AG do
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
♦ Thrust pad -VW 432- ss

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un

pt
an
d
itte

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erm

ab
ility
ot p

wit
is n

h re
ole,

spec
urposes, in part or in wh

t to the co
rrectness o
3.3.1 Removal
cial p

f inform
mer

– Remove the wheel.

atio
om

– Remove the brake drum.

n
c

i
or

n thi
e

– Remove the roller bearing sealant.

t

sd
iva

o
pr

cum
r

– Remove the internal and external roller bearing external tracks

fo

en
ng

with a hammer and a drift pin.

t.
yi Co
Cop py

3.3.2 Installation
t. rig
gh ht
pyri by
Vo
co lksw
by
– Install the external track of the external roller bearing.
cted agen
Prote AG.

3. Wheel bearings for drum brakes (with adjustment) 85

 SpaceFox, Space Cross, Suran, Suran Cross, Sportvan 2006 ➤
Running gear, axles, steering - Edition 05.2011

– Install the external track of the internal roller bearing.

– Fill with multipurpose grease the space between the internal
track and the roller bearing rollers.
– Fill the wheel hub with multipurpose grease.
AG. Volkswagen AG d
– Install the internal roller bearing roller spacer. agen oes
olksw not
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d by ara
– Install a new sealant on the rear wheel. orise nte
h eo
ut ra
– Install the brake drum. ss a c

ce
le
– Install the external bearing roller spacer, stop washer and nut.

un

pt
an
d
itte

y li
– Install the wheel.

erm

ab
ility
– Adjust the roller bearing clearance ⇒ page 82 . ot p

wit
is n

h re
ole,

3.4 Rear wheel internal roller bearing seal‐

spec
urposes, in part or in wh

ant - remove and install

t to the co
rrectne
3.4.1 Removal

s
– Remove the wheel.

s o
cial p

f
– Remove the wheel hub protection.

inform
mer

– Remove the cotter pin, sprocket and nut.

atio
om

n
– Remove the brake drum, along with the thrust washer and the
c

i
or

n
external roller bearing roller spacer.

thi
te

sd
iva

o
r

– Remove the sealant from the internal wheel roller bearing with
p

cum
r
fo

a screwdriver.

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ng

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3.4.2 Installation
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– Install a new sealant with a plastic or leather hammer. by c lksw
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Prote AG.
– Install the drum, roller spacer, thrust washer and nut.
– Install the wheel.
– Tighten the wheel hub fastening nut to 30 Nm, turning the
wheel during the tightening for perfect roller bearing seating.
– Adjust the roller bearing clearance ⇒ page 82 .

3.5 Stub axle - check

– Remove the axle stub ⇒ page 87 .
– Fasten the shaft tip to the vise using aluminum jaws.
– With the help of a square and a gauge, measure the axle end
in three different points.

Note

If the difference of values exceeds 0.25 mm, replace the axle stub.

– Install the axle tip ⇒ page 87

86 Rep. Gr.42 - Rear suspension

 SpaceFox, Space Cross, Suran, Suran Cross, Sportvan 2006 ➤
Running gear, axles, steering - Edition 05.2011

3.6 Axle end - remove and install,

3.6.1 Removal
– Remove the wheel with the brake drum.
– Remove the screws that fasten the the brake plate on the axle
stub.
– Remove the axle stub.

3.6.2 Installation
– The installation is performed in the reverse sequence from the
removal.
– Adjust the roller bearing clearance ⇒ page 82 .

AG. Volkswagen AG d
agen oes
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spec
es, in part or in w

t to the co
rrectness of i
l purpos

nform
mercia

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tion in
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te o

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Cop py
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Prote AG.

3. Wheel bearings for drum brakes (with adjustment) 87

 SpaceFox, Space Cross, Suran, Suran Cross, Sportvan 2006 ➤
Running gear, axles, steering - Edition 05.2011

44 – Wheels, tires, vehicle measurement

1 Wheel screws
AG. Volkswagen AG d
agen oes
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1.1 Screws with anti-theft lock
d
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Vehicles with aluminum wheels may be equipped with anti-theft ss c

ce
le
wheel fastening screw.

un

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d
itte
The correct adapter socket is included in the vehicle tool kit, prop‐

y li
rm

ab
erly fitted in the spare wheel.

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The requests for adapter sockets must be made using the part
, is n

h re
number Screw with Anti-theft Adapter Socket -8D0 601 139 F- ,
hole

spec
followed by a 3-digit code.
es, in part or in w

t to the co
To determine the 3-digit code, count the number of grooves in the
screw safety standard and use the following table:
Number of grooves 3-digit code

rrectness of i
10 000
l purpos

11 001

nform
ercia

13 002
14 003
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15 004

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17 006
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19 007

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20 008 C py
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Each adapter socket is shipped with one screw for the corre‐ Prote AG.
sponding wheel.

Note

The Socket set -T 40004- is a full set of sockets for removing and
installing the screws with this coding. It has the 10 combinations
possible.

1.2 Wheel screws - tightening torques

Wheel hub wheel screw for all vehicles 120 Nm

88 Rep. Gr.44 - Wheels, tires, vehicle measurement

 SpaceFox, Space Cross, Suran, Suran Cross, Sportvan 2006 ➤
Running gear, axles, steering - Edition 05.2011

2 Vehicle alignment

WARNING

Always replace self-locking nuts and screws which were sub‐

jected to angular torque.

2.1 General aspects

The vehicle must only be measured with an alignment equipment
recommended by VW/AUDI.
We recommend measuring the front and rear axle geometry in
each vehicle measurement.
Otherwise, the correct vehicle travelling behavior will not be en‐
sured!

Note

♦ It is recommended to align the vehicle after 1000 to 2000 km,

because the coil spring seating process is concluded by then.
AG. Volkswagen AG d
agen oes
♦ When making the adjustment, the values must be asVoclose
lksw as not
gu
possible to the nominal specification. ed
by ara
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Pay attention! The steering wheel and steering
ss column have a c
mark.

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A - Mark on the steering wheel

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ab
B - Mark on the steering column

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This is the only way to ensure that the rack will not be decentral‐

h re
hole

ized.

spec
es, in part or in w

Vehicles with Electronic Stability Program “ESP”.

t to the co
– If the steering wheel is moved in these vehicles, it is necessary
to check the basic adjustment of the Steering angle sensor -

rrectness of i
G85- ⇒ Perform the basic "adjustment on the Assisted Trou‐
bleshooting" with the Diagnosis, Measurement and Informa‐
l purpos

tion System -VAS 5052A- .

Steering columns supplied as replacement parts do not present
nform
ercia

a punch point.
m

at

After the vehicle alignment and the subsequent test drive, these
om

ion

steering columns must be marked.

c

in t
or

his
te

It is necessary to align the vehicle when:

a

do
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♦ the travelling behavior is irregular

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♦ involvement in an accident and the parts are replaced Cop py
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♦ irregular tire wearing py by
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♦ shaft parts replaced Prote AG.

Replaced front axle part Required alignment Replaced rear axle parts Required alignment
Yes No Yes No
Support arm X Damper X
Wheel roller bearing housing X Coil spring X
Track rod ball joint X Rear beam axle X
Steering box X

2. Vehicle alignment 89
 SpaceFox, Space Cross, Suran, Suran Cross, Sportvan 2006 ➤
Running gear, axles, steering - Edition 05.2011

Replaced front axle part Required alignment Replaced rear axle parts Required alignment
Yes No Yes No
Subframe X3)
Suspension pillar X
Subframe console X
Stabilizer X3)
3) Prerequisite: If the subframe and console are positioned before disassembly ⇒ page 20

2.2 Checking conditions:

• Check the suspension, wheel roller bearings, steering wheel
and connecting rods of the steering wheel for excessive play
and damages
• The depth of the tire profile grooves cannot be more
wagethan 2
n AG. Volkswagen AG do
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mm different in the same axle yV
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• Tire filling pressure as prescribed thoris e or
au ac
• Unladen vehicle ss

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• The fuel tank must be full.
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erm

• Spare wheel and tools in the respective assembly position in

ab
ility
the vehicle
ot p

wit
, is n

• The water reservoir for the windshield/headlight washer sys‐

h re
hole

tem must be full.

spec
es, in part or in w

• Make sure that the rotary plates and moving supports are not

t to the co
in the final stop (buffer) during the measurement.
Pay attention!

rrectness of i
• The alignment machine must be properly assembled and ad‐
l purpos

justed to the vehicle; follow the equipment operation instruc‐

tions manual. nform
ercia

If necessary, require a training by the manufacturer of the wheel

alignment equipment.
m

at
om

ion

The platform and the axle measurement machine/computer can,

c

in t
or

throughout time, deviate from the initial leveling/adjustment.

his
ate

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riv

The platform and the axle measurement machine/computer must

p

cum
or

be gauged and, if necessary, adjusted at least once a year.

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– Handle these highly sensitive units carefully and conscien‐ C py
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2.3 Preparation for measurement
cted agen
Prote AG.

Special tools and workshop equipment required

90 Rep. Gr.44 - Wheels, tires, vehicle measurement

 SpaceFox, Space Cross, Suran, Suran Cross, Sportvan 2006 ➤
Running gear, axles, steering - Edition 05.2011

♦ Brake pedal compression device -VAG 1869/2-

Axial vibration of the rim shall be compensated. Otherwise, an

erroneous measurement result will be generated.
If the rim compensation is not performed, it will not be possible to
perform a correct adjustment!
When you do this, follow the information from the alignment de‐
vice manufacturer.
– Perform rim compensation.
– Install the Brake pedal compression device -VAG 1869/2- .
– Depress the brake pedal with the depressor.

2.4 Vehicle identification label

Explanation for PR numbers on the vehicle identification label
Different types of suspension are installed, depending on the en‐
gine and vehicle versions. These suspensions are identified by
PR numbers.
The type of suspension installed on the front axle is identified on
the vehicle identification label with its respective PR number.
AG. Volkswagen AG d
Example of a vehicle identification
olks
wage label
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In this example therivehicle
se
d is equipped with the standard G16 ara
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suspension -arrow-.
ut
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sa c
The vehicle identification
s
label is located in the spare wheel com‐
ce
e
nl

partment and in the Service and Guaranty booklet.

pt
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itte

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The PR numbers are decisive to make the correspondence be‐

erm

ab

tween the nominal alignment vehicles and the vehicle.

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es, in part or in w

t to the co

2.5 Sequence for the alignment of the vehi‐

rrectness of i

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l purpos

The sequence of steps to follow should be observed:

1- Check the front axle camber and adjust it if necessary
nform
ercia

⇒ page 93 . If the values are out of tolerance, the tilting to

m

one of the vehicle sides must be checked and, if necessary,

at
om

io

compensated before performing the adjustment

n
c

in t
r

⇒ page 93 .
o

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ate

do
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2- Check the rear axle camber ⇒ page 94 . The camber is

p

cum
or

not adjustable. If the values are out of tolerance, the tilting

f

en
g

to one of the vehicle sides must be checked and, if neces‐

n

t.
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sary, compensated ⇒ page 93 . If the values still deviate C py
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91
Prote AG.
2. Vehicle alignment
 SpaceFox, Space Cross, Suran, Suran Cross, Sportvan 2006 ➤
Running gear, axles, steering - Edition 05.2011

from the specification, the rear axle may be replaced, if nec‐

essary.
3- Check rear axle convergence ⇒ page 94 . The conver‐
gence in the rear axle is not adjustable. If the values are out
of tolerance, the tilting to one of the vehicle sides must be
checked and, if necessary, compensated before performing
the adjustment ⇒ page 93 If the values still deviate from
the specification, the rear axle may be replaced, if neces‐
sary. . Volkswage n AG n AG d
wage oes
4- Check the front axle convergence yV
oand,
lks if necessary, adjust not
gu
it ⇒ page 95 . If the values are e out of tolerance, the tilting
d b ara
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to one of the vehicle sides thomust be checked and, if neces‐ eo
sary, compensated before au performing the adjustment ra
c
ss
⇒ page 93 .

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In general
itte

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If a value lies outside the tolerance, the transverse inclination of

ility
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the vehicle must be checked first ⇒ page 93 .

wit
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2.6 Nominal values for vehicle alignment
hole

spec
es, in part or in w

Specifications valid for all engines ⇒ page 92 .

t to the co
Specifications valid for all vehicle motorizations in “"0" position”
of transverse inclination ⇒ page 92

rrectness of i
2.6.1 Specifications valid for all engines
l purpos

♦ Explanation on the PR numbers ⇒ page 91

nform
ercia

Front axle
m

at
om

Power steering
ion
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in t
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PR Numbers 1N4
o

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ate

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Convergence per total axle (without compression) 10' ± 10′

p

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Camber (in straight-line) -15′ ± 30′

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Maximum permissible difference between both sides (?Cam‐ max. 30′
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Alignment angle difference with steering 20° to the left and to -1° 28′ ± 20′
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AG.

Caster angle (not adjustable) +4° 14′ ± 30′

Maximum permissible difference between the left side and max. 30′
the right side (Caster)

2.6.2 Specifications valid for all vehicle moto‐

rizations in “"0" position” of transverse
inclination
♦ Explanation on the PR numbers ⇒ page 91 .
Rear axle
PR Numbers 0N2
Camber -1° 30′ ± 20′
Maximum permissible difference between both sides max. 30′
(Camber)
Total convergence (with specified camber) +16′ ± 10′
Geometrical axle (maximum driving angular deviation) max. 20′

92 Rep. Gr.44 - Wheels, tires, vehicle measurement

 SpaceFox, Space Cross, Suran, Suran Cross, Sportvan 2006 ➤
Running gear, axles, steering - Edition 05.2011

2.7 Vehicles in “"0" position” of transverse

inclination
A n AG d G. Volkswage
agen
If the alignment values are outside the permitted
Volksw tolerances, the oes not g
cause may be incorrect vehicle inclination
ed
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ran
is tee
or
Vehicles with the steering wheelau on the right side or, for example,
th or
ac
vehicles with automatic transmission
ss may be slightly inclined to‐

ce
le
wards one side.
un

pt
an
d
itte
This is due to the installation position of the assemblies and their

y li
erm

ab
associated weight transfer.

ility
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wit
– Then, it is absolutely necessary to measure the distance -“nd”
is n

h re
- from the left and right sides.
ole,

spec
urposes, in part or in wh

A -line 0- on the roof indicates the horizontal (zero) position of the

t to the co
vehicle.
– Correct the differences, if necessary.

rrectne
On the front axle, compensate this difference by adding weights
on top of the relevant suspension tower.

ss
On the rear axle, compensate this difference by adding weights

o
cial p

f
to the respective side of the boot.

inform
mer

Sandbags approx. weight 10 kg are appropriate for that.

atio
om

n
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Prote AG.

2.8 Camber on front axle - adjust

Special tools and workshop equipment required
♦ Adjustment tool -T 40022-

Note

Move the subframe to the left or right, but never forward or back‐
ward!

– Remove the noise insulation.

2. Vehicle alignment 93
 SpaceFox, Space Cross, Suran, Suran Cross, Sportvan 2006 ➤
Running gear, axles, steering - Edition 05.2011

– Install the tool Adjustment tool -T 40022- with Adapter -

T40022/2- on the floor and on the console and apply slight
tension.

– Loosen the screws -arrows- that fasten the console and the
subframe to the body on only one side.
– Specifications for camber can be adjusted by turning the cable
-arrow A- ⇒ page 92 .
– If the value specified cannot be achieved, then loosen the
screws that fasten the console and the subframe to the body
on the other side and adjust again.
– When the value specified is achieved, install new screws on
the subframe to body and tighten to the specified torque
⇒ Item 11 (page 8) .

n AG. Volkswagen AG do
– Then, release the cable -arrow A-. lkswage es n
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byV ua
d ran
– Position the Adapter -T40022/2- in the arrow direction
o
ir se and re‐ tee
move the adjustment tool. auth or
ac
ss
– Tighten the screws that support the subframe to the body

ce
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nl

pt
⇒ Item 11 (page 8) .
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an
itte

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erm

If a value remains out of tolerance, the transverse inclination of

ab
ility
the vehicle must be checked and compensated ⇒ page 93 , and
ot p

wit
repeat the adjustment procedure if needed.
, is n

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spec
es, in part or in w

t to the co

2.9 Camber on rear axle - adjust

rrectness of i

The camber cannot be adjusted

l purpos

If a value lies outside the tolerance, the transverse inclination of

the vehicle must be checked first ⇒ page 93
nf
ercia

orm

If the measured values lie outside the permitted tolerances, the

m

atio
m

axle body must be checked for damage and replaced when nec‐
o

n in
c

essary.
or

thi
te

sd
a

2.10 Convergence on rear axle - adjust

iv

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The convergence cannot be adjusted.

