VW Passat b7 Running Gear Steering Eng

Service
Workshop Manual
Passat 2011 ➤
Passat Variant 2011 ➤
Running gear, axles, steering
Edition 03.2015
Service Department. Technical Information

Service
List of Workshop Manual Repair Groups
Repair Group
00 - Technical data
40 - Front suspension
42 - Rear suspension
43 - Self-levelling suspension
44 - Wheels, tyres, vehicle geometry
48 - Steering
Technical information should always be available to the foremen and mechanics, because their
careful and constant adherence to the instructions is essential to ensure vehicle road-worthiness and
safety. In addition, the normal basic safety precautions for working on motor vehicles must, as a
matter of course, be observed.
Passat 2011 ➤ , Passat Variant 2011 ➤
Running gear, axles, steering - Edition 03.2015
Contents
00 - Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1 Evaluating accident vehicles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.1 Checklist for evaluating running gear on accident vehicles . . . . . . . . . . . . . . . . . . . . . . . . 1
2 General information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
2.1 Tyre types . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
3 Repair instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
3.1 General repair instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
3.2 Steering box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
3.3 Gaskets and seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
3.4 Nuts and bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
3.5 Electrical components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
3.6 Lifting suspension to kerb weight position (vehicles with coil springs) . . . . . . . . . . . . . . . . 5
40 - Front suspension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
1 Front axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
1.1 Overview - front axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
2 Subframe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
2.1 Assembly overview - subframe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
2.2 Assembly overview - anti-roll bar . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
2.3 Removing and installing subframe without steering rack . . . . . . . . . . . . . . . . . . . . . . . . . . 20
2.4 Removing and installing subframe with steering rack . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
2.5 Repairing subframe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
2.6 Removing and installing anti-roll bar . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
2.7 Repairing thread in longitudinal member . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
2.8 Fixing position of subframe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
2.9 Lowering subframe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
3 Suspension strut, upper suspension link . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
3.1 Assembly overview - suspension strut, upper suspension link . . . . . . . . . . . . . . . . . . . . . . 49
3.2 Removing and installing suspension strut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
3.3 Repairing suspension strut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
4 Lower suspension link, swivel joint . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
4.1 Assembly overview - lower suspension link, swivel joint . . . . . . . . . . . . . . . . . . . . . . . . . . 69
4.2 Removing and installing lower suspension link . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
4.3 Renewing mounting bracket with suspension link bush . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
4.4 Checking swivel joint . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
4.5 Removing and installing swivel joint . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
4.6 Renewing bonded rubber bush for lower suspension link . . . . . . . . . . . . . . . . . . . . . . . . . . 86
5 Wheel bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
5.1 Assembly overview - wheel bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
5.2 Removing and installing wheel bearing housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
5.3 Removing and installing wheel bearing unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
6 Drive shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
6.1 Overview - drive shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
6.2 Assembly overview - drive shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
6.3 Removing and installing jointed shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
6.4 Loosening and tightening drive shaft bolt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114
6.5 Removing and installing drive shaft heat shield . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118
6.6 Dismantling and assembling drive shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118
6.7 Checking outer constant velocity joint . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133
6.8 Checking inner constant velocity joint . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134
42 - Rear suspension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 136
Contents i
1 Rear axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 136

1.1 Overview - rear axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 136
1.2 Lowering rear axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140
1.3 Removing and installing rear axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145
1.4 Removing and installing trim for rear axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 155
2 Subframe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 157
2.1 Assembly overview - subframe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 157
2.2 Assembly overview - add-on parts for subframe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 159
2.3 Fixing position of subframe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 159
2.4 Repairing subframe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 162
3 Anti-roll bar . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 191
3.1 Assembly overview - anti-roll bar . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 191
3.2 Removing and installing anti-roll bar . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 192
4 Suspension link, track rod . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 198
4.1 Assembly overview - transverse link . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 198
4.2 Removing and installing upper transverse link . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 203
4.3 Removing and installing lower transverse link . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 207
4.4 Removing and installing track rod . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 211
5 Suspension strut, shock absorber, spring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 218
5.1 Assembly overview - suspension strut, shock absorber, spring . . . . . . . . . . . . . . . . . . . . . . 218
5.2 Removing and installing shock absorbers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 224
5.3 Repairing shock absorber . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 233
5.4 Removing and installing spring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 241
6 Wheel bearing, trailing arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 246
6.1 Assembly overview - wheel bearing, trailing arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 246
6.2 Removing and installing wheel bearing housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 251
6.3 Removing and installing wheel bearing unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 258
6.4 Renewing bonded rubber bush for wheel bearing housing . . . . . . . . . . . . . . . . . . . . . . . . 263
6.5 Removing and installing trailing arm with mounting bracket . . . . . . . . . . . . . . . . . . . . . . . . 270
6.6 Repairing trailing arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 276
7 Drive shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 281
7.1 Assembly overview - drive shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 281
7.2 Removing and installing jointed shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 283
7.3 Loosening and tightening drive shaft bolt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 287
7.4 Dismantling and assembling drive shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 290
7.5 Checking inner constant velocity joint . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 293
43 - Self-levelling suspension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 296

1 Electronically controlled damping system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 296
1.1 Overview of fitting locations - electronically controlled damping system . . . . . . . . . . . . . . 296
1.2 Cable routing - front axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 298
1.3 Cable routing - rear axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 300
1.4 Removing and installing electronically controlled damping control unit . . . . . . . . . . . . . . . . 300
1.5 Re-adapting reference position (default position) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 301
1.6 Removing and installing front body acceleration senders . . . . . . . . . . . . . . . . . . . . . . . . . . 301
1.7 Removing and installing rear body acceleration sender . . . . . . . . . . . . . . . . . . . . . . . . . . . . 303
1.8 Removing and installing bracket for body acceleration sender . . . . . . . . . . . . . . . . . . . . . . 306
1.9 Shock absorber damping adjustment button . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 308
2 Vehicle level senders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 309
2.1 Assembly overview - front vehicle level senders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 309
2.2 Assembly overview - rear vehicle level senders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 310
2.3 Removing and installing front vehicle level senders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 314
2.4 Removing and installing rear vehicle level senders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 316
44 - Wheels, tyres, vehicle geometry . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 320

ii Contents
1 Wheels, tyres . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 320

1.1 Torque settings for wheel bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 320
1.2 Tyres with run-flat properties . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 320
1.3 Pressing tyre off wheel rim . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 322
1.4 Removing tyre from wheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 323
1.5 Installing tyre . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 324
1.6 Wheel change . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 324
1.7 Tyre sealant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 328
1.8 Tyre sealant disposal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 328
1.9 Models with breakdown set . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 328
2 Tyre pressure monitoring system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 330
2.1 Overview of fitting locations - tyre pressure monitor system . . . . . . . . . . . . . . . . . . . . . . . . 330
2.2 System description - tyre pressure monitoring system . . . . . . . . . . . . . . . . . . . . . . . . . . . . 331
2.3 Assembly overview - tyre pressure sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 333
2.4 Removing and installing tyre pressure monitor control unit . . . . . . . . . . . . . . . . . . . . . . . . 335
2.5 Removing and installing bracket for tyre pressure monitor control unit . . . . . . . . . . . . . . . . 335
2.6 Removing and installing tyre pressure sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 336
2.7 Changing tyres on vehicles with tyre pressure monitoring system . . . . . . . . . . . . . . . . . . . . 341
2.8 Removing and installing metal valve body . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 345
3 Wheel alignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 347
3.1 Notes for wheel alignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 347
3.2 Necessity of wheel alignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 347
3.3 Test prerequisites . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 348
3.4 Test preparations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 349
3.5 Specified values for wheel alignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 350
3.6 Wheel alignment procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 353
3.7 Adjusting camber at front wheels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 354
3.8 Adjusting camber on rear axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 355
3.9 Adjusting toe at rear axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 357
3.10 Adjusting front axle toe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 357
3.11 Vehicle data sticker . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 358
3.12 Steering angle sender - basic setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 359
4 Rough running due to wheels/tyres - causes and rectification . . . . . . . . . . . . . . . . . . . . . . 360
4.1 Causes of rough running . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 360
4.2 Conducting a road test before balancing wheels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 360
4.3 Balancing wheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 361
4.4 Vibration control system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 365
4.5 Checking radial and lateral runout of wheels and tyres . . . . . . . . . . . . . . . . . . . . . . . . . . . . 365
4.6 Checking radial and lateral run-out on wheel rim . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 366
4.7 Matching wheels and tyres . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 367
4.8 Determining flat spots on tyres . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 368
5 Adaptive Cruise Control (ACC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 370
5.1 Calibrating ACC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 370
6 Front camera for driver assist systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 375
6.1 Calibrating front camera for driver assist systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 375
48 - Steering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 383
1 Steering wheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 383
1.1 Assembly overview - steering wheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 383
1.2 Removing and installing steering wheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 383
2 Steering column . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 386
2.1 Assembly overview - steering column . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 386
2.2 Removing and installing steering column . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 389
2.3 Handling and transporting steering column . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 402
2.4 Checking steering column for damage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 403
Contents iii
2.5 Removing and installing ESL control unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 403

3 Steering box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 406
3.1 Assembly overview - steering rack . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 406
3.2 Removing and installing steering rack . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 409
3.3 Repairing steering rack . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 424
3.4 Removing and installing track rod . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 429
3.5 Removing and installing track rod ball joint . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 432
3.6 Removing and installing boot . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 433
iv Contents
00 – Technical data
1 Evaluating accident vehicles
(VRL007901; Edition 03.2015)
⇒ “1.1 Checklist for evaluating running gear on accident vehicles”,
page 1
1.1 Checklist for evaluating running gear on

accident vehicles
Damage to running gear may go unnoticed during repairs to load-
bearing and suspension parts of accident vehicles. Under certain
circumstances, this undiscovered damage could lead to serious
consequential damage during later vehicle operation. Therefore,
the following parts of accident vehicles must be examined in the
manner and order described independent of wheel alignment
which may have to be performed. If no deviations from specifica‐
tions are measured during wheel alignment, there are no defor‐
mations of the running gear.
Visual and functional examination of steering system
♦ Visual examination for deformation and cracks
♦ Examination for play in track rod joints and steering rack
♦ Visual examination for tears in boots
♦ Examine electrical and hydraulic lines and hoses for chafing,
cuts and kinks.
♦ Check steering rack and lines for secure seating
♦ Check for flawless function from lock to lock by moving the
steering from stop to stop. In the process, the steering wheel
must turn with a constant force without resistance.
Visual inspection and functional check of running gear
• Adhere to the sequence of the following inspection steps!
♦ Check all components shown in the assembly overviews for
deformation, cracks and other damage
♦ Renew damaged parts
♦ Align wheels on a Volkswagen AG-approved wheel alignment
stand
Visual and functional check of wheels and tyres
♦ Check for true running and imbalance ⇒ page 360 .
♦ Check tyres for cuts and impact damage in the tread and on
the flanks ⇒ page 360 .
♦ Check tyre inflation pressure; see tyre inflation pressure stick‐
er in fuel tank flap.
If rim of wheel and/or tyre is damaged, renew tyre. This also ap‐
plies if the circumstances of the accident and the damage to the
vehicle indicate possible damage which is not visible.
A further factor in the decision is the age of the tyre. Tyres should
not be older than 6 years.
If in doubt, the following always applies:
• Whenever a safety risk cannot be excluded, the tyre(s) must
be renewed.
1. Evaluating accident vehicles 1

Entire vehicle
Also check other vehicle systems such as:
♦ Brake system including ABS
♦ Visual and functional examination of exhaust system and pas‐
senger protection
Specifications for testing and adjusting can be found in the re‐
spective workshop manual in ELSA.
The accident vehicle check described here applies to the running
gear. This makes no claim to completeness for the overall vehicle.
Electronic vehicle systems
Safety-related systems such as ABS/EDL, airbags, electronically
regulated suspension systems, electromechanical or electrohy‐
draulic steering and other driver assist systems must be read with
the ⇒ Vehicle diagnostic tester for any event messages that may
be stored. If events are stored in the event memories of the above-
mentioned systems, repair them in accordance with the instruc‐
tions in the workshop manuals/ELSA. Following repairs, read
event memories of the affected systems again to be sure that
complete function has been restored.
2 Rep. gr.00 - Technical data

2 General information
⇒ “2.1 Tyre types”, page 3
2.1 Tyre types

Information concerning wheels, tyres and snow chains can be
found in ⇒ Wheels and Tyre Guide; Rep. gr. 44 and in ⇒ Wheels
and Tyres Guide - General Information; Rep. gr. 44 .
2. General information 3
3 Repair instructions
⇒ “3.1 General repair instructions”, page 4
⇒ “3.2 Steering box”, page 4
⇒ “3.3 Gaskets and seals”, page 4
⇒ “3.4 Nuts and bolts”, page 5
⇒ “3.5 Electrical components”, page 5
⇒ “3.6 Lifting suspension to kerb weight position (vehicles with
coil springs)”, page 5
3.1 General repair instructions

Information for conversion of rear axle to Nivomat ⇒ page 220 .
Information for conversion to heavy-duty running gear
⇒ page 220 .
3.2 Steering box

To achieve the desired results when performing repairs on the
steering rack it is important to work with the greatest possible care
and cleanliness, and to use proper tools in good condition. Also
note the basic rules on safety when performing repair procedures.
A number of general notes on the individual repair procedures,
which were otherwise repeated in the relevant sections of the
manual, are summarised here. They apply for this particular work‐
shop manual.
For a description of the design and function of the “APA” steering
system, see ⇒ Self-study programme No. 399 ; Electromechan‐
ical Steering with Parallel-axis Drive .
For a description of the design and function of the electrome‐
chanical power-assisted steering system, see ⇒ Self-study pro‐
gramme No. 317 ; Electromechanical Power-assisted Steering
with Double Pinion .
♦ Thoroughly clean all unions and the adjacent areas before
disconnecting.
♦ When installing the steering rack, make sure that dowel
sleeves between bracket and steering rack are seated cor‐
rectly.
♦ Place removed parts on a clean surface and cover them to
prevent them from getting dirty. Use sheeting and paper for
this purpose. Use only lint-free cloths.
♦ Fit only clean parts; remove new parts from their packaging
only immediately prior to fitting.
♦ Use only the grease and sealants with specified part numbers.
♦ If repairs cannot be carried out immediately, carefully cover or
seal open components.
3.3 Gaskets and seals

♦ Always renew oil seals and seals.
♦ After removing all seals, inspect the contact faces on housings
and shafts for burrs and damage and remove all which are
found.
♦ Completely remove all residue from liquid sealants from the
sealing surfaces, making sure that no residual sealant gets
into the steering rack housing.

3.4 Nuts and bolts

♦ Loosen and tighten bolts and securing nuts for covers and
housings diagonally.
♦ Avoid canting particularly sensitive parts such as control motor
with control unit. Loosen and tighten them diagonally in
stages.
♦ Specified torques given are for unlubricated nuts, bolts and
screws.
♦ Always renew self-locking nuts and bolts.
3.5 Electrical components

At some point, you have probably received an electric shock when
touching a metal object. This is due to the electrostatic charge
accumulated by the human body. This charge can cause mal‐
functions if you touch the electric steering rack and steering
column components.
– Before working on electrical components, touch an earthed
object, such as a water pipe or a lifting platform. Do not directly
touch connector contacts.
3.6 Lifting suspension to kerb weight posi‐

tion (vehicles with coil springs)
⇒ “3.6.1 Raising wheel bearing to unladen position (vehicles with
coil springs), front axle”, page 5
⇒ “3.6.2 Raising wheel bearing to unladen position on vehicles
with coil springs, rear axle, front-wheel drive”, page 9
⇒ “3.6.3 Raising wheel bearing to unladen position on vehicles
with coil springs, rear axle, four-wheel drive”, page 11
3.6.1 Raising wheel bearing to unladen position (vehicles with coil springs), front
axle
3. Repair instructions 5
Special tools and workshop

equipment required
♦ Engine and gearbox jack -
V.A.G 1383 A-
♦ Tensioning strap - T10038-
♦ Support - T10149-
Caution
All bolts on running gear components with bonded rubber

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

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

Before the respective wheel suspension is raised, the vehicle

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

vehicle will slip off the lifting platform!
– Turn wheel hub until one of the wheel bolt holes is at the top.
– Attach support - T10149- to wheel hub using wheel bolt.
Respective nuts and bolts may be tightened only when dimension

-a- between the centre of wheel hub and edge of wheel housing
has been attained.
The dimension -a- depends on the ride height of the installed run‐
ning gear:
Running gear 1) Ride height -a- in mm

Standard running gear (G02/ 383 ± 10 mm
G07/G11/G12/G15)
Standard running gear with fully 383 ± 10 mm
automatic ride height setting
(G02/G07/G15)
Standard running gear with 373 ± 10 mm
adaptive chassis control DCC
(G41)
Heavy-duty running gear (G04/ 403 ± 10 mm
G09)
Comfort heavy-duty running 393 ± 10 mm
gear (G05/G10/G16)
Sports running gear except 18" 368 ± 10 mm
wheels (G03/G08)
Sports running gear with 18" 368 ± 10 mm
wheels (G23/G28)
and 18" wheels (G41)
BlueMotion (G37/G38) 368 ± 10 mm
R36 (G36) 358 ± 10 mm
R36 with adaptive chassis con‐ 358 ± 10 mm
trol DCC (G46)
Raised running gear (G19/G50/ 398 ± 10 mm
G51/G52)
Passat Alltrack (G42/G43) 403 ± 10 mm
1)The type of running gear fitted to the vehicle is recorded on the
vehicle data sticker. The running gear is identified by the PR
number. Which PR No. is allocated to which running gear can be
found here ⇒ page 350 .
– Raise wheel bearing housing using engine and gearbox jack
- V.A.G 1383 A- until dimension -a- is attained.
WARNING
♦ Never raise or lower the vehicle while the engine and

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

– Lower wheel bearing housing.
– Pull engine and gearbox jack - V.A.G 1383 A- out from under
vehicle.
– Detach support - T10149- .

3.6.2 Raising wheel bearing to unladen position on vehicles with coil springs, rear
axle, front-wheel drive

equipment required
V.A.G 1383 A-
Note
All bolts on running gear components with bonded rubber bushes

may be tightened only when the component is in the unladen po‐
sition (normal position).

Axle components with bonded rubber bushes must therefore be
brought to a position equivalent to the unladen (normal) position
before being tightened.
To simulate this position on the lifting platform, raise the axle on
one side using the engine and gearbox jack - V.A.G 1383 A- and
support - T10149- .
Before the axle on one side is raised, both sides of the vehicle
must be strapped to the lifting platform arms with tensioning
straps - T10038- .
WARNING

– Attach support - T10149- with a wheel bolt.
Threaded connections may be tightened only when dimension
-a- between the centre of wheel hub and lower edge of wheel
housing, measured before starting work, has been attained.

Measuring dimension -a-

ning gear:

G07/G11/G12/G15)
(G02/G07/G15)
(G41)
G09)
gear (G05/G10/G16)
wheels (G03/G08)
wheels (G23/G28)
BlueMotion (G37/G38) 375 ± 10 mm
G51/G52)
Passat Alltrack 403 ± 10 mm
- V.A.G 1383 A- until dimension -a- is attained.
WARNING

♦ Do not leave the engine and gearbox jack under the ve‐
hicle for longer than necessary.

– Pull engine and gearbox jack out from underneath vehicle.
– Remove support - T10149- .
3.6.3 Raising wheel bearing to unladen position on vehicles with coil springs, rear
axle, four-wheel drive
Volkswagen Technical Site: http://vwts.ru http://vwts.info 3. Repair instructions 11


equipment required
V.A.G 1383 A-
Note
All bolts on running gear components with bonded rubber bushes

may be tightened only when the component is in the unladen po‐
sition (normal position).

Axle components with bonded rubber bushes must therefore be
brought to a position equivalent to the unladen (normal) position
before being tightened.
To simulate this position on the lifting platform, raise the axle on
one side using the engine and gearbox jack - V.A.G 1383 A- and
support - T10149- .

Before the axle on one side is raised, both sides of the vehicle
must be strapped to the lifting platform arms with tensioning
straps - T10038- .
WARNING

– Attach support - T10149- with a wheel bolt.
Threaded connections may be tightened only when dimension
-a- between the centre of wheel hub and lower edge of wheel
housing, measured before starting work, has been attained.
Measuring dimension -a-

ning gear:

G07/G11/G12/G15)
(G02/G07/G15)
(G41)
G09)
gear (G05/G10/G16)
wheels (G03/G08)
wheels (G23/G28)
R36 (G36) 358 ± 10 mm
R36 with adaptive chassis con‐ 358 ± 10 mm
trol DCC (G46)
G51/G52)
until dimension -a- is attained.
WARNING

♦ Do not leave the engine and gearbox jack under the ve‐
hicle for longer than necessary.

– Pull engine and gearbox jack out from underneath vehicle.
– Remove support - T10149- .

40 – Front suspension
1 Front axle
⇒ “1.1 Overview - front axle”, page 15
1.1 Overview - front axle
Note
♦ It is not permitted to carry out welding and straightening operations on load-bearing or wheel-guiding sus‐
pension components.
♦ Always renew self-locking nuts.
♦ Always renew corroded nuts and bolts.
♦ Bonded rubber bushes can be twisted only to a limited extent. Therefore, tighten the bolted connections of
components with bonded rubber bushes only when the wheel bearing housing has been raised (unladen
state) ⇒ page 5 .
I-
⇒ “2.1 Assembly overview -
subframe”, page 17
II -
lower suspension link, swivel
joint”, page 69
III -
wheel bearing”, page 90
1. Front axle 15
IV -
⇒ “2.2 Assembly overview - an‐
ti-roll bar”, page 19
V-
⇒ “3.1.1 Assembly overview -
suspension strut, upper sus‐
pension link, basic version”,
page 49
V-
suspension strut, upper sus‐
pension link, suspension strut
for adaptive chassis control
DCC”, page 50
⇒ “6.1 Overview - drive shaft”, page 99

⇒ “6.3 Removing and installing jointed shaft”, page 107
16 Rep. gr.40 - Front suspension

2 Subframe
⇒ “2.1 Assembly overview - subframe”, page 17
⇒ “2.2 Assembly overview - anti-roll bar”, page 19
⇒ “2.3 Removing and installing subframe without steering rack”,
page 20
⇒ “2.4 Removing and installing subframe with steering rack”, page
24
⇒ “2.5 Repairing subframe”, page 29
⇒ “2.6 Removing and installing anti-roll bar”, page 37
⇒ “2.7 Repairing thread in longitudinal member”, page 42
⇒ “2.8 Fixing position of subframe”, page 42
⇒ “2.9 Lowering subframe”, page 44
2.1 Assembly overview - subframe
Caution
1 - Subframe
❑ Fixing position
⇒ page 42
❑ Lowering ⇒ page 44
❑ Removing and installing
without steering rack
⇒ page 20
with steering rack
⇒ page 24
❑ Various versions
❑ Allocation ⇒ Electronic
parts catalogue “ETKA”
2 - Adapter
3 - Mounting bracket
❑ Fixing position
⇒ page 44
❑ With bonded rubber
bush
4 - Bolt
❑ M10 x 70
❑ 50 Nm + 90° further
❑ Renew after removing
5 - Bolt
❑ M12 x 1.5 x 100: 70 Nm
and turn 180° further
6 - Suspension link
❑ If damaged, also renew
swivel joint.
2. Subframe 17
⇒ page 71 .
❑ Renew mounting ⇒ page 86
❑ Different versions of suspension links are possible (cast steel, sheet steel, aluminium).
❑ Allocation ⇒ Electronic parts catalogue “ETKA”
Note
A mixed installation of suspension

links of different types or made of
different materials is not permissi‐
ble.
7 - Bolt
❑ M12 x 1.5 x 90
8 - Bolt
❑ M14 x 1.5 x 70
❑ Do not tighten until pendulum support is bolted to gearbox
9 - Bolt
❑ M10 x 75: 50 Nm and turn 90° further
❑ M12 x 1.5 x 85: 60 Nm and turn 90° further
10 - Bolt
❑ M10 x 35: 50 Nm and turn 90° further
❑ M12 x 1.5 x 50: 60 Nm and turn 90° further
11 - Lower bonded rubber bush for pendulum support
❑ Pressing out and in ⇒ page 29
❑ Different versions ⇒ page 19
12 - Pendulum support
❑ Bolt first to gearbox and then to subframe
13 - Upper bonder rubber bush for pendulum support
❑ Pressing out and in ⇒ page 29
❑ Different versions ⇒ page 19
14 - Bolt
❑ M12 x 1.5 x 110
❑ Tighten only in unladen state ⇒ page 5
15 - Bolt
❑ M12 x 1.5 x 100

Distinguishing characteristics of bonded rubber bushes for pen‐

dulum support
Note
♦ There are 2 different types of bonded rubber bushes for pen‐

dulum supports: the T version -I- and the V version -II-.
♦ They are allocated by means of the ⇒ Electronic parts cata‐
logue “ETKA” .
I - The corners of the inner core -1- point towards the opening for
pendulum support -arrow- (T version)
II - The corners of the inner core -2- point away from the opening
for pendulum support -arrow- (V version)
2.2 Assembly overview - anti-roll bar
1 - Anti-roll bar
⇒ page 37 .
2 - Coupling rod
❑ Link between anti-roll
bar and suspension
strut
3 - Nut
❑ 65 Nm
4 - Subframe
5 - Bolt
2. Subframe 19
2.3 Removing and installing subframe with‐

out steering rack
Special tools and workshop equipment required
♦ Torque wrench - V.A.G 1331-
Carry out the following work:

Removing
Note
The subframe is removed together with the suspension links.
– Loosen wheel bolts.