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If a value lies outside the tolerance, the transverse inclination of
t. C rig
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the vehicle must be checked first ⇒ page 93 . p by
co Vo
by lksw
cted agen
If the measured values lie outside the permitted tolerances, the Prote AG.
axle body must be checked for damage and replaced when nec‐
essary.

94 Rep. Gr.44 - Wheels, tires, vehicle measurement

 SpaceFox, Space Cross, Suran, Suran Cross, Sportvan 2006 ➤
Running gear, axles, steering - Edition 05.2011

2.11 Convergence on front axle - adjust

– Loosen lock nut -1-.
– Adjust the convergence by turning the steering bar to the left
and/or to the right.
– To do this, use a spanner on the hex head -arrow- of the
steering bar.
After turning the steering bars, confirm if the cauls are not twisted.
Twisted covers wear quickly.
– Tighten lock nut -1-.
After tightening lock nut -1-, it is possible that the adjusted value
slightly changes.
– Check the convergence value once more
If the convergence value measured lies within the tolerance, the
adjustment is correct.

Tightening torque
Component Tightening torque
Track rod lock nut 50 ± 5 Nm

2.12 Steering the wheel to the left and right -

check
This check procedure isagnecessary
en AG. V
olkswif:
agen AG
do
w es n
olks o
♦ the steeringdturns
by
V
to the stop are different in more
t gu
arathan 2°(de‐
grees), hfrom
orise
central steering wheel position nte
e
t or
au a
♦ theress is contact between the tire and front axle or body parts
c
when turning the steering wheel to its maximum position
ce
le
un

pt
an
d
itte

♦ the left steering wheel turning diameter is different from that in

y li
rm

ab

the right side

pe

ility
ot

The distances between the axle and tire wishbones -arrow- must
wit
, is n

h re

be the same with maximum steering wheel turning.

hole

spec

If the distances are different, they can be corrected by turning

es, in part or in w

steering linkage bars left or right.

t to the co

For example:
rrectness of i

If the right steering angle is smaller than the left one.

l purpos

– Loosen the lock nuts of the steering track rod.

– Turn the left steering wheel linkage bar counterclockwise
nform
ercia

(loosen from the steering bar joint).

m

– To achieve equal dimensions, turn the right steering bar in the

com

tio

opposite direction and in the same proportion (screw on the

n in
r

steering bar joint).

te o

thi
s
iva

do

– Check full convergence.

r
rp

cum
fo

en
g

Check if the total convergence is still according to the prescribed

n

t.
yi Co
specifications after completing the adjustment!
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

2. Vehicle alignment 95
 SpaceFox, Space Cross, Suran, Suran Cross, Sportvan 2006 ➤
Running gear, axles, steering - Edition 05.2011

After tightening lock nut-1-, it is possible that the adjusted value

slightly changes.
If the values do not deviate by more than 2' from the specified
ones, the adjustment is correct.
After turning track rods, ensure that the bellows are not twisted!

AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
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Tightening torque aut ra
ss c

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Component Tightening torque

un

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itte

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Track rod lock nut 50 ± 5 Nm
rm

ab
pe

ility
ot

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hole

spec
es, in part or in w

t to the co
rrectness of i
l purpos

nform
mercia

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com

tion in
r
te o

thi
s
iva

do
r
rp

cum
fo

en
ng

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

96 Rep. Gr.44 - Wheels, tires, vehicle measurement

 SpaceFox, Space Cross, Suran, Suran Cross, Sportvan 2006 ➤
Running gear, axles, steering - Edition 05.2011

48 – Steering
1 Steering wheel
Steering wheel with Ignition device for the driver's airbag -N95- .
Please refer to manual ⇒ Body - internal mountings; Rep. Gr.
69 ; Occupants' protection .

1.1 Horn activator -H- - remove and install

1.1.1 Removal
– Turn the ignition and all electric consumers off and remove the
key from ignition.
Vehicles without Airbag:
– Carefully remove the Horn activator -H- with an Spatula -VW
037- .

– Disconnect terminals -arrows-.

– Remove the Horn activator -H- . wage
n AG. Volkswagen AG do
es n
olks ot g
Vehicles with Airbag: d byV ua
ran
ir se tee
o
– Remove the Ignition device forau the driver's airbag -N95- .
th or
ac
Please refer to manual ⇒ Body
ss - internal mountings; Rep. Gr.
69 ; Occupants' protection .
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e
nl

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itte

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erm

ab
ility
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, is n

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spec
es, in part or in w

– Remove the attaching screws -arrows- in the contact support.

t to the co

– Disconnect the connector and remove the contact support.

rrectness of i
l purpos

nform
mercia

at
om

ion
c

in t
or

his
ate

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for

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ng

t.
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Cop py
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pyri by
Vo
co lksw
by
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Prote AG.

1. Steering wheel 97
 SpaceFox, Space Cross, Suran, Suran Cross, Sportvan 2006 ➤
Running gear, axles, steering - Edition 05.2011

Note

Make sure the support contact surfaces, as well as the contact

terminals on the steering wheel -arrows- are clean (with metal
visible) before the installation.

1.1.2 Installation
Installation is carried out in the reverse order of removal.

1.2 Steering wheel and Horn activator -H- - assembly overview

(up to the model 2010)

AG. Volkswagen AG d
1 - Screw agen oes
olksw not
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❑ 30 Nm + 90° rise
d b ara
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2 - Horn activator -H- s au ra
c
s
❑ Remove and install

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⇒ page 97

an
d
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erm

3 - Hexagon nut

ab
ility
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❑ 50 Nm

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is n

h re
❑ For fixed steering col‐
ole,

umn.

spec
urposes, in part or in wh

4 - Steering wheel

t to the co
❑ When assembling, the
centering marks on the

rrectne
steering wheel and the
steering column shall
coincide ⇒ page 89 ss o

❑ Remove and install

cial p

f in

⇒ page 101
form
mer

atio
om

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Cop py
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Prote AG.

(as from model-year 2011)

98 Rep. Gr.48 - Steering

 SpaceFox, Space Cross, Suran, Suran Cross, Sportvan 2006 ➤
. VolkswRunning
agen AG gear, axles, steering - Edition 05.2011
wagen AG d oes
olks not
yV gu
1 - Horn activator -H- ed
b ara
nte
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2 - Screw au
t ra
c
ss
❑ 30 Nm + 90°

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d
3 - Steering wheel

itte

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ab
❑ When assembling, the pe

ility
centering marks on the
ot

wit
, is n

steering wheel and the

h re
steering column shall
hole

spec
coincide ⇒ page 89
es, in part or in w

t to the co
❑ Remove and install
⇒ page 101

rrectness of i
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nform
mercia

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tion in
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(from the model 2011 onwards - vehicles with or without airbags)

1. Steering wheel 99
 SpaceFox, Space Cross, Suran, Suran Cross, Sportvan 2006 ➤
Running gear, axles, steering - Edition 05.2011

1 - Horn activator -H-

2 - Screw n AG. Volkswagen AG do
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❑ When assembling, the ss
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coincide ⇒ page 89

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❑ Remove and install

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⇒ page 101

h re
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(from the model 2011 onwards - vehicles with multifunction steer‐

ing wheel with or without airbags)

100 Rep. Gr.48 - Steering

 SpaceFox, Space Cross, Suran, Suran Cross, Sportvan 2006 ➤
Running gear, axles, steering - Edition 05.2011

1 - Horn activator -H-

2 - Screw
❑ 30 Nm + 90°
3 - Steering wheel
❑ When assembling, the
centering marks on the
steering wheel and the
steering column shall
coincide ⇒ page 89
❑ Remove and install
⇒ page 101

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hole

spec
es, in part or in w

t to the co
rrectness of i
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1.3 Steering wheel without airbag - remove

m

a
com

and install
tion in
r
te o

thi

Special tools and workshop equipment required

s
iva

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♦ "Torque wrench - 5 to 50 Nm ( socket 1/2")" -VAG 1331-

um
fo

en
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1.3.1 Removal
– Straighten the wheels.

1. Steering wheel 101

 AG. Volkswagen AG d
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SpaceFox, Space Cross, Suran, Suran Cross, aut Sportvan 2006 ➤
ho eo
ra
Running gear, axles, steering - Edition 05.2011
ss c

ce
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pt
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an
– Remove the Horn activator -H- -2- ⇒ page 97 .

itte

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– Remove the screw (internal multiple toothed) -1- or the nut

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-3-.

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rrectness of i
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Before removing the steering wheel, check whether the marking
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-arrow A- is aligned with the steering column punch point
AG.

-arrow B-.

– Pull off steering wheel -4-.

1.3.2 Installation
– Install the steering wheel -4- on the steering column.

Note

The centre marks on the steering wheel and steering column shall
match ⇒ page 89 .

– Install screw -1- to 30 Nm + 90° and mark with a punch point,

or install nut.
or
– Install hex nut -3- to 50 Nm and mark with a punch point.

WARNING

The screw -1- can be used up to five times.

The nut -3- is only used on vehicles with fixed column.

– Install the Horn activator -H- -2- ⇒ page 97 .

102 Rep. Gr.48 - Steering

 SpaceFox, Space Cross, Suran, Suran Cross, Sportvan 2006 ➤
Running gear, axles, steering - Edition 05.2011

2 Fixed steering column - repair

WARNING

Always replace self-locking nuts and screws which were sub‐

jected to angular torque.

2.1 Support and fixed steering column - assembly overview

(up to the model 2010)

1 - Fixed steering column

❑ Remove and install
⇒ page 104
2 - Hexagon screw
❑ 23 ± 2 Nm agen
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3 - Hexagon screw ed byV gu
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❑ 20 Nm ut
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❑ Replace after each re‐ ss c

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4 - Bushing

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❑ check condition after re‐

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moving the steering col‐

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spec
5 - Hexagon screw
urposes, in part or in wh

t to the co
❑ 7 Nm
6 - Support

rrectne
7 - Hexagon screw
❑ 23 Nm

ss o
8 - Right structure
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9 - Hexagon screw
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atio
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❑ M8 X 85
o

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❑ 23 Nm
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10 - Front panel
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11 - Hexagon screw
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❑ 25 Nm C py
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(as from model-year 2011)

2. Fixed steering column - repair 103

 SpaceFox, Space Cross, Suran, Suran Cross, Sportvan 2006 ➤
Running gear, axles, steering - Edition 05.2011

1 - Transverse support
❑ Remove and install.
Please refer to manual
⇒ Body - internal
mountings; Rep. Gr.
70 ; Lining / Insulation
2 - Hexagon screw
❑ 8 Nm
3 - Fixed steering column
❑ Remove and install
⇒ page 104
4 - Hexagon nut
❑ 15 ± 1.5 Nm
❑ Replace after each re‐
moval
5 - Screw
6 - Hexagon screw
❑ 23 ± 2 Nm

AG. Volkswagen AG d
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2.2 Fixed steering column - remove and in‐

an
itte

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erm

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ility
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wit
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hole

2.2.1 Removal
spec
es, in part or in w

t to the co

Special tools and workshop equipment required

♦ "Torque wrench - 5 to 50 Nm ( socket 1/2")" -VAG 1331-
rrectness of i
l purpos

nform
mercia

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or

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The steering column is supplied complete as a replacement part. yri
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Repair is not permitted.
by c lksw
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Prote AG.

104 Rep. Gr.48 - Steering

 SpaceFox, Space Cross, Suran, Suran Cross, Sportvan 2006 ➤
Running gear, axles, steering - Edition 05.2011

The switchbox cover can be transferred.

WARNING

Before starting toswwork

agen on the electricAsystem
AG. Volkswagen G d
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steering wheel,
by
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lk not be met:
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♦ Disconnect
tho
ri the battery earth strap Battery -A- .tePlease
eo re‐
fer
au to manual ⇒ Electrical equipment; Rep. Gr. 27
ra ;
c
ss
Starter, alternator, battery

ce
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nl

pt
du

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an
itte

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ility
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– Pull off steering wheel ⇒ page 97 .

wit
, is n

h re
hole

– Remove the steering column coverings. Please refer to man‐

spec
ual ⇒ Body - internal mountings; Rep. Gr. 70 ; Lining /
es, in part or in w

t to the co
Insulation .
– Remove switch set. Please refer to manual ⇒ Electrical sys‐
tem; Rep. Gr. 94 ; Switches, lights and external lamps .

rrectness of i
– Pull off connector -1- from the Immobilizer reading coil -D2- .
l purpos

– Open the cable support (right side) in the tabs -arrows- and
remove the wire.
nform
ercia

– Disconnect the earth strap from the steering column -arrow-.

m

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– Remove the earth strap and the support (left side) -1- from the
n
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or

switchbox cables.
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ate

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– Pull off connector -2- from the steering lock assembly.

– Remove the screw -1- from the universal joint and disconnect
the universal joint in the direction of the arrow.
If necessary, remove the access lid on the relay box to make work
easier.

2. Fixed steering column - repair 105

 SpaceFox, Space Cross, Suran, Suran Cross, Sportvan 2006 ➤
Running gear, axles, steering - Edition 05.2011

– Remove the screw -arrow- of pedal assembly (left side) -1-

over the bracket steering column.

– Remove screws -arrows- , and pull the steering column -1- out
of its housing.
– Remove the steering lock assembly. Please refer to manual
⇒ Electrical system; Rep. Gr. 94 ; Switches, lights and ex‐
ternal lamps .
– Check steering column for damage ⇒ page 118 .

n AG. Volkswagen AG do
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– If mounting bush s-1- d is damaged, remove it.
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– Remove the ascrew
uth
-2-. or
ac
ss
– Remove the bushing from support -1- from the steering col‐
ce
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pt
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umn fork -3-.

an
itte

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ility
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Note
wit
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hole

♦ In case the steering column is replaced, then remove the sup‐

spec

port bushing -1- and install on the new shaft

es, in part or in w

t to the co

♦ Before installing the mounting bush, check for damages

rrectness of i

2.2.2 Installation
l purpos

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Note
orm
m

atio
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Self-locking screws and nuts must be replaced whenever re‐

o

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moved.
or

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– If mounting bush -1- was removed because of damage, install

rp

cu
o

a new mounting bush.

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Note p by
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♦ In case the steering column is replaced, the support bushing
-1- from the old column must be installed on the new column
♦ Before installing the mounting bush, check for damages
♦ If the mounting bush is damaged, a new one must be installed

– Install the steering column on the support.

106 Rep. Gr.48 - Steering

 SpaceFox, Space Cross, Suran, Suran Cross, Sportvan 2006 ➤
Running gear, axles, steering - Edition 05.2011

– Install screw -arrow- located to the right of the steering column

support, above the pedals. Tightening torque
⇒ Item 9 (page 103) . . Volkswagen AG
gen AG wa does
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ility
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wit
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hole

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– Align the steering column with the support and install it.
es, in part or in w

t to the co
The hole -arrow A- and the pin -arrow B- should be aligned.

rrectness of i
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– Install and tighten the steering column screws -arrows-

o

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⇒ Item 2 (page 103) .

t.
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– Install the universal joint on steering box pinion. Tighten the
ht ht
rig by
py
new fastening screw for the universal joint with
co Vo
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⇒ Item 3 (page 103) . cted agen
Prote AG.

– Push on connector -2- from the steering lock assembly.

– Install the ground cable and the switchbox assembly cable on
the cable bracket -1-.
– Connect steering column ground cable -arrow-.

2. Fixed steering column - repair 107

 SpaceFox, Space Cross, Suran, Suran Cross, Sportvan 2006 ➤
Running gear, axles, steering - Edition 05.2011

– Install the cable to the support and close tabs -arrows-.

– Push on connector -1- from the Immobilizer reading coil -D2- .
– Install the steering lock assembly. Please refer to manual ⇒
Electrical system; Rep. Gr. 94 ; Switches, lights and external
lamps . gen AG
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– Install the steering column db
ycoverings.
Vo Please refer to manualot g
ua
⇒ Body - internal mountings;
orise Rep. Gr. 70 ; Lining / Insulation . ran
te
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ut ra
– Install trim for steering
ss
a column switch. Please refer to manual c
⇒ Electrical system; Rep. Gr. 94 ; Switches, lights and ex‐

ce
e
nl

pt
ternal lamps .
du

an
itte

y li
– Install the steering wheel:
erm

ab
ility
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without airbag: ⇒ page 101

wit
, is n

h re
with airbag: Please refer to manual ⇒ Body - internal mountings;
hole

spec
Rep. Gr. 69 ; Occupants' protection .
es, in part or in w

t to the co
WARNING

rrectness of i
When connecting the Battery -A- make sure no one is inside
the vehicle. Please refer to manual ⇒ Electrical equipment;
l purpos

Rep. Gr. 27 ; Starter, alternator, battery .

nform
mercia

at
om

ion
c

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or

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ate

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for

en
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t.
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Prote AG.