– Raise vehicle.
– Remove wheels.
– Remove lower noise insulation ⇒ General body repairs, ex‐
terior; Rep. gr. 66 ; Noise insulation; Assembly overview -
noise insulation .
– Remove nuts -arrows-.
– Pull swivel joint out of suspension link.

– Detach exhaust system bracket from subframe -arrows-.
– Remove hexagon nut -1- from coupling rod -3- (left and right
sides).
– Pull out coupling rod -3- from anti-roll bar -2- on left and right
side.
– Disconnect pendulum support from gearbox by removing bolts

-14-.
– Fix position of subframe ⇒ page 42 .
2. Subframe 21
– Remove bolts for steering rack -5- and -6-.
– Remove bolts -7- and -8- for anti-roll bar.
– Remove bolts -9- and -10- for subframe.

– Lower subframe with engine and gearbox jack - V.A.G 1383
A- .

– Remove cable guide from subframe -arrow-.

– Secure steering rack to body.
Installing
Install in reverse order. Note the following points:
– Always make sure that intermediate plate -1- is inserted be‐

tween subframe -2- and body.
– Fit wheels, torque setting ⇒ page 320 .
– Install noise insulation and tighten bolts. Specified torques ⇒
General body repairs, exterior; Rep. gr. 66 ; Noise insulation;
Assembly overview - noise insulation .
Specified torques
Component Specified torque
Anti-roll bar to subframe 20 Nm + 90° further
♦ Use new bolts
Anti-roll bar to coupling rod 65 Nm

♦ Use new nut
♦ Counterhold on multi-point socket of joint pin
Steering box to subframe 50 Nm + 90° further

♦ Use new bolts
Swivel joint to cast steel suspension link 60 Nm

♦ Use new nuts
♦ Tighten only in unladen state ⇒ page 5
Swivel joint to sheet steel or forged aluminium suspension 100 Nm

link
♦ Use new nuts
Exhaust system bracket to subframe

⇒ Rep. gr. 26 ; Exhaust pipes/silencers; Assembly overview - silencer .
Specified torques, subframe to body

Bolt Specified torque
M12 x 1.5 x 90 70 Nm + 180° further
♦ Use new bolts
2. Subframe 23

M12 x 1.5 x 100 70 Nm + 180° further
♦ Use new bolts
Specified torques for pendulum support to gearbox

M10 x 35 50 Nm + 90° further
♦ Use new bolt
M10 x 75 50 Nm + 90° further

♦ Use new bolt
M12 x 1.5 x 85 ; M12 x 1.5 x 50 60 Nm + 90° further

♦ Use new bolt
2.4 Removing and installing subframe with

steering rack
♦ Ball joint puller - T10187-


Removing
– Disconnect cable -1- from electrics box.
– Separate connection -1-.

– Unscrew cap nut -arrow- and remove earth cable.
– Remove wiring harness from bracket on longitudinal member
so that it can be removed together with the steering rack.
– Unscrew nuts -1- and remove footwell trim -2-.
2. Subframe 25
– Unscrew bolt -arrow- from universal joint -1- and pull off uni‐
versal joint in -direction of arrow-.
Caution
The following work must not be performed while the universal

joint is separated from the steering rack:
♦ Switching on ignition
♦ Turning the steering rack
♦ Turning the steering column
Not adhering to these instructions will result in irreparable
damage.

– Raise vehicle.
– Remove front wheels.
noise insulation .
– Pull connector off oil level and temperature sender - G266- on
sump and pull wiring off subframe.
sides).
side.

Right-hand drive (RHD)

– If fitted, unclip line -1- from bracket -arrow- on heat shield
above steering rack.
Continuation for all vehicles

– Loosen nut on track rod ball joint but do not remove complete‐
ly.
Caution
Leave nut screwed on a few turns to protect thread on pin.
– Push track rod ball joint off wheel bearing housing and remove
nut.
1- Ball joint puller - T10187-

-14-.
– Fix position of subframe with brackets. ⇒ page 42
2. Subframe 27
– Position
engine and gearbox jack - V.A.G 1383 A- -1- under subframe.
– Remove bolts -9- and -10- and lower subframe with engine
and gearbox jack - V.A.G 1383 A- .
– Secure subframe to engine and gearbox jack - V.A.G 1383 A-

with the appropriate strap.
Installing

– Install battery tray and battery ⇒ Electrical system; Rep. gr.
27 ; Battery; Removing and installing battery .
– Install noise insulation and tighten bolts. Specified torques ⇒
General body repairs, exterior; Rep. gr. 66 ; Noise insulation;
Assembly overview - noise insulation .

Specified torques
♦ Use new nut
Track rod ball joint to wheel bearing housing Tighten to 100 Nm, then loosen (turn back) 180°
♦ Use new nut and retighten to 100 Nm

♦ Use new nuts

link
♦ Use new nuts
Universal joint to steering rack 20 Nm + 90° further

♦ Use new bolt


M12 x 1.5 x 90 70 Nm + 180° further
♦ Use new bolts
M12 x 1.5 x 100 70 Nm + 180° further

♦ Use new bolts

M10 x 35 50 Nm + 90° further
♦ Use new bolt
M10 x 75 50 Nm + 90° further

♦ Use new bolt

♦ Use new bolt
2.5 Repairing subframe
Volkswagen Technical Site: http://vwts.ru http://vwts.info 2. Subframe 29


equipment required
♦ Assembly tool - T10205-
♦ Torque wrench - V.A.G
1332-
♦ Hydraulic press - VAS
6178-
♦ Foot pump - VAS 6179-
♦ Assembly tool - VAS 6779-
♦ Thrust plate - VW 401-

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

– Remove front noise insulation ⇒ General body repairs, exte‐
rior; Rep. gr. 50 ; Noise insulation; Assembly overview - noise
insulation .
sides).
side.
– Remove bolts -7- and -8- for anti-roll bar.

• Leave the anti-roll bar in its installation position in the vehicle.
2. Subframe 31
– Remove bolt -1-.

– Remove bolts -2- and -3-.
– Remove pendulum support.
Pressing out bonded rubber bush

– Fit assembly tool - VAS 6779- to subframe as shown in illus‐
tration.
– Place thrust piece for removal - VAS 6779-1- -1- on bonded
rubber bush so that flattened side -arrow- faces to direction of
travel.
1 - Thrust piece for removal - VAS 6779/1-

2 - Tube - VAS 6779/4- , with small outside diameter facing sub‐

frame
3 - Thrust piece - VAS 6779/5-
4 - Hydraulic press - VAS 6178- and thrust piece - T10205/13-
5 - Hexagon nut - VAS 6779/3-
6 - Threaded spindle - VAS 6779/2-
– Press out both bonded rubber bushes until upper bonded rub‐
ber bush -2- is visible in pendulum support opening -arrow- in
subframe.
– Carry out visual check of outer ring of upper bonded rubber
bush -2-.
• If outer ring of upper bonded rubber bush -2- is deformed, de‐
stroy it through opening of pendulum support -arrow- in pen‐
dulum support.
– Using a chisel or similar -1-, create a break in the outer ring of
the upper bonded rubber bush -2-.
Note
This process is necessary to prevent the canting of the outer ring

of the upper bonded rubber bush in the area of the opening of the
pendulum support in the subframe.
– Press out both bonded rubber bushes together.

Preparing bonded rubber bush for pressing in
Note
♦ There are two different types of bonded rubber bushes for

pendulum supports: the T version -I- and the V version -II-.
♦ They are allocated by means of the ⇒ Electronic parts cata‐
logue “ETKA” .
I - The corners of the inner core -1- point towards the opening for
pendulum support -arrow- (T version)
II - The corners of the inner core -2- point away from the opening
for pendulum support -arrow- (V version)
2. Subframe 33
– Place both bonded rubber bushes -1- and -2- together so that
the cut-outs -arrows- line up precisely.
– Bolt bonded rubber bushes -1- and -2- hand-tight together us‐
ing original bolt -3-.
– Insert bonded rubber bushes -1- into larger diameter of tube -

VAS 6779/6- -2- with bolt head facing upwards.
– Align bonded rubber bushes -1- in tube - VAS 6779/6- -2-. The
cut-out in the bonded rubber bush must align exactly with the
recess -arrow- in the tube - VAS 6779/6- -2-.
– Press in bonded rubber bush -3- in tube - VAS 6779/6- to stop,

as illustrated.
1- Press tool - VW 412-
2- Thrust piece - VAS 6779/5- , the side with the lettering »A«
must face upwards.
3- Bonded rubber bush
4- Tube - VAS 6779/6-
5- Tube - VAS 6779/4-
6- Thrust plate - VW 401-
– Remove bolt from bonded rubber bush.
– Fit counterhold - VAS 6779/7- -1- from the left in

-direction of arrow- on subframe -2-.

– Insert counterhold attachment - VAS 6779/7-1A- -1- into pen‐

dulum support opening in subframe.
– Bolt insert - VAS 6779/7-1A- to counter support - VAS 6779/7-
-2- using bolt -arrow-.
– Ensure that the insert - VAS 6779/7-1A- -1 - is correctly seated
in the pendulum support opening of the subframe -arrow-.
Pressing in bonded rubber bush

– Screw threaded spindle - VAS 6779/2- -7- into counterhold -
VAS 6779/7- -1-
– Fit assembly tool - VAS 6779- to subframe as shown in illus‐
tration.
2. Subframe 35
1 - Counterhold - VAS 6779/7-

2 - Tube - VAS 6779/6- : -arrow mark- on tube must be centred
between the two bolts -arrow-.
3 - Thrust piece - VAS 6779/9-
4 - Stepped ring - VAS 6779/8- : the mark -IIII- on stepped ring
must face lug -arrow B- on thrust piece - VAS 6779/9- .
6 - Hexagon nut - VAS 6779/3-
7 - Threaded spindle - VAS 6779/2-
– Press in both bonded rubber bushes together.
– Remove assembly tool - VAS 6779- from subframe and check
pressed-in bonded rubber bushes for proper seating.
– Bolt anti-roll bar to subframe and coupling rods.

– Insert pendulum support.

– Screw in bolts -2- and -3- and tighten.
– Screw in and tighten bolt -1-.
– Install front noise insulation ⇒ General body repairs, exterior;
Rep. gr. 50 ; Noise insulation; Assembly overview - noise in‐
sulation .
Specified torques
Pendulum support to gearbox M10 x 35 50 Nm + 90° further
♦ Use new bolt
Pendulum support to gearbox M10 x 75 50 Nm + 90° further

♦ Use new bolt
Pendulum support to gearbox M12 x 1.5 x 50 60 Nm + 90° further

♦ Use new bolt
Pendulum support to gearbox M12 x 1.5 x 85 60 Nm + 90° further

♦ Use new bolt
Pendulum support to subframe M14 x 1.5 x 70 100 Nm + 90° further

♦ Use new bolt
♦ Do not tighten until pendulum support is bolted to gear‐
box

♦ Use new nut
Anti-roll bar to subframe 20 Nm + 90°

♦ Use new bolts
2.6 Removing and installing anti-roll bar

2. Subframe 37

Removing
– Raise vehicle.
Caution

damage.

noise insulation .

– Remove hexagon nut -1- from coupling rod (left and right
sides).
– Remove nuts -arrows- on left and right sides of vehicle.
ly.
Caution
nut.
– Fixing position of subframe with brackets ⇒ page 42 .
– Unbolt anti-roll bar from subframe -7- and -8-

.
2. Subframe 39

-14-.
– Position engine and gearbox jack - V.A.G 1383 A- -1- under

subframe

– Remove bolts -9- and -10- and lower subframe slightly. Ob‐
serve electrical wiring.
– Push anti-roll bar to right as seen in direction of travel.
– Lift anti-roll bar -1- forwards over subframe -2- and down while
turning anti-roll bar slightly.
Installing
Install in reverse order.
– Install lower noise insulation ⇒ General body repairs, exterior;
sulation .
Note
♦ Coat seal on steering rack with suitable lubricant, e.g. soft

soap, before installing steering rack.
♦ After fitting the steering rack to the drive shaft ensure that the
seal is not kinked against the assembly plate on the steering
rack. The opening to the footwell must be sealed correctly.
Otherwise, this can result in water leaks and/or noise.
♦ Ensure sealing surfaces are clean.
Specified torques
♦ Use new nuts

link
♦ Use new nuts

♦ Use new nut
Suspension link to subframe 70 Nm + 180° further

♦ Use new bolt
♦ Tighten bolt in unladen state
2. Subframe 41

♦ Use new bolts

♦ Use new bolt


M12 x 1.5 x 90 70 Nm + 180° further
♦ Use new bolts
M12 x 1.5 x 100 70 Nm + 180° further

♦ Use new bolts

M10 x 35 50 Nm + 90° further
♦ Use new bolt
M10 x 75 50 Nm + 90° further

♦ Use new bolt

♦ Use new bolt
– After installing, perform basic settings for steering angle send‐

er - G85- ⇒ Vehicle diagnostic tester.
2.7 Repairing thread in longitudinal member

Repairing the thread in captive nuts in the longitudinal member is
possible only under certain conditions ⇒ Body Repairs; Rep. gr.
50 .
2.8 Fixing position of subframe


♦ Locating pins - T10096-
♦ Engine and gearbox jack - V.A.G 1383 A-

Installing locating pins - T10096-
To fix position of subframe, locating pins - T10096- must be
screwed one after the other into positions -1-, -2-, -3- and -4-.
Caution
The locating pins - T10096- may be tightened only to a maxi‐

mum of 20 Nm; otherwise the threads of the locating pins may
be damaged.
2. Subframe 43
Fixing position of mounting bracket

– Replace securing bolts on mounting bracket with locating pins
- T10096- one after the other on both sides of the vehicle and
tighten to 20 Nm.
Fixing position of subframe

– Replace the front bolts on subframe one after the other with
locating pins - T10096- and tighten them to 20 Nm.
The position of the front axle is now fixed.
Continue with removal of anti-roll bar ⇒ page 39 .
Continue with removal of steering rack, left-hand drive
⇒ page 412 .
Continue with removal of subframe without steering rack
⇒ page 22 .
Continue with removal of subframe with steering rack
⇒ page 28 .
Removing locating pins - T10096-
Remove in reverse order. Ensure that the locating pins - T10096-
are replaced one after the other with new bolts.

M12 x 1.5 x 90 70 Nm + 180° further
♦ Use new bolts
M12 x 1.5 x 100 70 Nm + 180° further

♦ Use new bolts
2.9 Lowering subframe



Removing
– Turn steering wheel to straight-ahead position and remove ig‐
nition key so that the electronic steering column lock engages.
Caution

damage.

noise insulation .
2. Subframe 45

-14-.
sides).
side.
Right-hand drive (RHD)


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

frame.
– Remove bolts -9- and -10- and lower subframe a maximum of

10 cm.
Note
Be sure to observe electrical wires to avoid overstretching them.
Installing

sulation .
Note
Ensure that bellows are not damaged or twisted.
Specified torques
♦ Use new nut

♦ Use new bolt

2. Subframe 47

M12 x 1.5 x 90 70 Nm + 180° further
♦ Use new bolts
M12 x 1.5 x 100 70 Nm + 180° further

♦ Use new bolts

M10 x 35 50 Nm + 90° further
♦ Use new bolt
M10 x 75 50 Nm + 90° further

♦ Use new bolt

♦ Use new bolt

3 Suspension strut, upper suspension

link
⇒ “3.1 Assembly overview - suspension strut, upper suspension
link”, page 49
⇒ “3.2 Removing and installing suspension strut”, page 52
⇒ “3.3 Repairing suspension strut”, page 67
3.1 Assembly overview - suspension strut,

upper suspension link
⇒ “3.1.1 Assembly overview - suspension strut, upper suspension
link, basic version”, page 49
⇒ “3.1.2 Assembly overview - suspension strut, upper suspension
link, suspension strut for adaptive chassis control DCC”,
page 50
3.1.1 Assembly overview - suspension strut, upper suspension link, basic version
1 - Nut
❑ 60 Nm
❑ Self-locking
2 - Suspension strut mounting
❑ Note correct installation
position ⇒ page 57
3 - Deep groove ball thrust
bearing
4 - Coil spring
⇒ page 68 .
❑ Observe colour coding
❑ Surface of coil must not
be damaged.
5 - Protective sleeve
6 - Bump stop
7 - Shock absorber
❑ Can be renewed sepa‐
rately
3. Suspension strut, upper suspension link 49

3.1.2 Assembly overview - suspension strut, upper suspension link, suspension

strut for adaptive chassis control DCC
1 - Shock absorber with front

left shock absorber damper
adjustment valve - N336-
❑ Can be renewed sepa‐
rately
2 - Bump stop
3 - Protective sleeve
4 - Coil spring
⇒ page 59 .
❑ Observe colour coding
Spring allocation via PR No.
These numbers are located on

the vehicle data sticker.
❑ Surface of coil must not
be damaged.
5 - Deep groove ball thrust
bearing
6 - Suspension strut mounting
❑ Note correct installation
7 - Hexagon nut
❑ 60 Nm
❑ Self-locking
Volkswagen Technical Site: http://vwts.ru http://vwts.info
8 - Suspension strut turret
9 - Bracket
❑ For front left body acceleration sender - G341-
❑ Removing and installing ⇒ page 306 .
❑ An “L” is punched into bracket
Note
Make sure to use correct bracket.
10 - Front left body acceleration sender - G341-

❑ Note installation position on bracket ⇒ Item 9 (page 50) ⇒ page 51
11 - Bolt
❑ 5 Nm

12 - Bolt
13 - Bracket
❑ For front right body acceleration sender - G342-
❑ An “R” is punched into bracket
14 - Front right body acceleration sender - G342-
❑ Note installation position on bracket ⇒ Item 13 (page 51) ⇒ page 51
15 - Nut
❑ 5 Nm
Installation position front left body acceleration sender - G341- on

bracket
Retaining lug -1- must engage in recess in front left body accel‐
eration sender - G341- -arrow-.
Note
Make sure to use correct bracket. An “L” is punched into bracket.
Installation position front right body acceleration sender - G342-

on bracket
Retaining lug -1- must engage in recess in front right body accel‐
Note
Make sure to use correct bracket. An “R” is punched into bracket.

3.2 Removing and installing suspension

strut
⇒ “3.2.1 Removing and installing suspension strut, basic version”,
page 52
⇒ “3.2.2 Removing and installing suspension strut, suspension
strut for adaptive chassis control DCC”, page 59
3.2.1 Removing and installing suspension strut, basic version

equipment required
♦ Spreader - 3424-
1332-
V.A.G 1383 A-

♦ Remover - T10520-
Removing
– Loosen drive shaft bolt at wheel hub:
♦ Twelve-point head bolt with ribbing ⇒ page 114
♦ Twelve-point head bolt without ribbing ⇒ page 116
Caution
Wheel bearings must not be subjected to load after bolt secur‐

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

– Raise vehicle.
– Remove wheel.
– Unscrew nut -arrow- and pull coupling rod -1- off suspension
strut.


– Pull wheel bearing housing with swivel joint out of suspension
link.
– Pull outer joint of drive shaft out of wheel hub.
If drive shaft cannot be pulled out of the wheel bearing by hand,
use ejector - T10520- .
Before using ejector - T10520- ensure that thrust piece -1- is in‐
serted.
Using ejector - T10520- :

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

– It is essential to follow specified sequence.

I - Tighten knurled nut -1- hand-tight.
II - Turn only bolt -2- using a spanner in order to press out drive
shaft using ejector - T10520- .
Note
At the end of the procedure or for pressing out drive shaft further
the spindle must be moved to its original position in order to de‐
ploy the hydraulic force!
– Secure drive shaft to body with wire.
Caution
Do not allow the drive shaft to hang down under its own weight,
for this would allow the inner joint to bend too far and be dam‐
aged.
– Bolt swivel joint to suspension link again.
– Use wheel bolt to attach engine and gearbox jack - V.A.G 1383
A- with support - T10149- to wheel hub.
WARNING
♦ Do not lift or lower vehicle while engine and gearbox jack

- V.A.G 1383 A- is under vehicle. The vehicle could slip off
the lifting platform.
– Separate threaded connection between wheel bearing hous‐

ing and suspension strut -arrow-.

– Insert spreader - 3424- in slot in wheel bearing housing.

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

– Remove wiper motor ⇒ Electrical system; Rep. gr. 92 ; Wind‐

screen wiper system; Removing and installing wiper motor .
– Remove hexagon bolts -arrows- for upper shock absorber

mounting and remove suspension strut.
Installing
– Place suspension strut on wheel bearing housing and fix in
place with the multi-point socket head bolt and a new nut.
The tip of the multi-point socket head bolt must point in the direc‐
tion of travel.
– Remove spreader - 3424- .

– Position suspension strut so that the two markings -arrows-

are always on the inner side.
– One of the two markings -arrows- must point in direction of
travel.
– Untie wheel bearing housing from subframe.
– Carefully raise wheel bearing housing with the gearbox jack

until bolts for connecting suspension strut to strut turret
-arrows- can be inserted.
If necessary, use a ladder, e.g. step ladder - VAS 5085- , to insert
the bolts.
– Tighten hexagon bolts -arrows- for upper shock absorber
mounting.
– Tighten threaded connection between wheel bearing housing

and suspension strut -arrow-

– Fit drive shaft in wheel hub.
– Fit wheel bearing housing with swivel joint in suspension link.

– Bolt swivel joint to suspension link -arrows-.
Note
– Tighten drive shaft bolt at wheel hub:

Caution
During this step, vehicle must not be standing on its wheels.

The wheel bearing can be damaged by the weight of the vehi‐
cle if the bolt is loosened.
Distinguishing features between twelve-point head bolt with rib‐

bing and twelve-point head bolt without ribbing.
The twelve-point head bolts can be distinguished by the contact
surfaces -arrow A- and -arrow B-.
I - Twelve-point head bolt with ribbing -arrow A-
II - Twelve-point head bolt without ribbing -arrow B-
– Install wiper motor ⇒ Electrical system; Rep. gr. 92 ; Wind‐
Continue installation in reverse order.
– Install wheel and tighten bolts or nuts ⇒ page 320 .
Specified torques
Suspension strut to wheel bearing housing 70 Nm + 90° further
♦ Use new nut
Suspension strut to body (suspension turret) 15 Nm + 90° further

♦ Use new bolts

♦ Use new nuts

link
♦ Use new nuts
Coupling rod to suspension strut 65 Nm

♦ Use new nut
Drive shaft to wheel hub “twelve-point head bolt with rib‐ 70 Nm + 90°
bing”
♦ Use new bolt


Drive shaft to wheel hub “twelve-point head bolt without 200 Nm + 180°
ribbing”
♦ Use new bolt
3.2.2 Removing and installing suspension strut, suspension strut for adaptive
chassis control DCC

equipment required
1332-
V.A.G 1383 A-


Removing
– Loosen drive shaft bolt at wheel hub ⇒ page 114 .
Caution


– Raise vehicle.
– Remove wheel.

– Unscrew hexagon nut -arrow- of coupling rod from suspension

strut.
– Detach wire for speed sensor from suspension strut.
– Unscrew vehicle level sender from suspension link.

link.
serted.



Note
Caution
Do not allow the drive shaft to hang down under its own weight,
for this would allow the inner joint to bend too far and be dam‐
aged.
– Bolt swivel joint to suspension link again.
WARNING
♦ Do not lift or lower vehicle while engine and gearbox jack

- V.A.G 1383 A- is under vehicle. The vehicle could slip off
the lifting platform.

– Separate threaded connection between wheel bearing hous‐

ing and suspension strut -arrow-.
– Insert spreader -3424- into slot of wheel bearing housing.