108 Rep. Gr.48 - Steering

 SpaceFox, Space Cross, Suran, Suran Cross, Sportvan 2006 ➤
Running gear, axles, steering - Edition 05.2011

3 Steering column with adjustment - re‐

pair

WARNING

Always replace self-locking nuts and screws which were sub‐

jected to angular torque.

3.1 Support and steering column with adjustment - assembly overview

(up to the model 2010)

1 - Adjustable steering column

❑ remove and install
⇒ page 110
2 - Hexagon screw
❑ 23 Nm
3 - Hexagon screw
❑ 20 Nm
❑ replace after each re‐
moval
4 - Hexagon screw
❑ M6 X 63 = 10 Nm
5 - Self-locking nut n AG. Volkswagen AG do
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❑ replace after each re‐ byV
olk ot g
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moval ir se
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tee
tho
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6 - Hexagon screw au ac
ss

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7 Nm
nl

pt
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an
itte

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7 - Bushing
erm

ab
ility
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❑ check condition after re‐

wit
moving the steering col‐
, is n

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umn
hole

spec
8 - Hexagon screw
es, in part or in w

t to the co
❑ M8 X 85 = 23 Nm
❑ M6 X 63 = 10 Nm rrectness of i

Note
l purpos

Until 10.31.06 hex head screw M8 X

85 was used, without self-locking
nf
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nut
rm
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atio
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9 - Support
or c

thi
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sd

10 - Hexagon screw
iva

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❑ 23 Nm
o

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11 - Right structure
Co
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12 - Front panel
ht
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13 - Hexagon screw
cted agen
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❑ 25 Nm

3. Steering column with adjustment - repair 109

 SpaceFox, Space Cross, Suran, Suran Cross, Sportvan 2006 ➤
Running gear, axles, steering - Edition 05.2011

(as from model-year 2011)

1 - Transverse support
n AG. Volkswagen AG do
❑ Remove and [Link] es n
ot g
Please refer to manual
d by
V ua
ran
⇒ Body - internal
oris
e
tee
mountings; au Rep. Gr.
th or
ac
70 ; Lining
ss / Insulation

ce
e
nl

pt
2 - Hexagon screw
du

an
itte

y li
❑ 8 Nm
erm

ab
ility
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3 - Adjustable steering column

wit
, is n

h re
❑ Remove and install
hole

⇒ page 110

spec
es, in part or in w

4 - Hexagon nut

t to the co
❑ 15 ± 1.5 Nm
❑ Replace after each re‐

rrectness of i
moval
l purpos

5 - Screw
6 - Hexagon screw

nf
ercia

or
❑ 23 ± 2 Nm

m
m

atio
om

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thi
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pyri by
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o
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cted agen
Prote AG.

3.2 Adjustable steering column - remove

and install
Special tools and workshop equipment required
♦ "Torque wrench - 5 to 50 Nm ( socket 1/2")" -VAG 1331-

110 Rep. Gr.48 - Steering

 AG. Volkswagen AG d
agen oes
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d by ara
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horis SpaceFox, Space e oCross, Suran, Suran Cross, Sportvan 2006 ➤
ut
ss a Running
ra
c gear, axles, steering - Edition 05.2011

ce
le
un

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3.2.1 Removal

an
d
itte

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ab
The steering column is supplied complete as a replacement part.

ility
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Repair is not permitted.

wit
is n

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The switchbox cover can be transferred.
ole,

spec
urposes, in part or in wh

t to the co
WARNING

Before starting to work on the electric system and removing the

rrectne
steering wheel, the following conditions must be met:
♦ Disconnect the ground cable from the battery. Please refer

ss
to manual ⇒ Electrical system; Rep. Gr. 27 ; Starter, al‐

o
cial p

f
ternator, battery

inform
mer

♦ The wheels must be in the straight line position

atio
om

n
If these instructions are not followed, the Airbag system, if fit‐
c

i
or

n
ted, may fail later.

thi
te

sd
iva

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pr

cum
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fo

en
ng

– Set the wheels to the straight line position.

t.
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Cop py
– Pull the lever below the steering column down.
t. rig
gh ht
pyri by
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o
– Pull the steering column downwards and remove it as much
by c lksw
cted agen
as possible.
Prote AG.

– Remove the driver's airbag unit (if any). Please refer to manual
⇒ Body - internal mountings; Rep. Gr. 69 ; Occupants' pro‐
tection .
Position the Airbag unit in such a way that it cannot be damaged
or fall.
♦ It is not permitted to leave the Airbag units unattended
– Pull off connector -1- by pressing the lock -arrow- down.
– Remove the screw (internal multiple toothed) on the steering
wheel -2-.
Before removing the steering wheel, check whether the marking
-arrow A- is aligned with the punch point -arrow B-.
If this is not the case:
– Mark installation position of steering wheel to steering column
using a felt tip pen or scriber for example.
– Remove the steering wheel ⇒ page 97 .
– Remove the steering column coverings. Please refer to man‐
ual ⇒ Body - internal mountings; Rep. Gr. 70 ; Lining /
Insulation .

Note

The upper lining can be completely removed only by subsequent‐

ly removing the steering column

Vehicles with Electronic Stability Program “ESP”.

3. Steering column with adjustment - repair 111

 SpaceFox, Space Cross, Suran, Suran Cross, Sportvan 2006 ➤
Running gear, axles, steering - Edition 05.2011

Vehicles equipped with ESP are also equipped with the Steering
angle sensor -G85- . It is fitted in the housing -1- along with the
contact ring.
After performing works on the switchbox, check the basic adjust‐
ment of the Steering angle sensor -G85- ⇒ page 117 .
Check if the front wheels are in the straight line position.
– Position the wheels in the straight line position and remove the
steering wheel, if necessary.

– Position the Steering angle sensor -G85- on the central posi‐

tion.
1 - A yellow dot must be visible through the hole -1-
2 - The marks -arrows- must align

AG. Volkswagen AG d
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– Pull off connectors -arrows-.

nl

pt
du

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itte

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erm

ab
ility
ot p

wit
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h re
hole

spec
es, in part or in w

t to the co
rrectness of i
l purpos

nform
mercia

at
om

ion
c

in t
or

his
ate

do
priv

cum
for

en
ng

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

112 Rep. Gr.48 - Steering

 SpaceFox, Space Cross, Suran, Suran Cross, Sportvan 2006 ➤
Running gear, axles, steering - Edition 05.2011

– Lift the hooks carefully -arrows- and remove the steering angle
sensor.
Continued for all vehicles
– Remove switch set. Please refer to manual ⇒ Electrical sys‐
tem; Rep. Gr. 94 ; Switches, lights and external lamps .

Note
AG. Volkswagen AG d
agen
♦ The column must be inVothe
lksw central position (wheels
oes
nin
ot straight
line position) when
se
dthe
by contact ring is removed and installed
g ua
ran
i tee
or
♦ The contact ring
au supplied as a new part is locked in the central r a
th o
position through
ss a cable clamp c

ce
e
nl

pt
du

an
– Pull off connector -1- from the Immobilizer reading coil -D2- .
itte

y li
erm

ab
ility
ot p

– Open the cable support (right side) in the tabs -arrows- and

wit
, is n

remove the wire.

h re
hole

spec
– Disconnect the earth strap from the steering column -arrow-.
es, in part or in w

t to the co
– Remove the earth strap and the support (left side) -1- from the
switchbox cables.

rrectness of i
l purpos

nf
ercia

orm
m

atio
om

n in
c

– Pull off connector -2- from the steering lock assembly.

or

thi
te

sd
iva

o
r
rp

cu
o

m
f

en
ng

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

– Remove the screw -1- from the universal joint and disconnect
the universal joint in the direction of the arrow.
Remove the access lid on the relay box, to make work easier.
Vehicles with fastening screw located on the right side of the
steering column

3. Steering column with adjustment - repair 113

 SpaceFox, Space Cross, Suran, Suran Cross, Sportvan 2006 ➤
Running gear, axles, steering - Edition 05.2011

– Remove the screw -arrow- of pedal assembly (left side) -1-

over the bracket steering column.
or
Vehicles with fastening screw located on the left side of the steer‐
ing column

– Remove the screw -arrow- located on the left and the self-
locking nut located on the right of the steering column support.
– Remove the screw -arrow- located on the left and the self-
locking nut located on the right of the steering column support.
– Remove the clutch pedal command switch, if necessary.
Continued for all vehicles
AG. Volkswagen AG d
agen oes
olksw not
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d by ara
ise nte
or eo
h
aut ra
ss c

ce
le
un

pt
an
d

– Remove screws -arrows- , and pull the steering column -1- out
itte

y li
erm

of its housing.

ab
ility
ot p

– Remove the steering lock assembly. Please refer to manual

wit
is n

⇒ Electrical system; Rep. Gr. 94 ; Switches, lights and ex‐

h re
ole,

ternal lamps .
spec
urposes, in part or in wh

– Check steering column for damage ⇒ page 118 .

t to the co
rrectness o
cial p

f inform

– If mounting bush -1- is damaged, remove it.

mer

atio
m

– Remove the screw -2-.

o

n
c

i
or

n thi

– Remove the bushing from support -1- from the steering col‐
te

sd
a

umn fork -3-.

iv

o
pr

cum
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fo

en
ng

t.
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Note C py
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♦ In case the steering column is replaced, then remove the sup‐
o
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port bushing -1- and install on the new shaft Prote AG.

♦ Before installing the mounting bush, check for damages

3.2.2 Installation

Note

Self-locking screws and nuts must be replaced whenever re‐

moved.

114 Rep. Gr.48 - Steering

 SpaceFox, Space Cross, Suran, Suran Cross, Sportvan 2006 ➤
Running gear, axles, steering - Edition 05.2011

– If mounting bush -1- was removed because of damage, install

a new mounting bush.

Note

♦ In case the steering column is replaced, the support bushing

-1- from the old column must be installed on the new column
♦ Before installing the mounting bush, check for damages
♦ If the mounting bush is damaged, a new one must be installed

– Install the steering column on the support.

Vehicles with fastening screw located on the right side of the
steering column
AG. Volkswagen AG d
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– Install screw -arrow- located to the right of theolkssteering column
w oes
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support, above the pedals. Tighteningetorqued b ara
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⇒ Item 8 (page 109) . ris
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Vehicles with fastening screw located on the left side of the steer‐

an
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ing column

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hole

spec
es, in part or in w

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– Install screw -arrow- located on the left and the new self-lock‐

rrectness of i
ing nut located on the right of the steering column support.
Tightening torque for the screw ⇒ Item 4 (page 109) .
l purpos

– If removed, install the clutch pedal command switch.

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– Align the steering column with the support and install it.
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The hole -arrow A- and the pin -arrow B- should be aligned.
cted agen
Prote AG.

3. Steering column with adjustment - repair 115

 SpaceFox, Space Cross, Suran, Suran Cross, Sportvan 2006 ➤
Running gear, axles, steering - Edition 05.2011

– Install and tighten the steering column screws -arrows-

⇒ Item 2 (page 109) .
– Install the universal joint on steering box pinion. Tighten the
new fastening screw for the universal joint
⇒ Item 3 (page 109) .

– Push on connector -2- on the steering lock assembly.

– Install the ground cable and the switchbox assembly cable on
the cable bracket -1-.
– Connect steering column ground cable -arrow-.
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– Install the cable to the support and close tabs -arrows-.

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– Push on connector -1- from the Immobilizer reading coil -D2- .

h re
hole

spec

The work sequence below refers only to vehicles with ESP:

es, in part or in w

t to the co

– Position the Steering angle sensor -G85- until the tabs fit.
– Remove the transport protection when a new Steering angle
rrectness of i

sensor -G85- is installed.

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at
om

ion
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in t
or

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ate

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Cop py
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Prote AG.

116 Rep. Gr.48 - Steering

 AG. Volkswagen AG d
agenSpaceFox, Space oeCross, Suran, Suran Cross, Sportvan 2006 ➤
olksw s no
t gu
yV
ed b Running aragear, axles, steering - Edition 05.2011
nte
ris
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– Position the Steering
ss a angle sensor -G85- on the central posi‐ c
tion.

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nl

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an
1 - A yellow dot must be visible through the hole -1- itte

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erm

ab
2 - The marks -arrows- must align

ility
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Make sure that the central position is maintained

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hole

spec
The basic adjustment for the steering angle sensor must be
es, in part or in w

checked after the assembly works:

t to the co
♦ when the Steering angle sensor -G85- was removed or re‐
placed

rrectness of i
♦ after the steering column is removed or replaced
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♦ after the switchbox is removed or replaced

♦ after removing or replacing the steering lock assembly

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ercia

orm
♦ when the steering wheel is not in the straight line position
m

atio
om

n in
Check the basic adjustment of the Steering angle sensor -G85-
or c

thi
te

– Connect the Diagnosis, Measurement and Information Sys‐

sd
iva

o
r

tem -VAS 5051- , and follow the instructions on the screen.

rp

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Continued for all vehicles

t.
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Cop py
.
– Install the steering lock assembly. Please refer to manual ⇒
ht rig
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Electrical system; Rep. Gr. 94 ; Switches, lights and external copy Vo
by lksw
lamps . cted agen
Prote AG.

– Install the steering column coverings. Please refer to manual

⇒ Body - internal mountings; Rep. Gr. 70 ; Lining / Insulation .
– Install trim for steering column switch. Please refer to manual
⇒ Electrical system; Rep. Gr. 94 ; Switches, lights and ex‐
ternal lamps .

– Install the steering wheel so that the mark -arrow A- on the

steering wheel and the mark -arrow B- on the steering column
align.
– Observe eventual additional marks.

Note

Steering columns supplied as a spare part do not have a centre

punch mark.

– Install the steering wheel:

without airbag: ⇒ page 101
with airbag: Please refer to manual ⇒ Body - internal mountings;
Rep. Gr. 69 ; Occupants' protection .
– Push on connector -1-.
Install by inverting the removal sequence.

WARNING

When connecting the Battery -A- make sure no one is inside

the vehicle. Please refer to manual ⇒ Electrical equipment;
Rep. Gr. 27 ; Starter, alternator, battery .

3. Steering column with adjustment - repair 117

 SpaceFox, Space Cross, Suran, Suran Cross, Sportvan 2006 ➤
Running gear, axles, steering - Edition 05.2011

3.3 Steering column - check

3.3.1 Visual checking

– Check all steering column parts for damages.

3.3.2 Check the operation

– Check whether the steering column turns easily and without
interference.
– Check whether the steering column can be adjusted for height
and length.
– Check measurement -nd-.
Measurement -nd-: minimum of 37 mm.
– If measurement -nd- is below 37 mm, the steering column is
n AG. Volkswagen AG do
damaged and must be replaced. lkswage es n
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es, in part or in w

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co lksw
by
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Prote AG.

118 Rep. Gr.48 - Steering

 SpaceFox, Space Cross, Suran, Suran Cross, Sportvan 2006 ➤
Running gear, axles, steering - Edition 05.2011

4 Power steering box - repair

4.1 Power steering box - assembly overview

WARNING

Always replace self-locking nuts and screws which were sub‐

jected to angular torque.

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lkswage es n
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Note byV ua
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♦ Repairs in the steering
ss
au
box are not expected. In case of com‐ ac
plaints, replace the entire steering box

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♦ Soldering and straightening works in the steering parts are not
itte

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1 - Screw
hole

spec
❑ 8 Nm
es, in part or in w

t to the co
2 - Heat shield
❑ See the ⇒ Electronic

rrectness of i
Parts Catalogue (ETKA)
l purpos

3 - Seal ring
4 - Hexagon nut nform
ercia

❑ 20 Nm + 90°
m

at

❑ replace after each re‐

om

io

moval
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5 - Steering arm
at

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6 - Pressure hose
for

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7 - Hollow screw t. Cop py
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❑ 38 Nm
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8 - Seal ring cted agen
Prote AG.

9 - Hollow screw
❑ 38 Nm
10 - Return hose
11 - Hexagon screw
❑ 50 Nm + 90°
❑ replace after each re‐
moval
❑ Refer to: ⇒ Electronic
Parts Catalogue (ETKA)
12 - Subframe
❑ Observe the notes on
repair work
13 - Spacer
❑ only for SpaceCross
and SuranCross

4. Power steering box - repair 119

 SpaceFox, Space Cross, Suran, Suran Cross, Sportvan 2006 ➤
Running gear, axles, steering - Edition 05.2011

14 - Steering box
❑ remove and install ⇒ page 120

4.2 Power steering box - remove and install

Special tools and workshop

equipment required
♦ Engine and gearbox jack +
gearbox or EQ 7081 -VAG
1383A-
♦ Clamps (diam. 25 mm)
-3094-
AG. Volkswagen AG d
agen oes
♦ Extractor -3287A- olksw not
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d b ara
♦ Star socket 36 mm or Ge‐ rise nte
ho eo
dore Ref. D32-36 -T 10125- s aut ra
c
s
♦ "Torque wrench - 5 to 50

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Nm ( socket 1/2")" -VAG

an
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erm

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♦ "Torquemeter - 40 to 200

wit
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Nm (socket 1/2")" -VAG

h re
1332-
hole

spec
es, in part or in w

t to the co
rrectness of i
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Prote AG.

4.2.1 Notes related to installation works in the

power steering box
♦ On works to be performed on the power steering box, it is
necessary to follow strict cleaning measures.
♦ Carefully clean the threaded joints and the surrounding area
before loosening them.
♦ Place the parts removed over a clean base and cover them it
the repair is not performed immediately.
♦ Do not use cloths that lint.
♦ Remove the replacement parts from the package only when
proceeding with the installation.
♦ Use only original parts

120 Rep. Gr.48 - Steering

 SpaceFox, Space Cross, Suran, Suran Cross, Sportvan 2006 ➤
Running gear, axles, steering - Edition 05.2011

4.2.2 Removal
– First, check if a code radio equipment is installed. If this is the
case, request the anti-theft code.
– Disconnect the ground cable from the battery. Please refer to
manual ⇒ Electrical system; Rep. Gr. 27 ; Starter, alternator,
battery .
– Lift the vehicle until the front axle is without any load.
– Loosen the grooved nut -arrow- with the Star socket 36mm or
Gedore Ref. D32-36 -T 10125- or the 30 mm star socket.
– Remove the wheel.
– Mark the position for the swivel tip screws on the wishbone.
AG. Volkswagen AG d
agen oes
olksw not
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– Remove screws -arrows-.

ility
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wit
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– Move the suspension column together with the swivel joint on

h re
the wishbone.
hole

spec
es, in part or in w

t to the co
rrectness of i
l purpos

nf
ercia

orm
m

atio
m

– Press the drive axle shaft out of the roller bearing case. To do
o

n in
c

this, install the Extractor -3283- as shown in the illustration.

or

thi
te

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While pressing the drive axle shaft outwards, make sure you have
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enough free space. py by
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Prote AG.
– Remove the wheel roller bearing case with the shaft articula‐
tion out of the transverse arm.

– Turn the suspension outward and support, for example, with

a wooden block -1- , and simultaneously remove the drive axle
shaft from the wheel roller bearing.
– Fasten the drive axle shaft to the body with a wire.

Note

The drive axle shaft must not be pressed downwards. Otherwise,

the internal articulation will be damaged due to excessive tilting.

4. Power steering box - repair 121

 SpaceFox, Space Cross, Suran, Suran Cross, Sportvan 2006 ➤
Running gear, axles, steering - Edition 05.2011

– Remove the screw -1- from the universal joint and remove the
universal joint in the arrow direction.

– Loosen the flexible tube from the transmitting cylinder reser‐

voir and remove it by using the Clamps (diam. 25 mm) -3094- .

AG. Volkswagen AG d
agen oes
olksw not
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ara
ed
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– Release the flexible tube from the rotary pump by removing

ce
le
un

the Clamps (diam. 25 mm) -3094- .

pt
an
d
itte

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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

– Remove the nut -1- of connection rod.

nform
ercia

– Detach the steering track rod ball point -2- from the steering
m

knuckle arm.
a
com

tion in
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Prote AG.

122 Rep. Gr.48 - Steering

 SpaceFox, Space Cross, Suran, Suran Cross, Sportvan 2006 ➤
Running gear, axles, steering - Edition 05.2011

– Remove the hexagonal nut -1- from the anti-roll rod on both
sides.
– Remove the rods -3- of stabilizer -2-.

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lkswage es n
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– Remove the hollow screw of the pressure duct -1- (19-mm

h re
wrench measurement) of steering gear housing.
hole

spec
es, in part or in w

– Remove the connecting screw of the return duct -2- (17 mm

t to the co
wrench measurement) of steering gear housing.
– Seal the ducts with a plastic bag and adhesive tape.

rrectness of i
– Seal the threaded holes of the hydraulic power steering box
with threaded plastic plugs.
l purpos

– Remove the subframe. ⇒ page 22 .

nf
ercia

o
– Remove the power steering box from behind.

rm
m

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om

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4.2.3 Installation
te

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Note
Co
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♦ Use new sealants for the hoses/ducts
p by
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cted agen
♦ Coat steering box seals with lubricant, e.g. soft soap, before
Prote AG.

installing steering box

♦ After fitting the steering box in the universal joint of the column,
make sure that the joint is against the assembly plate, without
twisting, and that it seals the opening for the pedal area cor‐
rectly. There may be noises and/or water may come in
♦ Make sure that the sealing surfaces are clean
♦ When replacing the power steering box, replace the steering
yoke bellows

Before installing the subframe screws, position the hydraulic pow‐

er steering box on the subframe and install the screws for the
power steering box.
– Fasten the subframe.
– Install the drive shaft in the wheel roller bearing.
– Fasten the swivel tip to the wishbone (screws on old marks).

Note

♦ Use new screws!

♦ Check if the protective bellows are not damaged or twisted

– Fasten the steering box to the subframe.

– Fasten the steering yoke to the steering arm.

4. Power steering box - repair 123

 SpaceFox, Space Cross, Suran, Suran Cross, Sportvan 2006 ➤
Running gear, axles, steering - Edition 05.2011

– Install the return hose and tighten the connecting screw.

Note

Make sure that the pressure duct does not interfere on the body
and the subframe

– Install the wheels and tighten the screws.

– Tighten the splined nut -arrow- with the Star socket 36mm or
Gedore Ref. D32-36 -T 10125- or the 30 mm star socket
⇒ Item 1 (page 60) .
– Install the universal joint on steering box pinion.
– Install the hex head screw from below and tighten it.
– Replenish the hydraulic oil level ⇒ page 141 .
After the installation, you must check the steering wheel position
through a test drive.
If the steering wheel is not in straight ahead position, the front axle
alignment must be checked and if necessary adjusted!
– Check alignment ⇒ page 89 .

4.3 Power steering box - disassemble and

assemble
AG. Volkswagen AG d
agen oes
olksw not
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Note ised b ara
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h
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♦ Always replace self-lockings nuts and screws which were sub‐
s a c
jected to angular torque.
ce
le
un

pt
an
d

♦ It is not permitted to repair the power steering box. In case of

itte

y li
rm

complaints, replace the entire steering box.

ab
pe

ility
ot

♦ Welding and straightening work on steering components are

wit
, is n

not permitted.
h re
hole

spec

♦ Type of oil: Hydraulic oil -325 029 011-

es, in part or in w

t to the co

♦ Oil quantity in the system: 0,7 ... 0.9 l

rrectness of i
l purpos

nform
mercia

a
com

tion in
r
te o

thi
s
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do
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cum
fo

en
ng

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

124 Rep. Gr.48 - Steering

 SpaceFox, Space Cross, Suran, Suran Cross, Sportvan 2006 ➤
Running
en AG. V
olkswaggear,
en AG axles, steering - Edition 05.2011
ag does
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Vol gu
1 - Right steering track rod ball ed
by ara
nte
joint thoris eo
au ra
❑ marked with “C” ss c

ce
e
❑ check: ⇒ page 128

nl

pt
du

an
itte
❑ note the assembly posi‐

y li
erm

ab
tion ⇒ page 128

ility
ot p
2 - Hexagon nut

wit
, is n

h re
❑ 50 Nm
hole

spec
es, in part or in w

3 - Clamp

t to the co
4 - Protection cover
❑ must not be twisted after

rrectness of i
the alignment
l purpos

❑ remove the steering box

to replace it

nf
ercia

5 - Clamp

orm
❑ fasten ⇒ page 127
m

atio
m

❑ replace - open with pli‐

o

n in
or c

ers

thi
te

sd
iva

6 - Gasket

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f

en
ng

7 - Left steering track rod ball yi

t.
Co
joint t. Cop py
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gh
❑ marked with “D”
ht
pyri by
Vo
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by c lksw
❑ check: ⇒ page 128 Prote
cted AG.
agen

8 - Hexagon nut
❑ 50 Nm
9 - Clamp
10 - Protection cover
❑ must not be twisted after
adjusting the alignment
❑ remove the steering box
to replace it
11 - Clamp
❑ fasten ⇒ page 127
❑ replace - open with pliers
12 - Right steering track rod
❑ supplied along with the steering box as a replacement part
13 - Steering box
14 - Left steering track rod
❑ supplied along with the steering box as a replacement part
15 - Rubber bearing
16 - Clamp with nuts
❑ replace if threads are damaged
17 - Heat shield
18 - Screw
❑ 8 Nm

4. Power steering box - repair 125

 SpaceFox, Space Cross, Suran, Suran Cross, Sportvan 2006 ➤
Running gear, axles, steering - Edition 05.2011

4.4 Steering track rod - remove and install

Special tools and workshop

equipment required
♦ Support for VW643 or VW
643/1 -VW 313-
♦ Torquemeter - 40 to 200
Nm (socket 1/2") -VAG
1332-
♦ Spanner insert 32 -VAG
1332/6-
♦ Clamp pliers or VW 004V -
VAG 1275-
♦ Support for transmission -
T10108-
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pe

ility
ot

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hole

spec
es, in part or in w

t to the co
rrectness of i
l purpos

nform
mercia

a
com

tion in
r
te o

thi

4.4.1 Removal
s
iva

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Note C py
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The steering bars can only be removed and installed with the
co lksw
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cted agen
steering box removed. Prote AG.

– Close the steering box pipes if this has not been done yet.
– Clean the steering box on the outer part along with the covers.
To disassemble the right steering bar, open the left caul tightening
clamp and push it backwards, because, to release the right steer‐
ing bar, it is necessary to press against the left gear rack.
– Open tightening clamp and push the cover backwards.

126 Rep. Gr.48 - Steering

 SpaceFox, Space Cross, Suran, Suran Cross, Sportvan 2006 ➤
Running gear, axles, steering - Edition 05.2011

– Attach the steering gear housing to Support for transmission

-T10108- and untighten the steering bar -1- from the gear rack
-2-.

4.4.2 Installation
The installation is performed in the reverse sequence from the
removal.
To fasten the steering box, use the hole “5” and the proper gear‐
. Volkswagen AG
box support hole, located onkthe
swa front.
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n
Vol ot g
by ua
Tightening torque: rised ran
tee
ho
ut
Steering bar to steering box 80 Nm
or
ac
sa s

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le

4.5 Protective caul - assemble

un

pt
an
d
itte

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rm

Special tools and workshop equipment required

ab
pe

ility
ot

♦ Clamp pliers or VW 004V -VAG 1275-

wit
, is n

h re
hole

spec
es, in part or in w

t to the co
rrectness of i
l purpos

nform
mercia

a
com

tion in
r
te o

– Check the protection cover for wear (cuts, cracks) and ensure
thi
s
iva

that seal surfaces are clean.

do
r
rp

cum
fo

– When installing the protective caul, turn the steering yoke first
en
ng

t.
yi
so that the bar ball pin gets in the installation position.
Co
Cop py
t. rig
– Attach the clamp with Clamp pliers or VW 004V -VAG 1275-
gh ht
pyri by
Vo
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by c lksw
cted agen
Prote AG.
Note

♦ Use only original clamps

♦ Under no circumstances shall the protective caul be installed
twisted (misaligned)

4. Power steering box - repair 127

 SpaceFox, Space Cross, Suran, Suran Cross, Sportvan 2006 ➤
Running gear, axles, steering - Edition 05.2011
AG. Volkswagen AG d
agen
4.6 Clearance, fastening and protective
by
Vol
ksw
oes
not
gu
cauls from the steeringhoyoke tips - check
d ara
e nte
ris eo
t
au ra
– With the lifted vehicle (wheels hanging
ss free), check the play c
by moving the steering track rods and wheels. Play: without

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e
nl

pt
du
play.

an
itte

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erm

ab
– Check fastening.

ility
– Check the sealing bellows for damages and correct fitting. ot p

wit
, is n

h re
hole

4.7 Correspondence of the steering yoke

spec
es, in part or in w

tips

t to the co
I - The right steering yoke tip is marked with -C-

rrectness of i
II - The left steering yoke tip is marked with -D-
l purpos

nform
mercia

at
om

ion
c

in t
or

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ate

do
priv

cum
for

en
ng

t.
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Prote AG.

4.8 Gear rack centering - determine

Before proceeding with the power steering box installation, install
the rack on the central position.
– Move the gear rack until the dimension -nd-.
1 - Measurement -nd- = 75.5 mm

128 Rep. Gr.48 - Steering

 SpaceFox, Space Cross, Suran, Suran Cross, Sportvan 2006 ➤
Running gear, axles, steering - Edition 05.2011

5 Hydraulic pump (power steering) - re‐

pair (valid for all engines, except
CCRA and CFZA)
AG. Volkswagen AG d
agen
5.1 Hydraulic pump with hydraulic piping and hoses - assembly overview
oes
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pump on the upper part

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❑ Assembly overview

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⇒ page 131

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pe

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ot

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pump on the lower part

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❑ Assembly overview

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⇒ page 132
es, in part or in w

t to the co
1 - Compensation reservoir
❑ Assembly overview

rrectness of i
⇒ page 130
l purpos

2 - Fitting of return piping on

the pressure piping

nform
ercia

3 - Fitting of return piping on

the pressure piping
m

a
com

ti
❑ Operating pressure -

on in
check ⇒ page 136
r
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thi
s
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4 - Fitting of pressure piping

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onto gearbox

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5. Hydraulic pump (power steering) - repair (valid for all engines, except CCRA and CFZA) 129
 SpaceFox, Space Cross, Suran, Suran Cross, Sportvan 2006 ➤
Running gear, axles, steering - Edition 05.2011

5.1.1 Compensation reservoir - assembly overview

1 - Reservoir cover with meas‐

uring rod
❑ Oil level: between the
“min”. and “max”.
marks; engine tempera‐
ture approx. 50 °C
❑ Arrow A: oil level when
the engine is cold
❑ With engine cold, oil lev‐
el cannot exceed the
min. marking
❑ Check the oil level with
reservoir cover installed
2 - Clamp
3 - Flexible return tube
4 - Flexible suction tube
5 - Internal hex head screw agen
AG. Volkswagen AG d
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❑ 10 Nm byV
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6 - Compensation reservoir ut
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es, in part or in w

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rrectness of i
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130 Rep. Gr.48 - Steering

 AG. Volkswagen AG d
agen oes
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byV gu
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ut
ho SpaceFox, Space e oCross, Suran, Suran Cross, Sportvan 2006 ➤
ra
a
ss Running
c gear, axles, steering - Edition 05.2011

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5.2 Hydraulic pump on the upper part - assembly overview

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1 - Support
, is n

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2 - Screw

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es, in part or in w

❑ 23 Nm

t to the co
3 - Hydraulic pump
❑ Remove and install

rrectness of i
⇒ page 132
l purpos

❑ Check operation pres‐

sure ⇒ page 136

nform
ercia

4 - Sealant
m

a
5 - Hollow screw
com

tion in
❑ 38 Nm
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6 - Pressure piping

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7 - Poly-V belt pulley

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9 - Poly-V belt
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10 - Poly-V belt tensioner de‐

vice
11 - Screw
❑ 23 Nm

5. Hydraulic pump (power steering) - repair (valid for all engines, except CCRA and CFZA) 131
 SpaceFox, Space Cross, Suran, Suran Cross, Sportvan 2006 ➤
Running gear, axles, steering - Edition 05.2011

5.3 Hydraulic pump on the lower part - assembly overview

1 - Support
2 - Hollow screw
❑ 38 Nm
3 - Pressure piping
4 - Sealant
5 - Suction tube
6 - Clamp
7 - Hydraulic pump
❑ Remove and install
⇒ page 134
❑ Check operation pres‐
sure ⇒ page 136
8 - Screw
❑ 23 Nm
9 - Poly-V belt pulley
10 - Screw
❑ 23 Nm
11 - Poly-V belt
12 - Poly-V belt tensioner

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5.4 Vehicles with hydraulic pump on the up‐

es, in part or in w

t to the co

per part - remove and install

rrectness of i

Note
l purpos

♦ Spare pumps are not filled with oil. Thus, before performing
the installation, fill it with Hydraulic Oil -325 029 901 1- and
nform
ercia

turn them manually. Otherwise, noises may appear during the

operation or damages to the pump.
m

at
om

ion
c

♦ Oil quantity in the system: 0,7 ... 0.9 l.

in t
or

his
ate

do
riv

5.4.1 Removal
p

cum
for

en
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– Mark Poly-V belt operation direction.
Co
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Prote AG.