3424- .
– Press brake disc towards suspension strut by hand.
Note
Otherwise the shock absorber tube can cant in the bore of the
– Pull wheel bearing housing downwards off shock absorber

tube and lower with engine and gearbox jack - V.A.G 1383 A-
until shock absorber tube is free.
– Secure wheel bearing housing to bracket/subframe with bind‐
ing wire.
WARNING

– Remove wiper motor ⇒ Electrical system; Rep. gr. 92 ; Wind‐

– Remove hexagon bolts -arrows- for upper shock absorber

mounting and remove suspension strut.
Installing

– Place suspension strut on wheel bearing housing and fix sus‐
pension strut in place with the multi-point socket head bolt and
a new nut.
The tip of the multi-point socket head bolt must point in the direc‐
tion of travel.
– Remove spreader - 3424- .
Insert spring plate with one of the two markings -arrows- pointing
in direction of travel.
Left suspension strut

Suspension strut must be inserted so that front left shock absorb‐
er damper adjustment valve - N336- points opposite to direction
of travel.
Right suspension strut

Suspension strut must be inserted so that front right shock ab‐
sorber damper adjustment valve - N337- points in direction of
travel.
Continuation for both sides

– Check installation position of bracket for front left/right body

acceleration sender - G341/G342- .
Note
♦ Use an 11 mm drill bit with -1- and drift - VW 222 A- for check‐
ing installation position.
♦ The holes in the bracket must line up with the holes in the
shock absorber tower.
– Remove wire on wheel bearing housing.
– Carefully raise wheel bearing housing with the gearbox jack

until bolts for connecting suspension strut to strut turret can be
inserted.
If necessary, use a ladder, e.g. step ladder - VAS 5085- , to insert
the bolts.
– Tighten hexagon bolts for upper shock absorber mounting.
– Tighten threaded connection between wheel bearing housing

and suspension strut -arrow-


– Fit wheel bearing housing with swivel joint in suspension link.
Note
– Screw vehicle level sender onto suspension link.
Note
♦ Lever on vehicle level sender must face towards outside of

vehicle.
♦ Thread of vehicle level sender must be screwed into front hole
in suspension link. Retaining lug for vehicle level sender must
engage in rear hole in order to guarantee correct installation
position.
– Push plug onto front left/right shock absorber damper adjust‐

ment valve - N336/N337- .
– Tighten drive shaft bolt at wheel hub ⇒ page 114 .
Note
During this step, vehicle must not be standing on its wheels or

wheel bearing will be damaged.
– Install wiper motor ⇒ Electrical system; Rep. gr. 92 ; Wind‐

– Fit wheel, torque setting ⇒ page 320 .
Specified torques
♦ Use new nut

♦ Use new bolts

♦ Use new nuts

link
♦ Use new nuts


Coupling rod to suspension strut 65 Nm
♦ Use new nut
Drive shaft to hub 70 Nm + 90° further

♦ Use new bolt
Vehicle level sender to suspension link 9 Nm
3.3 Repairing suspension strut

equipment required
1332-
♦ Spring compressor - V.A.G
1752/1-
♦ Spring retainer - V.A.G
1752/4-
♦ Strut support clamp - V.A.G
1752/20-
♦ Shock absorber set -
T10001-
♦ Commercially available
ratchet handle

– Remove coil spring strut ⇒ page 52 .

Removing coil spring

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

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

V.A.G 1752/4- -arrow-.
– Unscrew hexagon nut from piston rod.
– Remove individual components of suspension strut and coil
spring with spring compressor - V.A.G 1752/1- .
Install coil spring.
– Fit coil spring with spring compressor - V.A.G 1752/1- onto
lower spring support.
The end of the coil spring must lie against the stop -arrow-.
– Tighten new hexagon nut on piston rod.
– Relieve tension on spring compressor - V.A.G 1752/1- and
remove from coil spring.
– Install suspension strut ⇒ page 56 .
Specified torque
Suspension strut mounting to shock absorber 60 Nm
♦ Use new nut

4 Lower suspension link, swivel joint

⇒ “4.1 Assembly overview - lower suspension link, swivel joint”,
page 69
⇒ “4.2 Removing and installing lower suspension link”,
page 71
⇒ “4.3 Renewing mounting bracket with suspension link bush”,
page 80
⇒ “4.4 Checking swivel joint”, page 82
⇒ “4.5 Removing and installing swivel joint”, page 82
⇒ “4.6 Renewing bonded rubber bush for lower suspension link”,
page 86
4.1 Assembly overview - lower suspension link, swivel joint
Note
pension components.
components with bonded rubber bushes only when the wheel bearing housing has been raised (unladen
state) ⇒ page 5 .
4. Lower suspension link, swivel joint 69

1 - Bolt
2 - Front body
3 - Suspension strut
⇒ page 52 .
4 - Nut
❑ 65 Nm
5 - Multi-point socket head bolt
❑ Tip of bolt must point in
direction of travel
6 - Nut
7 - Swivel joint
❑ Checking ⇒ page 82
⇒ page 82 .
❑ Renew together with
suspension link if sus‐
pension link is damaged
8 - Wheel bearing housing
⇒ page 92 .
❑ If wheel bearing housing
is renewed, wheels
must be aligned
⇒ page 347
9 - Nut
❑ For cast steel suspension link: 60 Nm
❑ For sheet steel and forged aluminium suspension link: 100 Nm
❑ Self-locking
❑ Tighten only in unladen state ⇒ page 5
10 - Suspension link
❑ If damaged, also renew swivel joint.
❑ Renew mounting ⇒ page 86
❑ Different versions of suspension links are possible (cast steel, sheet steel, aluminium).
Note
A mixed installation of suspension

links of different types or made of
different materials is not permissi‐
ble.

11 - Bonded rubber bush

12 - Nut
❑ Self-locking
❑ Fixing position ⇒ page 44
❑ With bonded rubber bush
14 - Coupling rod
4.2 Removing and installing lower suspen‐

sion link
⇒ “4.2.1 Removing and installing lower suspension link, suspen‐
sion link with mounting bracket”, page 71
⇒ “4.2.2 Removing and installing lower suspension link, left side
of vehicle, for vehicles with automatic or dual clutch gearbox”,
page 74
4.2.1 Removing and installing lower suspen‐

sion link, suspension link with mounting
bracket

Removing

– Raise vehicle.
– Remove wheel.
noise insulation .
– If present, unscrew coupling rod of front left vehicle level send‐
er - G78- from suspension link.
– Pull suspension link out of swivel joint and turn wheel bearing
housing to outside to relieve suspension link.
– Fix position of mounting bracket ⇒ page 44 .
– Replace bolt for left side -1- or for right side -2- with locating
pins - T10096- and tighten locating pins to 20 Nm.
Caution
The locating pins - T10096- may be tightened only to a maxi‐

mum of 20 Nm; otherwise the threads of the locating pins may
be damaged.
– Now remove bolt -11- for left side and bolt -12- for right side.
– Remove bolts -1-.

– Remove suspension link with mounting bracket.
Installing
– Insert suspension link with mounting bracket into subframe.

– Start bolts -11- and -12- but do not tighten.
– Start bolt -1- and tighten.

– Replace locating pins - T10096- by a new bolt and tighten this.
– Bolt suspension link to swivel joint and tighten -arrows-.

– Bolt transverse link to subframe -11- and -12- in unladen state

⇒ page 5 .
sulation .
– Attach wheel and tighten; specified torque ⇒ page 320 .
Specified torques
Mounting bracket to body 70 Nm + 180° further
♦ Use new bolts
Mounting bracket to subframe 50 Nm + 90° further

♦ Use new bolts

♦ Use new nuts

link
♦ Use new nuts

♦ Use new bolt
♦ Tighten bolt in unladen state
Coupling rod for front left vehicle level sender - G78- to 9 Nm

suspension link
4.2.2 Removing and installing lower suspen‐

sion link, left side of vehicle, for vehicles
with automatic or dual clutch gearbox


Removing
nition key so that the steering lock engages.
Vehicles with keyless locking and starting system “Keyless Ac‐
cess”
– Switch off ignition and open driver's door so that the steering
lock engages.

Caution

damage.

– Raise vehicle.
– Remove front left wheel.
noise insulation .

-14-.

sides).
– Loosen bolt -12-.

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

subframe

– Remove bolts -9- and -10- and lower subframe as far as nec‐
essary.
Note
Be sure to observe electrical wiring.
– Remove bolt -12- and remove suspension link from subframe.

Installing


Note
♦ Ensure proper seating of dowel sleeves for steering rack in

suspension bracket.
♦ Ensure that bellows are not damaged or twisted.

sulation .
Specified torques
♦ Use new bolts

♦ Use new nuts

link
♦ Use new nuts

♦ Use new bolts
Mounting bracket to subframe 50 Nm + 90° further

♦ Use new bolts

♦ Use new bolts

♦ Use new bolt

♦ Use new bolts


M12 x 1.5 x 90 70 Nm + 180° further
♦ Use new bolts
M12 x 1.5 x 100 70 Nm + 180° further

♦ Use new bolts


M10 x 35 50 Nm + 90° further
♦ Use new bolt
M10 x 75 50 Nm + 90° further

♦ Use new bolt

♦ Use new bolt
4.3 Renewing mounting bracket with suspension link bush

equipment required
♦ Guide - VW 439-

♦ Tube - VW 426-

Pressing mounting bracket with bush off suspension link
The bonded rubber bush is available as a replacement part only
in conjunction with the mounting bracket.
– Press mounting bracket with bonded rubber bush off suspen‐
sion link.
Note
Hold suspension link firmly whilst pressing out.

2- Guide - VW 439-
Pressing in mounting bracket with bush onto suspension link
– Coat hexagon profile of suspension link with thinned assembly
lubrication oil - G 294 421 A1- (1:20).
– Carefully press bush onto suspension link to stop.

1- Tube - VW 426-
2- Mounting bracket with bonded rubber bush.
3- Suspension link

4.4 Checking swivel joint

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

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

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


equipment required
♦ Ball joint puller - 3287A-
1332-
V.A.G 1383 A-
♦ Angle wrench - V.A.G
1756-
Removing
– Loosen drive shaft bolt at wheel hub ⇒ page 114 .

Caution


– Raise vehicle.
– Remove wheel.
– Pull drive shaft slightly out of wheel hub.
serted.



Note
– Pull swivel bearing out of suspension link.

– Bend suspension link downwards as far as necessary.
– Loosen nut from suspension link -2- but do not remove com‐
pletely.
Caution
– Apply ball joint splitter - 3287A- as shown in figure and press

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

neath (danger of accident through falling parts when pressing out
the swivel joint).
Installing
– Fit swivel joint in wheel bearing housing.
– Screw on new self-locking nut and counterhold with Torx key
- T40- .

– Tighten nuts -arrows-.
Note

– Tighten drive shaft bolt at wheel hub ⇒ page 114 .
Note
During this step, vehicle must not be standing on its wheels or

wheel bearing will be damaged.
Specified torques
♦ Use new nuts

link
♦ Use new nuts
Swivel joint to wheel bearing housing 20 Nm + 90° further

♦ Use new nut
Drive shaft to hub 70 Nm + 90° further

♦ Use new bolt
4.6 Renewing bonded rubber bush for lower suspension link


equipment required
♦ Tube - T10219/1-
♦ Drift - T10219/2-


– Press out bonded rubber bush as illustrated.
2- Tube - T10219/1- (the cut-out must face the suspension link)
– Moisten outer surface of bonded rubber bush with assembly
oil - G 294 421 A1- .
– Press in bonded rubber bush as illustrated.

1- Drift - T10219/2-
3- Tube - T10219/1- (the cut-out must face the suspension link)
Note
At start of pressing-in process, bonded rubber bush is temporarily

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

2- Tube - T10219/1-

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

– Install suspension link ⇒ page 71 .
– Installing suspension link (left side of vehicles with dual clutch
or automatic gearbox) ⇒ page 74 .

5 Wheel bearing
⇒ “5.1 Assembly overview - wheel bearing”, page 90
⇒ “5.2 Removing and installing wheel bearing housing”,
page 92
⇒ “5.3 Removing and installing wheel bearing unit”, page 96
5.1 Assembly overview - wheel bearing
1 - Splash plate
2 - Wheel hub with wheel bear‐
ing
❑ The ABS sensor ring is
installed in the wheel
hub
3 - Bolt
WARNING
There
♦ are two versions of
the twelve-point head
bolt, with and without rib‐
bing. Distinguishing fea‐
ture ⇒ page 91 .
When
♦ installing a twelve-
point head bolt, always
note which version is be‐
ing installed.
The
♦ respective specified
torque must also be
used.
The
♦ specified torque for
twelve-point head bolts
»with« ribbing is 70 Nm +
90° when loosening and
tightening ⇒ page 114 .
The
»without« ribbing is 200
Nm + 180° when loosen‐
ing and tightening
⇒ page 116 .

4 - Bolt
❑ 12 Nm
5 - Bolt
❑ 8 Nm
6 - Front left speed sensor - G47- / front right speed sensor - G45-
❑ Can be tested in guided fault finding using ⇒ Vehicle diagnostic tester

❑ Before inserting speed sensor, clean inner surface of fitting hole and coat with lubricating paste - G 000
650- .
8 - Drive shaft
❑ With bolted-on brake carrier.
❑ If wheel bearing housing is renewed, wheels must be aligned ⇒ page 347

5. Wheel bearing 91
5.2 Removing and installing wheel bearing housing

equipment required
♦ Ball joint puller - 3287A-
1332-
V.A.G 1383 A-
♦ Angle wrench - V.A.G
1756-
Removing

Caution


– Raise vehicle.
– Remove wheel.
– Remove brake caliper with brake carrier and tie to body using
wire ⇒ Brake systems; Rep. gr. 46 ; Front brake; Assembly
overview - front brake .
– Remove ABS speed sensor ⇒ Brake systems; Rep. gr. 46 ;
Front brake; Assembly overview - front brake .
– Remove brake disc.
– Remove splash plate from wheel bearing housing.
ly.
Caution
– Push track rod off wheel bearing housing and remove nut.
– Loosen nuts -arrows-.