132 Rep. Gr.48 - Steering

 SpaceFox, Space Cross, Suran, Suran Cross, Sportvan 2006 ➤
Running gear, axles, steering - Edition 05.2011

– In order to relieve the Poly-V belt, displace the tensioner to‐

wards the -arrow-.
– Remove the Poly-V belt.

– Loosen the screws of Poly-V belt and lock it, if necessary.

– Remove the pump pulley.
– Remove the pump intake hose.

– Close the intake hose with a Clamp (diam. 25 mm) -3094- .

AG. Volkswagen A
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– Remove the by
Vointake
lk hose, loosening the clamp
not
gu with Space-
Saverrisclamp
ed pliers -VW 5163 (VWB)- . ara
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es, in part or in w

t to the co

– Close the return hose with a Clamp (diam. 25 mm) -3094- .

– Remove the screw.
rrectness of i

– Close the pressure hose with plastic bag or something similar.

l purpos

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mercia

a
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tion in
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te o

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s
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rig ht
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by lksw
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Prote AG.

5. Hydraulic pump (power steering) - repair (valid for all engines, except CCRA and CFZA) 133
 SpaceFox, Space Cross, Suran, Suran Cross, Sportvan 2006 ➤
Running gear, axles, steering - Edition 05.2011

– Loosen hexagon screws -1- and -2-.

– Remove the pump.
AG. Volkswagen AG d
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ot

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5.4.2 Installation

spec
es, in part or in w

t to the co
Install by inverting the removal sequence, paying attention to the
following:
– Fill the hydraulic pump with hydraulic oil. Insert oil through

rrectness of i
pump intake nozzle.
l purpos

– Manually turn the hub until oil comes out from the pressure
side.

nform
ercia

– Install the hydraulic pump on the support and tighten the

m

screws with a torque of 23 Nm.

a
com

tion in
– Install the intake hose and the clamp. The mark -arrow A-
r
te o

thi
should be aligned with the seam -arrow-. The clamp shall face

s
iva

do
the mark -arrow B-.
r
rp

cum
fo

– Install new sealants over the hollow screw.

en
ng

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– Tighten the hollow screw, applying a torque of 38 Nm.
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5.5 Vehicles with hydraulic pump installed

on the lower part - remove and install

Note

♦ Spare pumps are not filled with oil. Thus, before performing
the installation, fill it with Hydraulic Oil -325 029 011- and turn
them manually. Otherwise, noises may appear during the op‐
eration or damages to the pump.
♦ Oil quantity in the system: 0,7 ... 0.9 l.

5.5.1 Removal
– Mark Poly-V belt operation direction.

134 Rep. Gr.48 - Steering

 SpaceFox, Space Cross, Suran, Suran Cross, Sportvan 2006 ➤
Running gear, axles, steering - Edition 05.2011

– In order to relieve the Poly-V belt, displace the tensioner to‐

wards the -arrow-.
– Remove the Poly-V belt.

– Loosen the screws of Poly-V belt and lock it, if necessary.

– Remove the pump pulley.

– Close the intake hose with a Clamp (diam. 25 mm) -3094- .

– Remove the intake hose, loosening the clamp -3- with Space-
Saver clamp pliers -VW 5163 (VWB)- .
– Loosen the hollow screw -4-.
– Close the pressure hose with plastic bag or something similar.
G. Volkswagen AG d
– Loosen hexagon screws -1- and -2-. lkswagen A oes
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– Remove the pump. ir se
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5.5.2 Installation
erm

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Install by inverting the removal sequence, paying attention to the

wit
is n

following:
h re
ole,

spec

– Fill the hydraulic pump with hydraulic oil. Insert oil through
urposes, in part or in wh

pump intake nozzle.

t to the co

– Manually turn the hub until oil comes out from the pressure
side.
rrectne

– Install the hydraulic pump on the support and tighten the

screws with a torque of 23 Nm.
ss o
cial p

f inform
mer

atio
om

n
c

i
or

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te

sd
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pr

cum
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en
ng

t.
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t. rig
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pyri by
Vo
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by
cted agen
Prote AG.

5. Hydraulic pump (power steering) - repair (valid for all engines, except CCRA and CFZA) 135
 SpaceFox, Space Cross, Suran, Suran Cross, Sportvan 2006 ➤
Running gear, axles, steering - Edition 05.2011

– Install the intake hose and the clamp. The mark -arrow A-
should be aligned with the seam -arrow-. The clamp shall face
the mark -arrow B-.
– Install new sealants on the hollow screw.
– Tighten the hollow screw, applying a torque of 38 Nm.

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5.6 Hydraulic pump operation pressure - check

y li
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Special tools and workshop

h re
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equipment required

spec
urposes, in part or in wh

♦ Clamps (diam. 25 mm)

t to the co
-3094-
♦ Power steering control

rrectne
equipment -VAG 1402-
♦ Adapter -V.A.G 1402/2-

ss o
cial p

♦ Adapter -V.A.G 1402/3-

f inform
mer

♦ Adapter -V.A.G 1402/4-

atio
m

♦ Flexible tube of the adapter

o

n
c

i
or

n
set -V.A.G 1402/6- thi
te

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pr

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t.
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by
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Prote AG.

136 Rep. Gr.48 - Steering

 SpaceFox, Space Cross, Suran, Suran Cross, Sportvan 2006 ➤
Running gear, axles, steering - Edition 05.2011

♦ Standard type clamp pliers -VAS 5024A-

AG. Volkswagen AG d
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es, in part or in w

t to the co
rrectness of i
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5.6.1 Vehicles with hydraulic pump on the

nf
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lower part

orm
m

atio
Checking conditions:
om

n in
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• Poly-V belt/tension are correct.

thi
te

sd
iva

• Leak-proof hydraulic system.

o
r
rp

cu
o

m
f

en
ng

• Hoses/piping not bent and/or compressed.

t.
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op py
– Close the return hose with a Clamp (diam. 25 mm) -3094- .
t. C rig
gh ht
pyri by
Vo
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by
cted agen
Prote AG.

5. Hydraulic pump (power steering) - repair (valid for all engines, except CCRA and CFZA) 137
 SpaceFox, Space Cross, Suran, Suran Cross, Sportvan 2006 ➤
Running gear, axles, steering - Edition 05.2011

– Close the suction hose with a Clamp (diam. 25 mm)

en AG. V
olksw-3094-
agen AG.
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– Place a drip tray under the [Link] gu
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– Release the pump pressure
ut
hotube.
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pe

ility
ot

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hole

spec
es, in part or in w

t to the co
– Insert the adapter -1-. Use sealant.
1- Adapter -V.A.G 1402/1-

rrectness of i
2- Flexible tube of the adapter set -V.A.G 1402/6-
l purpos

nform
mercia

a
com

tion in
r
te o

thi
s
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do
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rp

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fo

en
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t.
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– Connect the Power steering control equipment -VAG 1402- . t. C rig
gh ht
pyri by
1- Flexible tube of Power steering control equipment -VAG
co Vo
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1402-
agen
Prote AG.

2- Adapter -V.A.G 1402/2-

3- Pressure piping with ring support
4- Hollow screw
5- Flexible tube of the adapter set -V.A.G 1402/6-
6- Power steering control equipment -VAG 1402-
– Remove the Clamp (diam. 25 mm) -3094- of suction and return
piping.
– Start the engine and fill the compensation container up with oil
if necessary.
– Turn the steering wheel approx. 10 times, from stopper to
stopper.
– Close the cock (no more than 5 seconds) during engine idling
and check the pressure reading.
Nominal value (gasoline engines and TotalFlex): 85 to 95 bar

Note

♦ Replace the pump if the nominal value is not attained or sur‐

passed.
♦ Check the steering system for leak proofness if there is lack
of liquid in the container.
♦ Replace the steering box if the pinion or gear rack seal leaks.
♦ In order to check the gear rack seal, open the protection cover
tube clamp and push the protection cover to the other side.

138 Rep. Gr.48 - Steering

 SpaceFox, Space Cross, Suran, Suran Cross, Sportvan 2006 ➤
Running gear, axles, steering - Edition 05.2011

5.6.2 Vehicles with hydraulic pump on the up‐

per part
Checking conditions:
• Poly-V belt/tension are correct.
• Leak-proof hydraulic system.
• Hoses/piping not bent and/or compressed.
– Close the return hose with a Clamp (diam. 25 mm) -3094- .

AG. Volkswagen AG d
agen oes
olksw not
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– Close the suction hose with a Clamp (diam. 25 mm) -3094- .

an
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– Place a drip tray under the vehicle.

ility
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wit
– Release the pump pressure tube.
is n

h re
ole,

– Connect the Power steering control equipment -VAG 1402- .

spec
urposes, in part or in wh

t to the co
rrectness o
cial p

f inform
mer

atio
om

n
c

i
or

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te

sd
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pr

cum
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fo

en
ng

t.
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t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.

5. Hydraulic pump (power steering) - repair (valid for all engines, except CCRA and CFZA) 139
 SpaceFox, Space Cross, Suran, Suran Cross, Sportvan 2006 ➤
Running gear, axles, steering - Edition 05.2011

1 - Power steering control

equipment -VAG 1402-
2 - Flexible tube of Power
steering control equipment -
VAG 1402-
3 - Flexible tube of the adapter
set -V.A.G 1402/6- n AG. Volkswagen AG do
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❑ 2 Units ss

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6 - Adapter -V.A.G 1402/2-

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7 - Pressure piping with ring

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support

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8 - Hollow screw
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spec
es, in part or in w

t to the co
rrectness of i
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nform
mercia

at
om

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c

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or

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ate

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cum
for

en
ng

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– Start the engine and fill the compensation container up with oil
if necessary.
– Turn the steering wheel approx. 10 times, from stopper to
stopper.
– Close the cock (no more than 5 seconds) during engine idling
and check the pressure reading.
Nominal value (gasoline engines and TotalFlex): 85 to 95 bar

Note

♦ Replace the pump if the nominal value is not attained or sur‐

passed.
♦ Check the steering system for leak proofness if there is lack
of liquid in the container.
♦ Replace the steering box if the pinion or gear rack seal leaks.
♦ In order to check the gear rack seal, open the protection cover
tube clamp and push the protection cover to the other side.

140 Rep. Gr.48 - Steering

 SpaceFox, Space Cross, Suran, Suran Cross, Sportvan 2006 ➤
Running gear, axles, steering - Edition 05.2011

5.7 Power steering oil - fill

Note

Using Hydraulic Oil -325 029 901 1- for power steering.

– Lift the vehicle until the front wheels are free.

– Turn the steering wheel 10 times from stopper to astopper
gen AG with
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does
the engine turned off. Volksw not
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– Check hydraulic oil level and fill it up oifrisnecessary.
e
tee
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– Release the hydraulic oil reservoir
ss cover.
ac

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– Run the engine for 10 seconds.

pt
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– Stop the engine.
erm

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ility
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– Check hydraulic oil level and fill it up if necessary.

wit
is n

h re
– Release the hydraulic oil reservoir cover.
ole,

spec
urposes, in part or in wh

– Repeat the work sequence below until the hydraulic oil level

t to the co
no longer lowers.
– Start the engine.

rrectne
– Turn the steering wheel 10 times from stopper to stopper.
– Stop the engine.

ss o
cial p

f
– Check hydraulic oil level and fill it up if necessary.

inform
mer

– After finishing the procedure, tighten reservoir cover.

atio
om

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c

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or

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Prote AG.

5. Hydraulic pump (power steering) - repair (valid for all engines, except CCRA and CFZA) 141
 SpaceFox, Space Cross, Suran, Suran Cross, Sportvan 2006 ➤
Running gear, axles, steering - Edition 05.2011

6 Hydraulic pump (power steering) - re‐

pair (valid for CCRA and CFZA en‐
gines) lksw
agen
AG. Volkswagen AG d
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WARNING ut
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Always replace self-locking nuts and screws which were sub‐

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nl

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jected to angular torque.

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itte

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erm

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ility
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6.1 Hydraulic pump with hydraulic piping and hoses - assembly overview

wit
, is n

h re
hole

spec
es, in part or in w

1 - Compensation reservoir

t to the co
2 - Return piping
3 - Pressure piping

rrectness of i
4 - Hydraulic pump
l purpos

❑ Operating pressure -
check ⇒ page 148

nf
ercia

o
❑ Remove and install

rm
m

atio
⇒ page 144
om

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or c

thi
te

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f

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t.
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by
cted agen
Prote AG.

142 Rep. Gr.48 - Steering

 SpaceFox, Space Cross, Suran, Suran Cross, Sportvan 2006 ➤
Running gear, axles, steering - Edition 05.2011
n AG. Volkswagen AG do
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6.1.1 Compensation reservoir - assembly overview lks es n
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1 - Reservoir cover with meas‐ ss
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uring rod

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an
❑ Oil level: between the

d
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“min.” and “max.”

rm

ab
pe
marks; engine tempera‐

ility
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ture approx. 50 °C

wit
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❑ Arrow A: oil level when
hole

spec
the engine is cold
es, in part or in w

❑ With engine cold, oil lev‐

t to the co
el cannot exceed the
min. marking

rrectness of i
❑ Check the oil level with
reservoir cover installed
l purpos

2 - Clamp

nform
ercia

3 - Flexible return tube

m

a
4 - Flexible suction tube
com

tion in
5 - Internal hex head screw
r
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s
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❑ 10 Nm

do
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fo

6 - Compensation reservoir

en
ng

t.
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Prote AG.

6. Hydraulic pump (power steering) - repair (valid for CCRA and CFZA engines) 143
 SpaceFox, Space Cross, Suran, Suran Cross, Sportvan 2006 ➤
Running gear, axles, steering - Edition 05.2011

6.2 Hydraulic pump - assembly overview swage

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1 - Sealant utho tee
or
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2 - Hollow screws ss

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❑ 38 ± 4 Nm

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3 - Pressure piping (outlet)

rm

ab
pe

ility
ot
4 - Screw

wit
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h re
❑ 20 Nm

hole

spec
5 - Hydraulic pump
es, in part or in w

t to the co
❑ Operating pressure -
check ⇒ page 148
❑ Remove and install

rrectness of i
⇒ page 144
l purpos

6 - Support
7 - Screw

nform
ercia

❑ 45 ± 4.5 Nm
m

a
com

tio
8 - Return pulley

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9 - Screw

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iva

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❑ 20 Nm

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10 - Power pump driving pulley
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pyri by
Vo
co lksw
by
cted agen
Prote AG.

6.3 Power pump - remove and install

WARNING

Repair works in the hydraulic pump are not expected.

144 Rep. Gr.48 - Steering

 SpaceFox, Space Cross, Suran, Suran Cross, Sportvan 2006 ➤
Running gear, axles, steering - Edition 05.2011

Special tools and workshop

equipment required
♦ Clamp pliers -VW 5163-
♦ Clamp (diam. 25 mm)
-3094-
♦ Rod for blocking Poly-V
pulleys -EQ -7112- . Volkswagen AG
gen AG does
swa
♦ Torque wrench - 5 to 50 Nm yV
olk not
gu
-VAG 1331- rised b ara
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

nform
mercia

at
om

ion
c

in t
or

his
ate

do
priv

cum
for

en
ng

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

or

6. Hydraulic pump (power steering) - repair (valid for CCRA and CFZA engines) 145
 SpaceFox, Space Cross, Suran, Suran Cross, Sportvan 2006 ➤
Running gear, axles, steering - Edition 05.2011

♦ Pliers or Hazet 790-1 -VW

5024-

AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
ss c

ce
e
nl

pt
du

an
itte

y li
erm

ab
Note

ility
ot p

wit
, is n

♦ The replacement pumps are not supplied with oil. Thus, before

h re
hole

performing the installation, fill it with Hydraulic Oil -325 029 901

spec
1- and turn them manually. Otherwise, noises may appear
es, in part or in w

during the operation or damages to the pump.

t to the co
♦ Oil quantity in the system: 0,7 .... 0.9l.

rrectness of i
6.3.1 Removal
l purpos

– Remove the noise insulation.⇒ Body - external mountings;

Rep. Gr. 50 . nf
ercia

orm

– Remove the Poly-V belt (elastic) ⇒ Engine; Rep. Gr. 13 .

m

atio
om

n in

– Using the Rod for blocking Poly-V pulleys -EQ -7112- to attach
or c

the pulley, loosen the Poly-V belt pulley screws (with inner
thi
te

sd
a

hexagon portion).
iv

o
r
rp

cu
o

– Remove the internal hex head screw from the Poly-V belt pul‐
f

en
ng

t.
yi
ley.
Co
Cop py
ht. rig
– Remove the pump pulley. rig ht
py by
co Vo
by lksw
– Remove the pump intake hose. cted agen
Prote AG.