5. Wheel bearing 93
serted.


Note
– Remove threaded connection between wheel bearing housing

and suspension strut -arrow-.

– Insert spreader - 3424- in slot in wheel bearing housing.

3424- .
– Position engine and gearbox jack - V.A.G 1383 A- under wheel
bearing housing.
– Pull wheel bearing housing from suspension strut.
Note
If wheel bearing housing is renewed, swivel joint must be trans‐

ferred. Always use new nuts.
Installing
Carry out installation in the reverse sequence, noting the follow‐
ing:
Caution


If wheel bearing housing is renewed, wheels must be aligned
⇒ page 347 .
Specified torques
♦ Use new nut

♦ Use new nuts

link
♦ Use new nuts
5. Wheel bearing 95

bing”
♦ Use new bolt
ribbing”
♦ Use new bolt
5.3 Removing and installing wheel bearing

unit

Removing
Caution


– Raise vehicle.
– Remove wheel.

– Remove brake caliper with brake carrier and tie to body using
wire ⇒ Brake systems; Rep. gr. 46 ; Front brake; Assembly
overview - front brake .
– Remove ABS speed sensor ⇒ Brake systems; Rep. gr. 46 ;
Front brake; Assembly overview - front brake .
– Remove brake disc.
Only vehicles with VL 100 drive shaft
– Press drive shaft as far as possible out of wheel hub (towards
gearbox).
– Remove bolts -arrows-.
– Take wheel bearing unit -1- out of wheel bearing housing.

– Pull drive shaft out of wheel hub.
– Remove bolts -arrows-.

– Take wheel bearing unit -1- out of wheel bearing housing.
Installing
– Install brake caliper ⇒ Brake systems; Rep. gr. 46 ; Front
brake; Assembly overview - front brake .
Caution

5. Wheel bearing 97

– Install ABS speed sensor ⇒ Brake systems; Rep. gr. 46 ; Front
brake; Assembly overview - front brake .
Specified torques
bing”
♦ Use new bolt
ribbing”
♦ Use new bolt
Wheel hub with wheel bearing to wheel bearing housing 70 Nm + 90° further
♦ Use new bolts

♦ Use new nuts

link
♦ Use new nuts

6 Drive shaft
⇒ “6.1 Overview - drive shaft”, page 99
⇒ “6.2 Assembly overview - drive shaft”, page 100
⇒ “6.4 Loosening and tightening drive shaft bolt”, page 114
⇒ “6.5 Removing and installing drive shaft heat shield ”,
page 118
⇒ “6.6 Dismantling and assembling drive shaft”, page 118
⇒ “6.7 Checking outer constant velocity joint”, page 133
⇒ “6.8 Checking inner constant velocity joint”, page 134
6.1 Overview - drive shaft
I-
drive shaft, constant velocity
joint VL100”, page 100
II -
drive shaft, constant velocity
joint VL107”, page 103
III -
drive shaft, triple roller joint
AAR3300i ”, page 105
Distinguishing between drive shafts when installed

VL100 VL107 AAR3300i
Diameter of inner joint in 100 107 -
mm
6. Drive shaft 99
VL100 VL107 AAR3300i

Cover between inner joint - X -
and drive flange
Inner joint with flange shaft X X X
bolted to gearbox (only
manual and dual clutch
gearboxes)
6.2 Assembly overview - drive shaft

⇒ “6.2.1 Assembly overview - drive shaft, constant velocity joint
VL100”, page 100
⇒ “6.2.2 Assembly overview - drive shaft, constant velocity joint
VL107”, page 103
⇒ “6.2.3 Assembly overview - drive shaft, triple roller joint
AAR3300i ”, page 105
6.2.1 Assembly overview - drive shaft, constant velocity joint VL100
1 - Outer constant velocity joint

❑ Renew only as com‐
plete unit
❑ Removing ⇒ page 121 .
❑ Installing: drive onto
shaft as far as stop us‐
ing plastic hammer
2 - Bolt

WARNING
There
ture ⇒ page 102 .
When
ing installed.
The
torque must also be
used.
The
The
ing and tightening
⇒ page 116 .

3 - Right drive shaft
4 - Clamp
❑ Tightening ⇒ page 123
5 - Boot
❑ Check for splits and chafing
❑ Material: Hytrel (polyester elastomer)
6 - Clamp
7 - Dished spring
❑ Installation position ⇒ page 121 .
8 - Thrust washer
9 - Retaining ring
❑ Insert in groove in shaft
10 - Boot for constant velocity joint
❑ Without breather hole
❑ Drive off constant velocity joint with a drift
❑ Coat sealing surface with D 454 300 A2 before installing constant velocity joint
11 - Clamp
6. Drive shaft 101

12 - Left drive shaft

13 - Locking plate
❑ Initially tighten diagonally to 10 Nm and then tighten diagonally to specified torque.
M8 bolt: 40 Nm
M10 bolt: 70 Nm
❑ Always renew bolts after removing
15 - Retaining ring
❑ Remove and install with circlip pliers - VW 161 A-
16 - Seal
❑ Adhesive surface on constant velocity joint must be free of oil and grease!
17 - Inner constant velocity joint
❑ Renew only as complete unit
❑ Pressing off ⇒ page 122
❑ Pressing on ⇒ page 122
18 - Dished spring


6.2.2 Assembly overview - drive shaft, constant velocity joint VL107

plete unit
ing plastic hammer
2 - Bolt
WARNING
There
ture ⇒ page 105 .
When
ing installed.
The
torque must also be
used.
The
The
Nm + 180° when loosen‐ Volkswagen Technical Site: http://vwts.ru http://vwts.info
ing and tightening
⇒ page 116 .

3 - Retaining ring
4 - Thrust washer
5 - Dished spring
6 - Clamp
7 - Boot
6. Drive shaft 103

8 - Clamp
9 - Drive shaft
10 - Clamp
❑ Coat sealing surface of constant velocity joint with -D 454 300 A2- before installing.
12 - Clamp
13 - Locking plate
14 - Cap
❑ Drive off carefully with drift
❑ Adhesive surface must be free of oil and grease!
16 - Seal
17 - Retaining ring
❑ Remove and install with circlip pliers - VW 161 A- .
18 - Cover
❑ Always renew
❑ M10 x 52
❑ 70 Nm


6.2.3 Assembly overview - drive shaft, triple roller joint AAR3300i
1 - Bolt
WARNING
There
ture ⇒ page 107 .
When
ing installed.
The
torque must also be
used.
The
The
ing and tightening
⇒ page 116 .

plete unit
❑ Installing: drive onto shaft with plastic hammer until compressed circlip seats
3 - Retaining ring
6. Drive shaft 105

4 - Thrust washer
5 - Dished spring
6 - Clamp
8 - Clamp
9 - Drive shaft
10 - Triple roller star with rollers
The chamfer -arrow- points towards drive shaft splines.
11 - Retaining ring
12 - Clamp
13 - Boot for triple roller joint
14 - Clamp
15 - Adapter
16 - Joint body
❑ M10 x 23
❑ 70 Nm


6.3 Removing and installing jointed shaft

⇒ “6.3.1 Removing and installing drive shaft, constant velocity
joint”, page 107 .
⇒ “6.3.2 Removing and installing drive shaft, triple roller joint
AAR3300i”, page 110 .
6.3.1 Removing and installing drive shaft,

constant velocity joint
Caution
When removing and installing drive shafts, do not allow them

to hang free and stop against joints due to excessive bending.
Removing
6. Drive shaft 107


Caution


noise insulation .
– Unbolt drive shaft from gearbox flange shaft.
– Remove wheel.
– Push drive shaft outer joint out of wheel hub by hand.
link.
serted.



Note
Installing
Remove any paint residues and/or corrosion on thread and
splines of outer joint.
– Insert drive shaft.
– Guide outer joint into wheel hub splines as far as possible.
Note
– Place inner joint of drive shaft in position and tighten bolts di‐
agonally to 10 Nm.
– Tighten multi-point socket-head bolts diagonally to the speci‐
fied torque.
sulation .
Caution

6. Drive shaft 109


Specified torques
♦ Use new nuts

link
♦ Use new nuts
bing”
♦ Use new bolt
ribbing”
♦ Use new bolt
Drive shaft to flange shaft on gearbox “M8 multi-point sock‐ 40 Nm

et” ♦ Initially tighten diagonally to 10 Nm
♦ Use new bolts
Drive shaft to flange shaft on gearbox “M10 multi-point 70 Nm

socket” ♦ Initially tighten diagonally to 10 Nm
♦ Use new bolts
6.3.2 Removing and installing drive shaft, tri‐

ple roller joint AAR3300i

Caution

Removing
Caution

fitted as this would damage the wheel bearing. If it is necessary
for a vehicle to be moved, please comply with the following
instructions:
– Remove wheel.
noise insulation .
– Unbolt drive shaft from gearbox flange shaft.
6. Drive shaft 111


link.
serted.



Note
Installing
Remove any paint residues and/or corrosion on thread and
splines of outer joint.
– Insert drive shaft.
– Guide outer joint into wheel hub splines as far as possible.
Note
agonally to 10 Nm.
– Tighten multi-point socket-head bolts diagonally to the speci‐
fied torque.
sulation .
Caution


6. Drive shaft 113

Specified torques
♦ Use new nuts

link
♦ Use new nuts
bing”
♦ Use new bolt
ribbing”
♦ Use new bolt
Drive shaft to flange shaft on gearbox “M10 multi-point 70 Nm

socket” ♦ Initially tighten diagonally to 10 Nm
♦ Use new bolts
6.4 Loosening and tightening drive shaft

bolt
⇒ “6.4.1 Loosening and tightening drive shaft bolt, twelve-point
head bolt with ribbing”, page 114
head bolt without ribbing”, page 116
6.4.1 Loosening and tightening drive shaft

bolt, twelve-point head bolt with ribbing
♦ Socket, 24 mm - T10361A-

♦ Angle wrench - V.A.G 1756 A-

Caution

instructions:
Loosening twelve-point head bolt

– To avoid damage to wheel bearing, do not loosen twelve-point
head bolt using 24 mm socket - T10361A- further than 90° with
vehicle still standing on its wheels.
– Raise vehicle so that wheels are off the ground.
– Have second mechanic apply brakes.
6. Drive shaft 115

– Remove twelve-point head bolt -arrow-.

Fitting twelve-point head bolt
– Renew twelve-point head bolt.
Note
The wheels must not be in contact with the ground when the drive
shaft bolt is tightened; otherwise, the wheel bearing will be dam‐
aged.

– Tighten twelve-point head bolt to 70 Nm.
– Lower vehicle onto its wheels.
– Turn twelve-point head bolt 90° further.

bolt, twelve-point head bolt without rib‐
bing
♦ Socket, 24 mm - T10361A-


Caution

instructions:


Note
aged.

6. Drive shaft 117

6.5 Removing and installing drive shaft heat

shield
Front-wheel drive:
Hexagon bolt -1- 25 Nm
Automatic gearbox 09M - front wheel drive:

Loosen bolts -1- 40 Nm
Four-wheel drive:
Nuts -1- 20 Nm
♦ Initially tighten all nuts to
10 Nm
6.6 Dismantling and assembling drive shaft

⇒ “6.6.1 Dismantling and assembling drive shaft, constant veloc‐
ity joint VL100”, page 118
⇒ “6.6.2 Dismantling and assembling drive shaft, constant veloc‐
ity joint VL107”, page 123
⇒ “6.6.3 Dismantling and assembling drive shaft, triple roller joint
AAR3300i”, page 128
6.6.1 Dismantling and assembling drive shaft, constant velocity joint VL100


equipment required
♦ Press tool - VW 408 A-
♦ Tube - VW 416 B-
♦ Thrust washer - VW 447 H-
6. Drive shaft 119

♦ Circlip pliers - VW 161 A-

1331-
1332-
♦ Special pliers - V.A.G 1682-
♦ Multi-purpose tool - VW 771-

♦ Puller - T10382-
Removing outer constant velocity joint

– Clamp drive shaft in vice using protective jaw covers.
– Fold back boot.
– Set puller - T10382- up so that smooth side of puller plate -
T10382/1- points to spindles - T10382/2- .
– Assemble puller - T10382- complete with multi-purpose tool -
VW 771- .
– Pull constant velocity joint from drive shaft with puller -
T10382- and multi-purpose tool - VW 771- .
1- Puller plate - T10382/1-
2- Spindles - T10382/2-
Driving on outer constant velocity joint
Installation position of dished spring and thrust washer on outer

joint
1- Dished spring
2- Thrust washer
– Install new retaining ring.
– If necessary, push new joint boot onto drive shaft.
– Knock onto shaft with plastic hammer until circlip engages.
6. Drive shaft 121

Pressing off inner constant velocity joint

Assembling
1- Dished spring
Installation position of dished spring at inner joint

1- Dished spring
2- Thrust washer
Pressing on inner constant velocity joint
Note
Chamfer on internal circumference of ball hub (splines) must face

contact shoulder on drive shaft.