146 Rep. Gr.48 - Steering

 SpaceFox, Space Cross, Suran,
AG. VSuran
olkswagCross,
en AG Sportvan 2006 ➤
Running agen
ksw gear, axles, steering e-sEdition 05.2011
do
ol not
V y gu
db ara
ise nte
– Restrain the suction hose (inlet) with a Clampth(diam.
or 25 mm) eo
-3094- . ss
au ra
c

ce
e
– Using the Clamp pliers -VW 5163- , open the clamp and loosen

nl

pt
du

an
the suction hose (inlet).

itte

y li
erm

ab
– Restrain the return hose (outlet) with a Clamp (diam. 25 mm)

ility
ot p
-3094- .

wit
, is n

h re
– Remove hollow screw.

hole

spec
– Close the pressure tubes with a plastic bag or similar object.

es, in part or in w

t to the co
rrectness of i
6.3.2 Installation
l purpos

– Fill the hydraulic pump with hydraulic oil, inserting through the

nf
ercia

pump intake nozzle.

orm
m

– Manually turn the hub until oil comes out from the pressure

atio
m

side.
o

n in
or c

thi
e

– Install the hydraulic pump on the support and tighten the

t

sd
iva

screws. Tightening torque ⇒ Item 4 (page 144) .

o
r
rp

cu
o

m
f

– Insert the intake tube and install the clamp. The mark

en
ng

t.
yi Co
-arrow A- should be aligned with the arrow seam. The clamp Cop py
should be perpendicular to the mark -arrow B-. ht. rig
rig ht
py by
o Vo
– Install new sealants on the hollow screw.
by c lksw
cted agen
Prote AG.
– Tighten the hollow screw. Tightening torque
⇒ Item 2 (page 144) .
– The remaining installation steps are carried out in reverse or‐
der of removal.

6. Hydraulic pump (power steering) - repair (valid for CCRA and CFZA engines) 147
 SpaceFox, Space Cross, Suran, Suran Cross, Sportvan 2006 ➤
Running gear, axles, steering - Edition 05.2011

6.4 Hydraulic pump operation pressure - check

Special tools and workshop

equipment required
♦ Clamps (diam. 25 mm)
-3094-
♦ Power steering control
equipment -VAG 1402-
♦ Adapter -V.A.G 1402/2-
♦ Adapter -V.A.G 1402/3-
♦ Adapter -V.A.G 1402/4-
♦ Flexible tube of the ??
adapter set -V.A.G 1402/6-

n AG. Volkswagen AG do
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
erm

ab

♦ Standard type clamp pliers -VAS 5024A-

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

148
cted agen
Prote AG.
Rep. Gr.48 - Steering
 SpaceFox, Space Cross, Suran, Suran Cross, Sportvan 2006 ➤
Running gear, axles, steering - Edition 05.2011

♦ Adapter -V.A.G 1402/1- AG. Volkswagen AG d

agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c

ce
e
nl

pt
du

an
itte

y li
erm

ab
ility
ot p

wit
, is n

h re
hole

spec
es, in part or in w

t to the co
6.4.1 Checking procedure

rrectness of i
– Restrain the return piping (outlet) with a Clamp (diam. 25 mm)
l purpos

-3094- .
– Restrain the suction hose (inlet) with a Clamp (diam. 25 mm)

nf
ercia

-3094- .

orm
m

– Place oil drip pan underneath vehicle.

atio
om

n in
c

– Release the pump pressure tube screw.

or

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.

6. Hydraulic pump (power steering) - repair (valid for CCRA and CFZA engines) 149
 SpaceFox, Space Cross, Suran, Suran Cross, Sportvan 2006 ➤
Running gear, axles, steering - Edition 05.2011

6.4.2 Connect control device for power steering - VAG 1402-

1 - Control device for power

steering - VAG 1402-
2 - Control device flexible tube
for power steering - VAG 1402-
3 - Adapter - VAG 1402/6-
4 - Adapter - V.A.G 1402/4-
5 - Sealants
❑ 2 Units
6 - Adapter - V.A.G 1402/2-
7 - Pressure piping with ring
support
8 - Hollow screw

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

– Remove Clamps (diam. 25 mm) -3094- of suction and return

ility
ot p

piping.
wit
, is n

h re

– Start engine and, if needed, fill fluid level from compensation

hole

spec

container.
es, in part or in w

t to the co

– Turn the steering wheel approx. 10 times, from stopper to

stopper.
– Check operating pressure.
rrectness of i

6.4.3 Checking conditions:

l purpos

• Poly-V belt (elastic)/tightening of poly-V belt (elastic) in order

nf
ercia

• Correct system sealing.

rm
m

atio
m

• Flexible tubes/tubing unbent/unclipped.

o

n in
or c

thi

• Close cutoff valve (not longer than 5 seconds) during engine

te

sd
a

idling and read pressure.

iv

o
r
rp

cu
o

m
f

en
ng

t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote
150
AG.
Rep. Gr.48 - Steering
 SpaceFox, Space Cross, Suran, Suran Cross, Sportvan 2006 ➤
Running gear, axles, steering - Edition 05.2011

Nominal value: 85 ... 95 bar

Note

♦ Replace the pump if the nominal value is not attained or sur‐

passed.
♦ Check the steering system for leak proofness if there is lack
of liquid in the container.
♦ Check tubings/connections for leaks; close and dry, if needed.
♦ Replace steering box if pinion or cogwheel sealing leaks.
♦ In order to check the gear rack seal, open the protection cover
tube clamp and push the protection cover to the other side.

6.5 Power steering oil - fill

Note AG. Volkswagen AG d

agen oes
olksw no
Using Hydraulic Oil -325 y V 901 1- for power steering. t gua
b029
ed ran
ris tee
tho or
u
– Lift the vehicle
ss until the front wheels are free.
a ac

ce
e
nl

– Check hydraulic oil level and fill it up if necessary.

pt
du

an
itte

y li
– Release the hydraulic oil reservoir cover.
erm

ab
ility
ot p

– Run the engine for 10 seconds. wit

, is n

h re
– Stop the engine.
hole

spec

– Check hydraulic oil level and fill it up to the level, if necessary.

es, in part or in w

t to the co

– Release the hydraulic oil reservoir cover.

Repeat the work sequence below until the hydraulic oil level no
rrectness of i

longer lowers:
l purpos

– Start the engine.

– Turn the steering wheel 10 times from stopper to stopper.
nf
ercia

or

– Stop the engine.

m
m

atio
om

– After finishing the procedure, tighten reservoir cover.

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.

6. Hydraulic pump (power steering) - repair (valid for CCRA and CFZA engines) 151
 AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
o eo
SpaceFox, Space Cross, Suran, Suran Cross, aut Sportvan 2006 ➤
h
ra
s c
Running gear, axles, steering - Edition 05.2011
s

ce
e
nl

pt
du

an
itte

y li
7 Hydraulic power steering (Diesel en‐

erm

ab
ility
ot p
gines) - repair

wit
, is n

h re
hole

spec
WARNING

es, in part or in w

t to the co
Always replace self-locking nuts and screws which were sub‐
jected to angular torque.

rrectness of i
l purpos
7.1 Hydraulic power steering fª JTEKT - as‐
sembly overview

nform
mercia

at
om

ion
Note
c

in t
or

his
ate

do
riv

♦ Repairing the steering box is not allowed. In case of com‐

p

cum
plaints, replace the entire steering box.
for

en
ng

t.
yi
♦ To lubricate the rack, use only Grease for steering gear hous‐
Co
Cop py
ing -AOF 063 000 04- ht. rig
rig ht
py by
o Vo
♦ Replace self-locking nuts and screws
by c lksw
cted agen
Prote AG.
♦ Type of oil: Hydraulic oil -G 004 000 M2-
♦ Oil filling capacity on the system: approx. 0.8 liters

152 Rep. Gr.48 - Steering

 SpaceFox, Space Cross, Suran, Suran Cross, Sportvan 2006 ➤
Running gear, axles, steering - Edition 05.2011

1 - Screw
❑ 8 Nm
2 - Heat shield
3 - Gasket
AG . Volkswagen AG
4 - Electro-hydraulic power ksw
agen does
not
l
steering sensor -G250- by
Vo gu
ara
ed
❑ Remove and installho ris nte
eo
⇒ page 161 au
t ra
c
ss
❑ Check “Assisted Trou‐

ce
e
nl

pt
bleshooting” with Diag‐
du

an
itte

nosis, Measurement

y li
erm

ab
and Information System

ility
ot p

-VAS 5051A/52-

wit
, is n

h re
5 - Screw
hole

spec
❑ 6 Nm
es, in part or in w

t to the co
6 - Hexagon nut
❑ 20 Nm + 90°

rrectness of i
❑ replace after each re‐
moval
l purpos

7 - Steering arm

nform
ercia

8 - Pressure hose
m

9 - Hollow screw

at
om

ion
❑ 40 Nm
c

in t
or

his
te

10 - Gasket
a

do
priv

cum
or

11 - Connecting screw
f

en
ng

t.
yi
❑ 30 Nm
Co
Cop py
t. rig
gh
12 - ?Sealant
ht
pyri by
Vo
o
by c lksw
cted
13 - Return hose
agen
Prote AG.

14 - Steering box
❑ Remove and install ⇒ page 155
15 - Subframe
❑ Check the repair notes ⇒ page 7
16 - Hexagon screw
❑ 50 Nm + 90°
❑ replace after each removal

7. Hydraulic power steering (Diesel engines) - repair 153

 SpaceFox, Space Cross, Suran, Suran Cross, Sportvan 2006 ➤
Running gear, axles, steering - Edition 05.2011

7.2 Hydraulic power steering fª TRW - as‐

sembly overview

Note

♦ It is not permitted to repair the steering box. In case of com‐

plaints, replace the entire steering box
♦ To lubricate the rack, use only Grease for steering gear hous‐
ing -AOF 063 000 04-
♦ Replace self-locking nuts and screws
♦ Type of oil: Hydraulic oil -G 004 000 M2-
♦ Oil filling capacity on the system: approx. 0.8 liters

1 - Screw
❑ 8 Nm
2 - Heat shield
3 - Gasket
4 - Electro-hydraulic power
steering sensor -G250-
❑ remove and install
⇒ page 161
❑ it can be checked in the
function “Assisted Trou‐
bleshooting” with Diag‐
nosis, Measurement
and Information System
-VAS 5051A/52-
5 - Screw
❑ 6 Nm agen
AG. Volkswagen AG d
oes
olksw not
6 - Hexagon nut d by
V gu
ara
ise nte
❑ 20 Nm + 90° hor eo
aut ra
❑ replace after each re‐ ss c
moval
ce
le
un

pt
an
d
itte

7 - Steering arm
y li
rm

ab
pe

ility

8 - Pressure hose
ot

wit
, is n

9 - Hollow screw
h re
hole

❑ 40 Nm
spec
es, in part or in w

t to the co

10 - Gasket
11 - Connecting screw
rrectness of i

❑ 30 Nm
l purpos

12 - Sealant
13 - Return hose
nform
ercia

14 - Steering box
m

❑ remove and install ⇒ page 155

com

tion in
r

15 - Subframe
te o

thi
s
iva

❑ Observe the notes on repair work ⇒ page 7

do
r
rp

cum
fo

16 - Hexagon screw
en
ng

t.
yi Co
❑ 50 Nm + 90° Cop py
t. rig
gh ht
pyri by
Vo
o
154
by c lksw
cted
Rep. Gr.48 - Steering
agen
Prote AG.
 SpaceFox, Space Cross, Suran, Suran Cross, Sportvan 2006 ➤
Running gear, axles, steering - Edition 05.2011
❑ replace after each removal

7.3 Electro-hydraulic power steering gear housing - remove and install

Special tools and workshop

equipment required
♦ Engine and gearbox jack +
gearbox or EQ 7081 -VAG
1383A- and Tray for engine
jack EQ 7081 -VAG
1359/2-
♦ Drip tray -VAG 1306-
♦ Extractor -3287 A-
♦ Star socket 36mm or Ge‐
dore Ref. D32-36 -T 10125-
♦ "Torque wrench - 5 to 50
Nm ( socket 1/2")" -VAG
1331-
♦ "Torquemeter - 40 to 200
Nm (socket 1/2")" -VAG
1332-
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
rm

ab
pe

ility
ot

wit
, is n

h re
hole

spec
es, in part or in w

t to the co
rrectness of i
l purpos

nform
ercia

7.3.1 Instructions for working with the hydraul‐

m

ic power steering box

com

tion in
r
te o

thi

♦ Absolute cleaning is mandatory when working with hydraulic

s
iva

power steering
do
r
rp

cum
fo

♦ Completely clean the connections and surrounding areas be‐

en
ng

t.
yi
fore disconnecting any component
Co
Cop py
ht. rig
♦ Parts removed must be placed on a clean and covered sur‐
rig ht
py by
o Vo
face, if the repair is not performed immediately by c lksw
cted agen
Prote AG.
♦ Do not use cloths with lints
♦ Only unpack the replacement parts immediately before instal‐
ling them
♦ Use only original parts

7. Hydraulic power steering (Diesel engines) - repair 155

 SpaceFox, Space Cross, Suran, Suran Cross, Sportvan 2006 ➤
Running gear, axles, steering - Edition 05.2011

7.3.2 Removal
– Disconnect the Battery -A- . Please refer to manual ⇒ Elec‐
trical equipment; Rep. Gr. 27 ; Starter, alternator, battery .
– Remove the Battery -A- and its console. Please refer to man‐
ual ⇒ Electrical equipment; Rep. Gr. 27 ; Starter, alternator,
battery .
– Lift the vehicle until the front axle is without any load.
– Loosen the grooved nut -arrow- with the ?Star socket 36mm n AG. Volkswagen AG do
lkswage es n
or Gedore Ref. D32-36 -T 10125- or the 30-mm star socket. byV
o ot g
ua
d ran
ir se
– Remove the wheel. utho tee
or
a ac
ss

ce
le
un

pt
an
d
itte

y li
erm

ab
ility
ot p

wit
is n

h re
ole,

spec
urposes, in part or in wh

t to the co
– Loosen the fastening nut -1- from the yoke.

rrectne
– Separate the steering yoke tip -2- from the wheel roller bearing
case, by using the Extractor -3287 A- .

ss
– Mark the position for the swivel tip screws on the wishbone.

o
cial p

f inform
mer

atio
om

n
c

i
or

n thi
te

sd
iva

o
pr

cum
r
fo

en
ng

t.
yi Co
Cop py
. rig
– Remove the attaching screws -arrows-.
t
gh ht
pyri by
Vo
co
– Move the suspension column together with the swivel joint on
by lksw
cted agen
Prote
the wishbone.
AG.

– Remove the hexagon nuts -1- from both sides of the coupling
rod -3-.
– Remove the coupling rod -3- from the anti-roll bar -2-.

156 Rep. Gr.48 - Steering

 SpaceFox, Space Cross, Suran, Suran Cross, Sportvan 2006 ➤
Running gear, axles, steering - Edition 05.2011

– Press the drive axle shaft out of the roller bearing case. To do
this, install the Extractor -3283- as shown in the illustration.

Note

While pressing the drive axle shaft outwards, make sure you have
enough free space.

– Remove the wheel roller bearing case with the shaft articula‐
tion out of the transverse arm.

– Turn the suspension outward and support, for example, with

a wooden block -1- , and simultaneously remove the drive axle
shaft from the wheel roller bearing.
– Fasten the drive axle shaft to the body with a wire.

Note
. Volkswagen AG
gen AG does
swa
The drive axle shaft must not be pressed y V downwards. Otherwise,
olk not
gu
the internal articulation will be damaged
rised b due to excessive tilting. ara
nte
ho eo
aut ra
The drive shaft should not besleft hanging, as it may be damaged
s c

ce
le

in case of excessive inclination.

un

pt
an
d
itte

y li
erm

– Remove cover -1- from engine/pump assembly -2-.

ab
ility
ot p

– Remove as much hydraulic oil from the pump as possible, with

wit
is n

the help of a suction bottle.

h re
ole,

spec
urposes, in part or in wh

t to the co
rrectness o
cial p

f inform
mer

atio

– Remove the screw -1- from the universal joint and uncouple
om

in the arrow direction.

n
c

i
or

n thi
e

Vehicles with hydraulic power steering fª JTEKT.

t

sd
iva

o
pr

– Remove the screw -arrow-.

um
r
fo

en
ng

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

7. Hydraulic power steering (Diesel engines) - repair 157

 SpaceFox, Space Cross, Suran, Suran Cross, Sportvan 2006 ➤
Running gear, axles, steering - Edition 05.2011

– Remove the Electro-hydraulic power steering sensor -G250-

-1- from the steering box.
Vehicles with hydraulic power steering fª TRW.

– Remove screws -arrows-.

– Remove the Electro-hydraulic power steering sensor -G250-
-1- from the steering box.
Continuation for all vehicles.