Tighten clamp on outer joint

– Position clamp tensioner - V.A.G 1682- as shown in diagram.
Ensure jaws of tensioner lie in corners -arrows B- of ears on
O-type clip.
– Tighten clamp by turning spindle with a torque wrench (do not
cant pliers).
Note
♦ Because a stainless steel boot clamp is required due to the

hard material of the joint boot (compared to rubber), it is pos‐
sible to tighten the clamp only with clamp tensioner - V.A.G
1682- .
♦ Specified torque: 25 Nm.
♦ Use torque wrench -C - with setting range of 5 ... 50 Nm (e.g.
torque - V.A.G 1331- ).
♦ Make sure thread of spindle -A- on pliers moves freely. Lubri‐
cate with MoS2 grease if necessary.
♦ If the thread is tight (e.g. due to dirt), the required clamping
force for the clip will not be attained although the correct torque
is applied.
Tightening clamp on small diameter
6.6.2 Dismantling and assembling drive shaft, constant velocity joint VL107
6. Drive shaft 123


equipment required
♦ Support sleeve - VW 522-
♦ Tensioner - 40 - 204 A-

♦ Puller - T10382-

– Fold back boot.
VW 771- .
2- Spindles - T10382/2-
6. Drive shaft 125


joint
1- Dished spring
2- Thrust washer
Driving off cover for inner joint

– Remove retaining ring.
– Remove both clamps and slide boot towards outer joint.
– Drive off boot with drift.

Assembling

– Press joint on to stop.
– Install retaining ring.

– Coat sealing surface of cover with -D 454 300 A2- .

– Apply a continuous bead of sealant with a diameter of 2 ... 3
mm to clean surface of cover in area of inner holes -arrow-.
– Using bolts -arrows-, align new cover in relation to bolt holes.

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

– Apply special pliers -V.A.G 1682- as shown in diagram. En‐
sure jaws of tensioner lie in corners -arrows B- of ears on O-
type clip.
cant pliers).
Note
♦ Due to the hard material of the protective boot (compared to

rubber) and the necessity of using a stainless steel clamp, it
is only possible to tension the clamp with clamp tensioner -
V.A.G 1682- .
♦ Use torque wrench -C - with setting range of 5 ... 50 Nm (e.g.
torque - V.A.G 1331- ).
force for the clamp will not be attained although the specified
tightening torque is applied.
6. Drive shaft 127

6.6.3 Dismantling and assembling drive shaft, triple roller joint AAR3300i

equipment required
♦ Tube - VW 416 B-

♦ Hose clip pliers - V.A.G

1275-
1331-
♦ Torque wrench -
V.A.G 1332-
6. Drive shaft 129

♦ Puller - T10382-

– Fold back boot.
VW 771- .
2- Spindles - T10382/2-

joint
1- Dished spring
2- Thrust washer
Dismantling triple roller joint
– Unfasten both clamps on inner joint and push back boot.
– Pull joint body off drive shaft.


1 - Pliers (commercially available)
- or -VW 161 A-
– Set drive shaft into press.
– Press triple roller star off drive shaft.

– Pull boot off shaft.
– Clean shaft, joint body and groove for seal.
Assembling triple roller joint
– Push small hose clip for boot onto shaft.
– Push joint boot onto shaft.
– Push joint body onto shaft.
Fitting triple roller star
Drive shaft (tapered version)
Chamfer on triple roller star faces towards shaft and serves as an
assembly aid.
– Fit triple roller star onto shaft and press on to stop.

– Ensure that pressure does not exceed 3.0 t.
– If necessary, coat splines of drive shafts and triple roller star
with lubricating paste - G 052 142 A2- .
– Insert retaining ring, ensuring that it is seated correctly.
– Press half of total amount of grease from repair kit into triple
roller joint.
– Slide joint body over rollers and hold.
– Press remaining amount of grease from repair kit into rear of
triple roller joint.
– Install joint boot.
Fitting triple roller star
Drive shaft (cylindrical version)
6. Drive shaft 131

– Fit triple roller star onto shaft and press on to stop.

– Ensure that pressure does not exceed 3.0 t.
– If necessary, coat splines of drive shafts and triple roller star
with lubricating paste - G 052 142 A2- .
– Insert retaining ring, ensuring that it is seated correctly.
– Press 70 grammes of drive shaft grease from repair set into
triple roller joint.
– Slide joint body over rollers and hold.
– Press 60 grammes of drive shaft grease from repair kit into
rear of triple roller joint.
– Install joint boot.
– Install clamp.
Note
To make it easier to insert the multi-point socket-head bolts when

installing the drive shaft, position ear -arrow A- of hose clip be‐
tween mounting flanges -arrows B- of joint body.
Tightening clamp on large diameter of inner joint

– Position clamp tensioner - V.A.G 1682- as shown in illustra‐
tion. Ensure jaws of tensioner lie in corners -arrows B- of ears
on O-type clip.
cant pliers).
Note
♦ Due to the hard material of the protective boot (compared to

rubber) and the necessity of using a stainless steel clamp, it
is only possible to tension the clamp with clamp tensioner -
V.A.G 1682- .
♦ Use torque wrench -C- with adjustment range 5 … 50 Nm, (e.g.
torque wrench - V.A.G 1331- ).
force for the clamp will not be attained although the specified
tightening torque is applied.


O-type clip.
cant pliers).
Tightening clamp on small diameter of inner/outer joint
6.7 Checking outer constant velocity joint

The joint is to be dismantled to renew the grease if it is heavily
soiled, or to check the running surfaces of the balls for wear and
damage.
Removing
– Before dismantling, mark position of ball hub in relation to ball
cage and joint body with an electric scriber or oil stone.
– Swing ball hub and ball cage.
– Remove balls one at a time.
– Turn cage until the two rectangular windows -arrow- align with
joint body.
– Take out cage with hub.
6. Drive shaft 133

– Swing segment of hub into square cage window.

– Tip hub out of cage.
The six balls for each joint belong to a tolerance group. Check
stub axle, hub, cage and balls for small indentations (pitting) and
traces of seizing. Too much circumferential backlash in the joint
becomes noticeable during load change jolts; in such cases, the
joint must be renewed. Smoothing and traces of wear of the balls
are no reason to change the joint.
Installing
– Pack half of total grease quantity (40 g) into joint body.
– Fit cage with hub into joint body.
– Press in opposing balls one after the other; the original position
of the hub relative to the cage and joint body must be restored.
– Fit new retaining ring into hub.
– Distribute remaining grease in boot.
6.8 Checking inner constant velocity joint

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

– Insert hub into cage via the two chamfers. The hub can be
installed in any position. Press balls into cage.
The ball hub has two different distances between the ball tracks:
a smaller one and a larger one.
– Insert hub complete with cage and balls into joint body, making
sure that a smaller gap -b- faces open side of joint body.
– Also make sure that chamfer on inner circumference of ball
hub is visible after swinging it into place.
– Swivel hub into joint body; at the same time, hub must be
swivelled out of cage -arrows- far enough to allow balls to fit
into ball races.
– Swivel in hub with balls by applying firm pressure to cage

-arrow-.
Checking function of constant velocity joint
The constant velocity joint is correctly assembled if the ball hub
can be moved by hand backwards and forwards over its entire
range of axial movement.
6. Drive shaft 135

42 – Rear suspension
1 Rear axle
⇒ “1.1 Overview - rear axle”, page 136
⇒ “1.2 Lowering rear axle”, page 140
⇒ “1.3 Removing and installing rear axle”, page 145
⇒ “1.4 Removing and installing trim for rear axle”, page 155
1.1 Overview - rear axle

⇒ “1.1.1 Overview - rear axle, front-wheel drive”, page 136
⇒ “1.1.2 Overview - rear axle, four-wheel drive”, page 139
1.1.1 Overview - rear axle, front-wheel drive
Note
pension components.
components with bonded rubber bushes only when the wheel bearing housing is raised to unladen position
⇒ page 9 .
♦ Always renew bonded rubber bush on both sides of the vehicle.
136 Rep. gr.42 - Rear suspension

I - Assembly overview: sub‐

frame (front-wheel drive)
⇒ page 157
II - Assembly overview: trans‐
verse link, track rod (front-
wheel drive) ⇒ page 198
1. Rear axle 137

III - Assembly overview: wheel

bearing housing, trailing arm
(front-wheel drive)
⇒ page 246
IV - Assembly overview: shock
absorber, coil spring (front-
absorber for adaptive chassis
control DCC (front-wheel
drive) ⇒ page 222
V - Assembly overview: anti-
roll bar (front-wheel drive)
⇒ page 191

1.1.2 Overview - rear axle, four-wheel drive
Note
pension components.
components with bonded rubber bushes only when the wheel bearing housing is raised to unladen position
⇒ page 11 .
♦ Always renew bonded rubber bush on both sides of the vehicle.
I - Assembly overview: sub‐

frame, final drive (four-wheel
drive) ⇒ page 158
II - Assembly overview: trans‐
verse link, track rod (four-
1. Rear axle 139

III - Assembly overview: wheel

bearing housing, trailing arm
(four-wheel drive)
⇒ page 249
absorber, coil spring (four-
absorber for adaptive chassis
control DCC (four-wheel drive)
⇒ page 223
V - Assembly overview: anti-
roll bar (four-wheel drive)
⇒ page 192
1.2 Lowering rear axle

⇒ “1.2.1 Lowering rear axle, front-wheel drive”, page 140
⇒ “1.2.2 Lowering rear axle, four-wheel drive”, page 143
1.2.1 Lowering rear axle, front-wheel drive



Lower subframe with attachments.
– Raise vehicle.
– Remove wheels.
– Remove coil springs ⇒ page 241 .
– Remove rear silencer of exhaust system ⇒ Rep. gr. 26 ; Ex‐
haust pipes/silencers; Removing and installing rear silencer .
Vehicles with rear left vehicle level sender - G76-
– Unclip speed sensor wire from retainer -1- -arrows-.
1. Rear axle 141

– Unclip brake lines -1- from bracket -arrow- on left of body.

– Pull retaining clip -2- from subframe -3- and detach brake
hose.
Note
Do not open brake line.
BlueMotion vehicles
– Remove cover -1-.
– Remove underbody cover -2- ⇒ General body repairs, exte‐
rior; Rep. gr. 66 ; Underbody cover; Assembly overview -
underbody cover .
– Remove trim for rear axle ⇒ page 155
– Use tensioning straps - T10038- to strap vehicle to support

beams of lifting platform on both sides.
WARNING
If the vehicle is not strapped down, there is a great danger that

the vehicle will slip off the lifting platform!

– Carefully lower subframe with attachments about 2 cm.
– Unclip brake line from left clip on subframe -arrow-.

– Unclip brake line from remaining clips on left side of subframe.
Note
The clips will be destroyed and must be renewed.
– Lower subframe with attachments about 140 mm.

Installing subframe with attachments
Specified torques
Subframe to body 90 Nm + 90° further
♦ Use new bolts

1.2.2 Lowering rear axle, four-wheel drive


Lower subframe with attachments.
– Raise vehicle.
– Remove wheels.
– Unbolt brake calipers on both sides of vehicle and suspend
from body.
1. Rear axle 143


hose.
Note
– Remove propshaft ⇒ Rep. gr. 39 ; Propshaft; Removing and

installing propshaft .
BlueMotion vehicles
underbody cover .

WARNING


– Separate connector on Haldex clutch above final drive.

– Unclip brake line on left side -arrow-.

– Unclip brake line above left drive shaft flange.
Note
– Lower subframe with attachments about 140 mm.

– Install propshaft ⇒ Rep. gr. 39 ; Propshaft; Removing and
installing propshaft .
Specified torques
♦ Use new bolts
1.3 Removing and installing rear axle

⇒ “1.3.1 Removing and installing rear axle, front-wheel drive”,
page 145
⇒ “1.3.2 Removing and installing rear axle, four-wheel drive”,
page 149
1.3.1 Removing and installing rear axle, front-

wheel drive
1. Rear axle 145


Removing subframe with attachments
– Raise vehicle.
– Remove wheels.
– Unbolt brake calipers on both sides of vehicle and suspend
from body.
– Remove bolt -arrow-.