AG. Volkswagen AG d
agen oes
olksw not
V gu
by
– Remove the hollow screw of the pressure duct rise-1-
d (19-mm ara
nte
wrench measurement) of steering gear housing.
ut
ho eo
ra
s a c
– Remove the connecting screw of the return duct -2- (17 mm
s

ce
e
nl

wrench measurement) of steering gear housing.

pt
du

an
itte

y li
– Seal the ducts with the help of a plastic bag and adhesive tape.
erm

ab
ility
ot p

– Seal the electro-hydraulic power steering box threaded holes

wit
, is n

with plastic seal plugs.

h re
hole

spec
es, in part or in w

t to the co
rrectness of i

– Remove screws -1- from the steering box fastened to the sub‐
frame.
l purpos

– Position the subframe ⇒ page 20 .

nform
ercia

– Remove the electro-hydraulic power steering gear housing.

m

at
om

ion
c

in t
or

his
ate

do
priv

cum
for

en
ng

t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
7.3.3 Installation
cted agen
Prote AG.

WARNING

Always replace self-locking nuts and screws which were sub‐

jected to angular torque.

158 Rep. Gr.48 - Steering

 SpaceFox, Space Cross, Suran, Suran Cross, Sportvan 2006 ➤
Running gear, axles, steering - Edition 05.2011

Note

♦ Use new sealants for the hoses/ducts

olkswagen AG
en AG. V
♦ Coat steering box seals with lubricant,
olks
wag e.g. soft soap, before
does
no
installing steering box db
yV t gu
ara
ir se nte
♦ After fitting the steering uthbox
o
in the universal joint of the column, eo
ra
make sure that the joint is against the assembly plate, without
a c
ss
twisting, and that it seals the opening for the pedal area cor‐

ce
e
nl

pt
du

rectly. There may be noises and even water infiltration

an
itte

y li
erm

♦ Make sure that the sealing surfaces are clean

ab
ility
ot p

♦ When replacing the hydraulic power steering box, also replace

wit
, is n

the steering yoke cauls

h re
hole

spec
es, in part or in w

Before installing the subframe screws, position the hydraulic pow‐

t to the co
er steering box on the subframe and install the screws for the
hydraulic power steering box.

rrectness of i
– Fasten the subframe ⇒ page 20 .
l purpos

Only for vehicles without ABS

– Clean threaded and indented surfaces.

nf
ercia

o
– Lubricate the toothed area -1- and the thread -2- with Molyb‐

rm
m

atio
denum Paste -G 052 751 A1- . See the ⇒ Chemical material
om

manual .

n in
or c

thi
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Only for vehicles with 13" running gear with ABS/ESP

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Prote AG.

7. Hydraulic power steering (Diesel engines) - repair 159

 SpaceFox, Space Cross, Suran, Suran Cross, Sportvan 2006 ➤
Running gear, axles, steering - Edition 05.2011

Install the articulated shaft on the wheel bearing as follows:

– Apply the Adhesive -D 185 400 A2- to the stub axle threads
-A- or to the nut thread. See the ⇒ Chemical material manual .
– Apply 2g of Adhesive -D 185 400 A2- to area -B-. Refer to the
⇒ Chemical material manual .
– The areas where the Adhesive -D 185 400 A2- should be free
from grease, oil, water or any other type of material. See the
⇒ Chemical material manual .
– Tighten the nut with 50 Nm.
olkswagen AG
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The torque must th be applied within 2 minutes after inserting the
o eo
shaft tip into
ss
a the wheel hub. After the torque process, the ve‐
u ra
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hicle must remain at least 1.5 hours with no strain on the semi-

ce
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shaft (only parking operations allowed).

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Continuation for all vehicles:

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– Fasten the swivel tip to the wishbone (screws on old marks).
hole

spec
Tightening torque ⇒ Item 17 (page 8) .
es, in part or in w

Note t to the co
rrectness of i

Check if the protective bellows are not damaged or twisted

l purpos

– Fasten the steering box to the subframe

⇒ Item 16 (page 153) .
nf
ercia

orm

– Bolt track rod ball joint to steering arm ⇒ Item 6 (page 153) .
m

atio
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n in

– Install the Electro-hydraulic power steering sensor -G250- to

or c

the steering gear housing, and tighten it

thi
te

sd
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⇒ Item 5 (page 153) .

iv

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– Install the return hose and tighten the connection screw (key
f

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measurement 17 mm) ⇒ Item 11 (page 153) .
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– If the pressure duct extends beyond the subframe, the dis‐ cop Vo
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tance between the pressure duct and the subframe must be cted agen
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adjusted.
– The distance between the pressure duct -1- and the subframe
-2- should be 10 mm.
– To perform this operation, use a 10 mm drill bit -A- between
the pressure duct -1- and the subframe -2-.
– Then, tighten the pressure duct hollow screw
⇒ Item 9 (page 153) .

Note

Make sure that the pressure duct does not interfere on the body
and the subframe

– Install the wheels and tighten the screws ⇒ page 88 .

160 Rep. Gr.48 - Steering

 SpaceFox, Space Cross, Suran, Suran Cross, Sportvan 2006 ➤
Running gear, axles, steering - Edition 05.2011

– Tighten the splined nut -arrow -.

– Fill with new hydraulic oil, using a hose with 400 to 500 mm of
length and a funnel.
Use Hydraulic Oil -G 004 000 M2- . Refer to the ⇒ Chemical
material manual
– Install the universal joint on steering box pinion.
– Install the hex head screw from below and tighten it
⇒ Item 5 (page 154) .
– Install Battery -A- ⇒ Electrical equipment; Rep. Gr. 27 ; Start‐
er, alternator, battery .
– Connect the Battery -A- ⇒ Electrical equipment; Rep. Gr. 27 ;
Starter, alternator, battery .
– Bleed steering system ⇒ page 177 .
– Check hydraulic oil level ⇒ page 179 .
• After the installation, you must check the steering wheel posi‐
tion through a test drive.
• If the steering wheel is not in straight ahead position, the front
axle alignment must be checked and if necessary adjusted.
– Check alignment ⇒ page 89 .

7.4 Electro-hydraulic power steering sensor

-G250- - remove and install
Special tools and workshop equipment required
♦ "Torque wrench - 5 to 50 Nm ( socket 1/2")" -VAG 1331-
AG. Volkswagen
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7.4.1 Removal
rrectness of i

– Remove the cable -1- of Electro-hydraulic power steering sen‐

sor -G250- from supports -arrow-.
l purpos

– Remove the left front wheel.

nform
ercia

– Remove front left wheel housing liner ⇒ Body - external

mountings; Rep. Gr. 66 ; External equipment .
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Prote AG.

7. Hydraulic power steering (Diesel engines) - repair 161

 SpaceFox, Space Cross, Suran, Suran Cross, Sportvan 2006 ➤
Running gear, axles, steering - Edition 05.2011

– Open spacer -arrow A-.

– Remove the cable -1- of Electro-hydraulic power steering sen‐
sor -G250- from supports -arrow B-.

– Remove radiator vent control unit -1- of sill -arrows-.

AG. Volkswagen AG d
agen oes
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– Pull off connector -1- from engine/pump assembly -2-.

wit
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Vehicles with hydraulic power steering fª JTEKT:
hole

spec
es, in part or in w

t to the co
rrectness of i
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c

– Remove the screw -arrow-.

or

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– Remove the Electro-hydraulic power steering sensor -G250-

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-1- from steering gear housing.

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Vehicles with hydraulic power steering fª TRW:
Co
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Prote AG.

162 Rep. Gr.48 - Steering

 SpaceFox, Space Cross, Suran, Suran Cross, Sportvan 2006 ➤
Running gear, axles, steering - Edition 05.2011

– Remove screws -arrows-.

– Remove the Electro-hydraulic power steering sensor -G250-
-1- from steering gear housing.

7.4.2 Installation
– Install the Electro-hydraulic power steering sensor -G250- to
the steering gear housing, and tighten it
⇒ Item 5 (page 153) .
– Connect the connector to the motor/pump set.
– Install radiator vent control unit -1- on the longitudinal member
fastening the nuts -arrows- with n6ANm.G. Volkswagen AG
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– Install the cable -1- of Electro-hydraulic power steering sensor

-G250- on support -arrow B-.
– Close the spacer -arrow A-.
rrectness of i
l purpos

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– Install the cable -1- of Electro-hydraulic power steering sensor

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-G250- on support -arrow-. C py
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– Install the left front wheel case protection. Please refer to
cop Vo
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manual ⇒ Body - external mountings; Rep. Gr. 66 ; External cted agen
Prote AG.
equipment .
– Fit wheel and tighten screws ⇒ page 88 .

7. Hydraulic power steering (Diesel engines) - repair 163

 SpaceFox, Space Cross, Suran, Suran Cross, Sportvan 2006 ➤
Running gear, axles, steering - Edition 05.2011

7.5 Hydraulic power steering box fª JTEKT - disassemble and assemble

1 - Right steering track rod ball

joint
❑ marked with “C”
❑ check: ⇒ page 168
❑ remove from the steer‐
ing arm
❑ note the assembly posi‐
tion ⇒ page 169
2 - Hexagon nut
❑ 50 Nm
3 - Clamp
4 - Protection cover
❑ must not be twisted after
adjusting the alignment
❑ You must remove the
steering box to replace it
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5 - Clamp yV
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❑ replace - open with pli‐ o
ir se
ran
tee
ers auth or
ac
ss
❑ fasten ⇒ page 168

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6 - Gasket

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7 - Screw
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❑ 8 Nm

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8 - Heat shield
hole

spec
es, in part or in w

9 - Right steering track rod

t to the co
❑ 80 Nm
❑ remove and install

rrectness of i
⇒ page 166
❑ supplied as a pre-adjus‐
l purpos

ted replacement part

❑ align the vehicle after replacing it ⇒ page 89
nform
ercia

10 - Clamp with nuts

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❑ replace if threads are damaged

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11 - Rubber bearing
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12 - Steering box
um
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❑ remove and install ⇒ page 155

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13 - Gasket
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14 - Electro-hydraulic power steering sensor -G250-
by lksw
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❑ remove and install ⇒ page 161
❑ it can be checked in the function “Assisted Troubleshooting” with Diagnosis, Measurement and Infor‐
mation System -VAS 5051--
15 - Screw
❑ 6 Nm
16 - Left steering track rod ball joint
❑ marked with “D”
❑ check ⇒ page 168
❑ remove from the steering arm

164 Rep. Gr.48 - Steering

 SpaceFox, Space Cross, Suran, Suran Cross, Sportvan 2006 ➤
Running gear, axles, steering - Edition 05.2011

17 - Left steering track rod

❑ 80 Nm
❑ remove and install ⇒ page 166
❑ supplied as a pre-adjusted replacement part
❑ check length and adjust ⇒ page 167

7.6 Hydraulic power steering box fª TRW - disassemble and assemble

1 - Right steering track rod ball

joint
❑ marked with “C”
❑ check: ⇒ page 168
❑ note the assembly posi‐
tion ⇒ page 169
2 - Hexagon nut AG. Volkswagen AG d
agen oes
❑ 50 Nm Volksw not
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3 - Clamp horis nte
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4 - Protection cover ss c

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❑ must not be twisted after

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adjusting the alignment
itte

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❑ remove the steering box

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to replace it

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5 - Clamp
hole

spec
❑ replace: open with pliers
es, in part or in w

❑ fasten ⇒ page 168 t to the co

6 - Gasket
rrectness of i

7 - Screw
l purpos

❑ 8 Nm
8 - Heat shield
nform
ercia

9 - Right steering track rod

m

at

❑ 80 Nm
om

ion
c

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❑ remove and install

or

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⇒ page 166
at

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❑ supplied as a pre-adjus‐
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⇒ page 89
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10 - Clamp with nuts Prote
cted AG.
agen

❑ replace if threads are damaged

11 - Rubber bearing
12 - Steering box
❑ remove and install ⇒ page 155
13 - Gasket
14 - Electro-hydraulic power steering sensor -G250-
❑ remove and install ⇒ page 161
❑ it can be checked in the function “Assisted Troubleshooting” with Diagnosis, Measurement and Infor‐
mation System -VAS 5051--

7. Hydraulic power steering (Diesel engines) - repair 165

 SpaceFox, Space Cross, Suran, Suran Cross, Sportvan 2006 ➤
Running gear, axles, steering - Edition 05.2011

15 - Screw
❑ 6 Nm
16 - Left steering track rod ball joint
❑ marked with “D”
❑ check ⇒ page 168
17 - Left steering track rod
❑ 80 Nm
❑ remove and install ⇒ page 166
❑ It is supplied as pre-adjusted spare part
❑ check length and adjust ⇒ page 167

7.7 Steering track rod - remove and install

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Special tools and workshop olksw not
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♦ Support for VW643 or VW aut ra
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643/1 -VW 313- s

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♦ "Torquemeter - 40 to 200

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Nm (socket 1/2")" -VAG
erm

ab
1332-

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♦ Spanner insert 32 -VAG

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1332/6-
hole

spec
es, in part or in w

♦ Clamp pliers or VW 004V -

t to the co
VAG 1275-
♦ Gearbox support -T 10108-

rrectness of i
l purpos

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mercia

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or

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for

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7.7.1 Removal
The steering bars can only be removed and installed with the
steering box removed.
– Close the steering box tubes in case it was not previously
done.

166 Rep. Gr.48 - Steering

 SpaceFox, Space Cross, Suran, Suran Cross, Sportvan 2006 ➤
Running gear, axles, steering - Edition 05.2011

– Clean the steering box on the outer section with the bellows.
To remove the right steering bar, open the left bellows tightening
clamp and push the bellows backwards because it is necessary
to press against the left gear rack to release the right steering bar.
– Open the clamp with the Clamp pliers or VW 004V -VAG 1275-
and move the bellows backwards.
AG. Volkswagen AG d
Vehicles with hydraulic power steering fª JTEKT agen oes
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– Attach the steering gear housing to Gearboxorise support -T nte
10108- and loosen the rod -1- from the aut gear rack -2-.
h eo
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To fasten the steering box, use the hole “5” and the proper gear‐

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pt
box support hole, located on the front. du

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itte

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Vehicles with hydraulic power steering fª TRW
erm

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ility
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hole

spec
es, in part or in w

t to the co
rrectness of i
– Attach the steering gear housing to Gearbox support -T
l purpos

10108- and loosen the rod -1- from the gear rack -2-.
To fasten the steering box, use the hole “5” and the proper gear‐

nf
ercia

box support hole, located on the front.

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7.7.2 Installation
agen
Prote AG.

The installation is processed in the reverse order from removal.

Tightening torque:
Steering bar to steering box 80 Nm

7.8 Left steering bar length - check and ad‐

just
Special tools and workshop equipment required
♦ Clamp pliers or VW 004V -VAG 1275-

7. Hydraulic power steering (Diesel engines) - repair 167

 SpaceFox, Space Cross, Suran, Suran Cross, Sportvan 2006 ➤
Running gear, axles, steering - Edition 05.2011

7.8.1 Check
– Check and adjust the left steering bar following the distance if
necessary “nd” .
Measurement -nd- = 365 ± 5 mm
Then you must check and, if necessary, adjust the total conver‐
gence at the wheel alignment bench; Steering wheel alignment
⇒ page 89 .

7.8.2 Install the protective caul

– Check the protective caul for wearing (tears, cracks) and make
sure that the sealing surfaces are clean.
– When installing the protective caul, turn the steering yoke first
so that the bar ball pin gets in the installation position.
– Attach the clamp with Clamp pliers or VW 004V -VAG 1275- .

AG. Volkswagen AG d
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♦ Use only original clamps thor eo
au ra
♦ Under no circumstances shall the protective caul be installed ss c

ce
le

twisted (misaligned)
un

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erm

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wit
7.9 Clearance, fastening and protective
is n

h re
ole,

cauls from the steering yoke tips - check

spec
urposes, in part or in wh

t to the co
– With the lifted vehicle (wheels hanging free), check the play
by moving the steering track rods and wheels. Play: without
play. rrectne
– Check fastening.
– Check the sealing bellows for damages and correct fitting.
ss o
cial p

f inform
mer

atio
om

n
c

i
or

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te

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pr

cum
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t.
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Cop py
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by
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Prote AG.

168 Rep. Gr.48 - Steering

 SpaceFox, Space Cross, Suran, Suran Cross, Sportvan 2006 ➤
Running gear, axles, steering - Edition 05.2011

7.10 Correspondence of the steering yoke

tips
I - The right steering yoke tip is marked with -C-.
II - The left steering yoke tip is marked with -D-.

7.11 Gear rack centering - determine

Prior to assembling the steering box, the gear rack shall be placed
in central position.
– Move the gear rack to the position where the distance -nd- is
reached.
Measurement -nd- = 75.5 mm

n AG. Volkswagen AG do
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es, in part or in w

t to the co
rrectness of i
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Cop py
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7. Hydraulic power steering (Diesel engines) - repair 169

 n AG. Volkswagen AG do
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SpaceFox, Space Cross, Suran, Suran Cross, th Sportvan 2006 ➤
o tee
or
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Running gear, axles, steering - Edition 05.2011
ss
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8 Hydraulic power steering motor/

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pump set (Diesel engines)

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WARNING

urposes, in part or in wh

t to the co
Always replace self-locking nuts and screws which were sub‐
jected to angular torque.

rrectne
8.1 Motor/pump set; fª JTEKT - assembly

ss o
overview
cial p

f inform
mer

atio
m

Note
o

n
c

i
or

n thi
te

♦ The motor/pump set must not be repaired

sd
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pr

cum
r

♦ In case of complaints, determine the causes through pressure

fo

en
ng

and tightness tests along with self-diagnosis

t.
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♦ If the hydraulic fluid reservoir level is low, check the steering
t
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system for leaks cop Vo
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cted agen
Prote
♦ If there are leaks in the hose connection areas, you must tight‐
AG.

en and dry them

♦ Do not reuse drained hydraulic oil
♦ Always replace the seal
♦ Filling capacity on the oil system: approx. 0.8 liters

170 Rep. Gr.48 - Steering

 SpaceFox, Space Cross, Suran, Suran Cross, Sportvan 2006 ➤
Running gear, axles, steering - Edition 05.2011

1 - Hexagon screw
❑ 7 Nm
2 - Rubber bearing n AG. Volkswagen AG do
swage es n
3 - Support byV
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ir se
4 - Hexagon screw tho tee
or
au ac
❑ 20 Nm + 90° ss

ce
❑ replace after each re‐ le
un

pt
an
d

moval
itte

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rm

ab
5 - Bushing
pe

ility
ot

wit
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6 - Support

h re
hole

❑ for set/pump

spec
es, in part or in w

7 - Screw

t to the co
❑ 7 Nm
8 - Shim

rrectness of i
9 - Cover with dipstick
l purpos

❑ Check hydraulic oil level

⇒ page 179

nform
ercia

10 - Sealant
m

a
com

tio
11 - Engine/pump assembly

n in
r
te o

thi
❑ the repair is not expec‐

s
iva

ted

do
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cum
❑ remove and install
fo

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ng

⇒ page 173
t.
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Cop py
❑ check the pressure on
t. rig
gh ht
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the motor/pump set p by
co Vo
lksw
⇒ page 175
by
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Prote AG.
12 - Hexagon screw
❑ 7 Nm
13 - Bushing
14 - Support
15 - Rubber bearing
16 - Sealant
❑ replace after each removal
17 - Connecting screw
❑ 30 Nm
18 - Pressure hose
19 - Return hose/tube
20 - Spring clamp

8. Hydraulic power steering motor/pump set (Diesel engines) 171

 SpaceFox, Space Cross, Suran, Suran Cross, Sportvan 2006 ➤
Running gear, axles, steering - Edition 05.2011
AG. Volkswagen AG d
agen oes
ksw
8.2 Motor/pump set; fª TRW - assembly overview
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1 - Cover with dipstick ss c

ce
e
nl

❑ Check hydraulic oil level

pt
du

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⇒ page 179
itte

y li
erm

ab
2 - Sealant

ility
ot p

wit
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3 - Expansion tank

h re
hole

❑ To remove from the mo‐

spec
tor/pump set, slightly
es, in part or in w

t to the co
heat with a hot air blow‐
er.
4 - Clamp

rrectness of i
5 - Retainer
l purpos

❑ replace after each re‐

moval

nform
ercia

6 - Hexagon nut
m

at
om

i
❑ 7 Nm

on
c

in t
or

❑ By tightening properly

his
ate

on the support,
do
priv

c
⇒ Item 7 (page 172) ap‐ um
for

ply counter pressure

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ng

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op
7 - Bracket
C py
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❑ 7 Nm
p by
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cted
❑ Check if there are dam‐
agen
Prote AG.
ages, tears to the rub‐
ber; check the metal
plate released from the
rubber; replace if neces‐
sary.
8 - Engine/pump assembly
❑ The repairs are not ex‐
pected
❑ Only the expansion tank
can be replaced
⇒ Item 3 (page 172) , the
clamp ⇒ Item 4 (page 172) and the retainer ⇒ Item 5 (page 172)
❑ Remove and install ⇒ page 173
❑ Check the pressure on the motor/pump set ⇒ page 175
9 - Hexagon screw
❑ 20 Nm + 90°
❑ replace after each removal
10 - Support
❑ from the motor/pump set
11 - Spring clamp
12 - Return hose
13 - Retainer
❑ replace after each removal
14 - Cap screw
❑ 30 Nm
15 - Pressure tube

172 Rep. Gr.48 - Steering

 SpaceFox, Space Cross, Suran, Suran Cross, Sportvan 2006 ➤
Running gear, axles, steering - Edition 05.2011

8.3 Motor/pump assembly - remove and install

Special tools and workshop

equipment required
♦ "Torque wrench - 5 to 50
Nm ( socket 1/2")" -VAG
1331-
♦ "Torquemeter - 40 to 200
Nm (socket 1/2")" -VAG
1332-
♦ Drip tray -VAG 1306-

AG. Volkswagen AG d
agen oes
olksw not
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ara
ed
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♦ The motor/pump set must not be repaired

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♦ In case of complaints, determine the causes through pressure

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and tightness tests along with self-diagnosis

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♦ Do not reuse drained hydraulic oil

♦ The pressure and return hoses must not be tightened using,
for example, Clamps (diam. 25 mm) -3094- or tools. Tighten‐
ing may damage the pressure and return hoses
♦ To prevent damages, a radius with curvature lower than 100
mm must be avoided when bending or applying pressure on
the pressure and return hoses

8. Hydraulic power steering motor/pump set (Diesel engines) 173

 SpaceFox, Space Cross, Suran, Suran Cross, Sportvan 2006 ➤
Running gear, axles, steering - Edition 05.2011

8.3.1 Removal
Check if a code radio is installed. If this is the case, request the
anti-theft code.
– Remove the battery and the battery support. Please refer to
manual ⇒ Electrical system; Rep. Gr. 27 ; Starter, alternator,
battery .
– Remove cover -1- from engine/pump assembly -2-.
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– Remove as much hydraulic oil from the motor/pump setVol as
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– Remove the left front wheel. aut ra
ss c
– Remove left front wheel box protector. Please refer to manual

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un

pt
⇒ Body - external mountings; Rep. Gr. 66 ; External equip‐

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d
itte

ment .

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ab
pe

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– Remove the noise insulation. Please refer to manual ⇒ Gen‐
ot

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eral body repairs, exterior; Rep. Gr. 50 ; Body - Front part .
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es, in part or in w

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– Open the clamp -arrow-.
– Remove the pressure and return hoses-1- and -2- from the

rrectness of i
clamp.
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– Remove the cable -3- of Electro-hydraulic power steering sen‐

sor -G250- from spacer.

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– Remove radiator vent control unit -1- of sill -arrows-.
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– Open the return hose clamp -1- and remove from the motor/
pump set connection return duct.
– Remove the pressure duct -2- from engine/pump assembly
-3-.
– Seal the motor/pump set threaded holes with plastic plugs, for
example.
– Seal the pressure hose, return hose and connections of the
engine/pump assembly with plastic bag and adhesive tape.
– Remove screws -arrows- and slightly lower the motor/pump
set along with the support.

174 Rep. Gr.48 - Steering

 SpaceFox, Space Cross, Suran, Suran Cross, Sportvan 2006 ➤
Running gear, axles, steering - Edition 05.2011

– Pull off connectors -1-, -2- and -3- from engine/pump assembly
-4-.
– Remove the motor/pump set along with the support.

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8.3.2 Installation

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♦ Use new seal for the duct/hose connections
♦ Make sure that the sealing surfaces are clean

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The installation is performed in the reverse order from removal.

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– Activate the radio code.

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– Top up with new hydraulic oil, using a funnel and a hose of
form
mer

approx. 400...500 mm. atio

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Using Hydraulic Oil -G 004 000 M2- . Refer to the ⇒ Chemical

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material manual
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– Bleed steering system ⇒ page 177 .

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– Check hydraulic oil level ⇒ page 179 .

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Tightening torque:
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Motor/pump set support to body ⇒ Item 4 (page 171) .
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Pressure pipe to motor/pump assembly ⇒ Item 17 (page 171) .

8.4 Motor/pump set pressure; fª JTEKT -

check
Special tools and workshop equipment required
♦ Power steering control equipment -VAG 1402-

8. Hydraulic power steering motor/pump set (Diesel engines) 175

 SpaceFox, Space Cross, Suran, Suran Cross, Sportvan 2006 ➤
Running gear, axles, steering - Edition 05.2011

♦ Adapter -VAG 1402/6-

♦ Adapter -VAG 1402/13-

♦ Adapter -VAG 1402/14-
Check if a code radio is installed. If this is the case, request the
anti-theft code.
– Disconnect the Battery -A- and remove gen AGthe console
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Battery -A- ⇒ Electrical equipment;
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ternator, battery . ris
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– Remove the cover s-1-
au from engine/pump assembly -2-. ac
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– Remove as much hydraulic oil from the pump as possible, with

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the help of a suction bottle.

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– Remove the engine noise insulation. Please refer to manual ab

ility
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⇒ General body repairs, exterior; Rep. Gr. 50 ; Body - Front wit

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part .
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– Remove the pressure tubes from the motor/pump set.

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– Assemble the adapters as indicated in the illustration.

1- Motor/pump set
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2- Power steering control equipment -VAG 1402-

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3- Adapter -VAG 1402/6-

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4- Adapter -VAG 1402/14-

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5- Pressure tube
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6- Adapter -VAG 1402/13-
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176 Rep. Gr.48 - Steering

 SpaceFox, Space Cross, Suran, Suran Cross, Sportvan 2006 ➤
Running gear, axles, steering - Edition 05.2011

Note

Pay attention to the pressure gauge handle position, because it

must be on the position -2-

– Fill with hydraulic fluid and check the level ⇒ page 179 .
– Bleed the steering system ⇒ page 177 .
– Test the distribution pressure now.
Checking condition:
• System tightness
• The flexible tubes/cables are not bent or strangled.
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– With engine idling close tap for 5 seconds at the most (position

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Nominal pressure value:
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90…105 bar
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spec
If the nominal value is not reached, replace the motor/pump set
es, in part or in w

t to the co
⇒ page 173 .
Completely turn the steering by means of the steering wheel until
the stop, immobilize it and, with the blocking valve in the position

rrectness of i
-2-, read the pressure.
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If the value measured is clearly lower than the first one, there is
leakage in the steering box.

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– Disassemble the pressure gauge and adapter.

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– Assemble the pressure tubes from the motor/pump set.
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– Fill with hydraulic fluid and check the level ⇒ page 179 .
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– Bleed the steering system ⇒ page 177 .

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– Check the hydraulic fluid level and replenish, if necessary

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⇒ page 179 . C py
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– Test the leak-proofness of the steering system ⇒ page 178 .
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– Install the engine noise insulation. Please refer to manual ⇒
Prote AG.

General body repairs, exterior; Rep. Gr. 50 ; Body - Front part .

Tightening torque:
Pressure tube to the motor/pump set 30 Nm
4)

4) Use new retainer.

8.5 Steering system - bleed

– Remove the left front wheel.
– Remove left front wheel box protector. Please refer to manual
⇒ Body - external mountings; Rep. Gr. 66 ; External equip‐
ment .
– Check hydraulic oil level and fill it up if necessary
⇒ page 179 .

8. Hydraulic power steering motor/pump set (Diesel engines) 177

 SpaceFox, Space Cross, Suran, Suran Cross, Sportvan 2006 ➤
Running gear, axles, steering - Edition 05.2011

– Lift the vehicle until the front wheels are free.

– Turn the steering wheel from stop to stop 10 times with the
engine stopped.
– Check hydraulic oil level and fill it up if necessary
⇒ page 179 .
– Release the hydraulic oil reservoir cover. Do not tighten.
– Run the engine for 10 seconds and then stop it.
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– Release the hydraulic oil reservoir cover.
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– Repeat the work sequence below until
s the hydraulic oil level

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no longer lowers:
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– Start the engine.
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– Turn the steering wheel 10 times from stopper to stopper.
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– Stop the engine.
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– Check hydraulic oil level and fill it up if necessary
es, in part or in w

t to the co
⇒ page 179 .
– After the bleeding procedure is concluded, tighten the motor/
pump set reservoir lid manually.

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8.6 Leak-proofness of the steering system -
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check

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Note
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If after the repair the hydraulic oil level on the reservoir is still low,

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you must obligatorily check the hydraulic power steering system

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for leaks
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– Remove the left front wheel.
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– Remove the noise insulation. Please refer to manual ⇒ Gen‐
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cted
eral body repairs, exterior; Rep. Gr. 50 ; Body - Front part .
agen
Prote AG.

– Remove left front wheel box protector. Please refer to manual

⇒ Body - external mountings; Rep. Gr. 66 ; External equip‐
ment .
– Run the engine at idle speed.
– Turn the steering wheel on both sides until obtaining stopper.
Keep it in this position on each side for 5 to 10 seconds. The
maximum pressure possible will be produced.
– Check the hoses and return hoses for leak proofness.
– Check all tubes and hose connections for correct seating and
leak proofness. When the tubes and hoses are leaking, tighten
the connections to the torque specified or replace the sealing
or the piping/hose.
– Check the engine/pump assembly for leak proofness. In case
of leak, replace it.
– Check the hydraulic oil reservoir for leakages. On vehicles with
a JTEKT motor/pump set, if the reservoir leaks, the motor/
pump set must be replaced.
– Check the hydraulic fluid level and replenish, if necessary
⇒ page 179 .

178 Rep. Gr.48 - Steering

 SpaceFox, Space Cross, Suran, Suran Cross, Sportvan 2006 ➤
Running gear, axles, steering - Edition 05.2011

Note

If the hydraulic oil level in the reservoir lowers, even with the
pipes/hoses and or pressure duct connections without leaks, the
hydraulic power steering box may be the cause for the hydraulic
oil loss. In this case, the hydraulic power steering box must be
checked, after being removed from the vehicle

– Remove the hydraulic power steering box ⇒ page 155 .

Check the following parts for leakages with the steering box re‐
moved:
♦ Steering box valve body pinion seal
♦ All connections from the steering box tubes
For the next phases, pull the protective cauls away:
– Open the protection cover clamps.
– Remove the protection cover. The steering box must be re‐
placed if the hydraulic oil is visible on the steering box body
and/or on the protective cauls.
– Install the hydraulic power steering box ⇒ page 158 .
– Install the left front wheel case protection. Please refer to
manual ⇒ Body - external mountings; Rep. Gr. 66 ; External
equipment .
– Install the left front wheel and tighten the screws ⇒ page 88 .

8.7 Oil level - check

– Disassemble the air filter case, if necessary.
– Remove the battery and the battery support. Please refer to
manual ⇒ Electrical equipment; Rep. Gr. 27 ; Starter, alter‐
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– Remove the reservoir lid -1- from engine/pump
ris
ed assembly -2-. ran
tee
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– Clean the oil dipstick with a clean cloth.
sa
u ac
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– Manually press the cover, loosen it again and check the oil
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level.
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Completely press the cover in order to obtain an accurate fluid

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level reading.
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– Do not start the engine and leave the wheels in straight line
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position.
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Prote AG.

8. Hydraulic power steering motor/pump set (Diesel engines) 179

 SpaceFox, Space Cross, Suran, Suran Cross, Sportvan 2006 ➤
Running gear, axles, steering - Edition 05.2011

– Check the oil level.

The oil level must be between the lower mark -arrow A- and upper
mark -arrow B- of oil dipstick.

Note

♦ If oil level is above mark -arrow B-, it is necessary to drain the AG. Volkswagen AG d
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♦ If the oil level is below the indicated area, the hydraulic systemhor eo
ut
must be checked for leaks (check the hydraulic power steerings a ra
c
system tightness) ⇒ page 178 ). It is not enough to simply re‐
s

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plenish the oil level

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♦ Do not reuse the hydraulic oil after draining it

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ility
♦ Using Hydraulic Oil -G 004 000 M2- to replenish. Refer to the⇒ ot p

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Chemical material manual

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hole

spec
– If it is proven that the hydraulic system does not have leaks,
es, in part or in w

t to the co
you must replenish the hydraulic oil level.
– Tighten the motor/pump set reservoir lid manually.

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py by
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Prote AG.

180 Rep. Gr.48 - Steering