– Separate speed sensor connectors.


hose.
Note
– Disconnect connectors of electric parking brake at brake cal‐

iper.
– Press out inner pins of rivets -arrows A-.

– Remove mounting bracket -1-.
BlueMotion vehicles
underbody cover .
1. Rear axle 147


WARNING

Natural gas vehicles

– Remove fuel tanks 1 and 2 (natural gas) ⇒ Rep. gr. 20 ; Fuel
tank; Removing and installing fuel tank .
– Remove line -1- from mounting bracket -arrow A-.

– Mark installation position of mounting bracket -2- on body.
– Remove bolts -arrows B-.
– Unclip brake lines on both sides -arrow-.
Note
– Unclip brake line from remaining clips on subframe.
Note
– Carefully lower subframe with attachments.
Note
When lowering, ensure sufficient clearance to brake lines and

electrical wiring.


– When installing wire of electric parking brake, make sure that

dimension -a- between connector -1- and mounting bracket
-2- is precisely maintained.
Dimension -a- = 150 mm
Specified torques
♦ Use new bolts
Shock absorber to wheel bearing housing 180 Nm

♦ Use new bolts
1.3.2 Removing and installing rear axle, four-

wheel drive

Removing subframe with attachments
1. Rear axle 149

– Raise vehicle.
– Remove wheels.
– Unclip speed sensor wire on both sides from bracket -1-

-arrows-.
– Disconnect connectors for rear right speed sensor - G44- and
rear left speed sensor - G46- .

hose.
Note

– Disconnect connectors of electric parking brake at brake cal‐
iper.



-14-.
– Push engine and gearbox forwards and secure in position with

a suitable piece of wood -A-.
– Check whether marks (spots of paint) are present on flexible

coupling and final drive flange -arrows-. If no marks are
present, mark positions of flexible coupling and final drive
flange relative to each other -arrows-.
1. Rear axle 151

– Unbolt rear propshaft tube with flexible coupling and vibration

damper from rear final drive -arrows-.
Note
To loosen and tighten propshaft, counter-hold on bevel box using

counter-hold tool - T10172- and adapters - T10172/5- . This re‐
quires the assistance of a second mechanic.
– Unscrew bolts for centre bearing -arrows- two turns.
– Support propshaft -A- on tunnel support -1- using a wooden

block.
– Push rear propshaft tube as far as possible in direction of
gearbox.
– When pulling off propshaft, always ensure that bushing

-arrow- is not damaged.

BlueMotion vehicles
underbody cover .

WARNING


– Unclip brake lines on both sides -arrow-.
Note
1. Rear axle 153

– Unclip brake line from clips -arrows- above drive shaft flange
on gearbox -1-.
Note
– Carefully lower subframe with attachments.
Note
When lowering, ensure sufficient clearance of brake lines, elec‐

trical cables and centring pin to propshaft.

Note
Renew the damaged brake line clips on the subframe.
– When connecting propshaft, always ensure that bushing

-arrow- is not damaged.

Attach propshaft to rear final drive ⇒ Rep. gr. 39 ; Propshaft;
Removing and installing propshaft .
Specified torques
♦ Use new bolts

♦ Use new bolts

1.4 Removing and installing trim for rear

axle
Removing
– Remove nuts/bolts -1-.
– Pull shield -2- downwards off subframe and detach above at
the same time -arrow-.
Installing
– Hook shield into bottom part of subframe -arrow- and swivel in

-direction of arrow- so that it engages into upper part of sub‐
frame.
1. Rear axle 155

– Tighten nuts/bolts -1-.
Note
After installing shield, check again whether shield lug -2- has en‐
gaged properly in subframe -arrow-.
Specified torques
Component Nm
Shield to subframe 2 Nm

2 Subframe
⇒ “2.1 Assembly overview - subframe”, page 157
⇒ “2.2 Assembly overview - add-on parts for subframe”,
page 159
⇒ “2.3 Fixing position of subframe”, page 159
⇒ “2.4 Repairing subframe”, page 162
2.1 Assembly overview - subframe

⇒ “2.1.1 Assembly overview - subframe, front-wheel drive”, page
157
⇒ “2.1.2 Assembly overview - subframe, four-wheel drive”,
page 158
2.1.1 Assembly overview - subframe, front-wheel drive

-Arrow- indicates direction of travel.
1 - Subframe
❑ Fixing position
⇒ page 159
2 - Rear bonded rubber bush
❑ Renewing ⇒ page 162 .
3 - Front bonded rubber bush
2. Subframe 157
2.1.2 Assembly overview - subframe, four-wheel drive

1 - Subframe
2 - Rear bonded rubber bush
❑ Renewing, to week
21/2012 ⇒ page 168
❑ Renewing, from week
22/2012 ⇒ page 177
3 - Front bonded rubber bush
❑ Renewing, to week
21/2012 ⇒ page 168
❑ Renewing, from week
22/2012 ⇒ page 177
4 - Final drive
⇒ Rep. gr. 39 ; Rear fi‐
nal drive; Removing and
installing rear final
drive .
5 - Bolt
6 - Washer
❑ Installed between final
drive and subframe
7 - Washer
❑ Washer must be placed
with holes on lugs of
bonded rubber bush.
8 - Bolt

2.2 Assembly overview - add-on parts for subframe
1 - Subframe
2 - Bolt
3 - Angle piece
❑ With pop rivet screw.
4 - Nut
❑ 20 Nm
5 - Trim
❑ Tighten nuts to 2 Nm
⇒ page 155
❑ During installation, trim
must be attached to
subframe from below
⇒ Item 1 (page 159)
-arrow A- and engaged
above -arrow B-.
6 - Angle piece
❑ With pop rivet screw.
2.3 Fixing position of subframe

⇒ “2.3.1 Fixing position of subframe, front-wheel drive”,
page 159
⇒ “2.3.2 Fixing position of subframe, four-wheel drive”,
page 161
2.3.1 Fixing position of subframe, front-wheel

drive
2. Subframe 159

– Position engine and gearbox jack - V.A.G 1383 A- underneath
subframe and secure with tensioning strap.
– Unscrew one hexagon bolt -1- or -2- on both sides.
Note
Only the right side of vehicle is shown to improve clarity.

screwed in successively at positions -1- and -2- on both sides of
vehicle.

– Secure position of subframe with locating pins - T10096- .
Note
The locating pins - T10096- may be tightened only to a maximum

of 20 Nm; otherwise the threads of the locating pins may be dam‐
aged.
– Replace securing bolts on subframe with locating pins -

T10096- one after the other on both sides of the vehicle and
tighten to 20 Nm.
The position of the subframe is now fixed.
2.3.2 Fixing position of subframe, four-wheel

drive

2. Subframe 161

vehicle.
Note
Only the left side of vehicle is shown to improve clarity.
Note

aged.

tighten to 20 Nm.
2.4 Repairing subframe

⇒ “2.4.1 Repairing subframe, front-wheel drive”, page 162
⇒ “2.4.2 Repairing subframe, up to week 21/2012”, page 168
⇒ “2.4.3 Repairing subframe, four-wheel drive, from week
22/2012”, page 177
2.4.1 Repairing subframe, front-wheel drive


equipment required
V.A.G 1383 A-
6178- and thrust piece -
T10205/13-
Pressing out front bonded rubber bush ⇒ page 163

Pressing in front bonded rubber bush ⇒ page 165
Pressing out rear bonded rubber bush ⇒ page 166
Pressing in rear bonded rubber bush ⇒ page 168
Pressing out front bonded rubber bush
2. Subframe 163
– Raise vehicle.
– Remove rear wheels.
– Disconnect electrical connections between rear axle and
body.
– Remove anti-roll bar ⇒ page 192 .
BlueMotion vehicles

WARNING


– Unscrew one hexagon bolt -1- on both sides.
Note

screwed in successively at positions -1- on both sides of vehicle.

Note

aged.

tighten to 20 Nm.
– Lower subframe approx. 10 cm with engine and gearbox jack
- V.A.G 1383 A- .
– Fit tools as shown in illustration.

1 - Nut - T10263/5-
2 - Thrust piece - T10356/1-
3 - Subframe
4 - Tube - T10356/2-
6 - Nut - T10263/5-
7 - Spindle - T10263/4-
– Take up play in special tools.
– Press out bonded rubber bush.
Note
♦ The outer ring of the bush shears off when the bonded rubber
bush is pulled out. This occurs with a loud bang.
♦ After the bush has been pulled out, it must be removed from
the tube - T10356/2- with light hammer blows.
Pressing in front bonded rubber bush
2. Subframe 165
– Set up special tools with bonded rubber bush on subframe as

shown.
1 - Nut - T10263/5-
2 - Guide piece - T10356/3- with side A towards subframe
3 - Subframe
5 - Thrust piece - T10356/4- with side A towards bonded rubber
bush
6 - Tube - T10356/2-
8 - Nut - T10263/5-
9 - Spindle - T10263/4-
– Take up play in special tools and bonded rubber bush.
– Operate pump to press bonded rubber bush in until collar lies
»flush« on subframe.
Pressing out rear bonded rubber bush
– Raise vehicle.
body.
BlueMotion vehicles

WARNING



Note

Note

aged.

tighten to 20 Nm.
– Lower subframe approx. 10 cm with engine and gearbox jack
- V.A.G 1383 A- .
2. Subframe 167

1 - Nut - T10263/5-
3 - Subframe
4 - Tube - T10356/6-
6 - Nut - T10263/5-
7 - Spindle - T10263/4-
Note
♦ The outer ring of the bush shears off when the bonded rubber
bush is pulled out. This occurs with a loud bang.
♦ After the bush has been pulled out, it must be removed from
the tube - T10356/2- with light hammer blows.
Pressing in rear bonded rubber bush

shown.
1 - Nut - T10263/5-
2 - Guide piece - T10356/3- with side B towards subframe
3 - Subframe
5 - Thrust piece - T10356/4- with side B towards bonded rubber
bush
7 - Nut - T10263/5-
8 - Spindle - T10263/4-
Continue installation in reverse order. Note the following points:
– Bleed brake system ⇒ Brake systems; Rep. gr. 47 ; Hydraulic
system .
Specified torques
♦ Use new bolts
2.4.2 Repairing subframe, up to week 21/2012


equipment required
V.A.G 1383 A-
T10205/13-
Pressing out front bonded rubber bush ⇒ page 169

Pressing in front bonded rubber bush ⇒ page 172
Pressing out rear bonded rubber bush ⇒ page 173
Pressing in rear bonded rubber bush ⇒ page 175
– Raise vehicle.
body.
– Remove track rods ⇒ page 213 .
2. Subframe 169
– Remove clip -1-.
Note
BlueMotion vehicles

WARNING



Note

Note

aged.

tighten to 20 Nm.
– Lower subframe 10 cm using engine and gearbox jack - V.A.G
1383 A- .
– Mark installation position of bonded rubber bush in relation to
subframe, for example using a felt-tip pen.

1 - Nut - T10263/5-
2 - Washer , from -T10263-
3 - Tube - T10263/6-
5 - Nut - T10263/5-
6 - Spindle - T10263/4-
Note
The outer ring of the bush shears off when the bonded rubber
bush is pressed out. This occurs with a loud bang.
2. Subframe 171
– The bonded rubber bush must be removed from the tube -

T10356/6- once the bush has been pressed out.
– Clamp tube - T10356/6- on the intended surfaces in a vice.
– Insert a screwdriver between tube - T10356/6- and bonded
rubber bush and lever bush out of tube -arrow-. If necessary,
apply a drift to bush and drive out with light hammer blows.
Distinguishing features of bonded rubber bushes

I - Front bonded rubber bush
II - Rear bonded rubber bush
The front bonded rubber bushes have two notches on the upper
side -arrows- and differ to the rear slightly in height ⇒ Electronic
parts catalogue “ETKA” .
The bonded rubber bush must be installed in a certain direction;
note mark on subframe.
– Insert bonded rubber bush -1- in subframe so that the nose

and the plate -arrows- face perpendicular to direction of travel.
– Apply thrust piece - T10263/3- -2- so that flattened sides also
face perpendicular to direction of travel.


shown.
1 - Nut - T10263/5-
6 - Nut - T10263/5-
7 - Spindle - T10263/4-
– Install track rods ⇒ page 213 .
– Install anti-roll bar ⇒ page 194 .
– Join electrical connections between rear axle and body.
– Install rear silencer of exhaust system ⇒ Rep. gr. 26 ; Exhaust
pipes/silencers; Removing and installing rear silencer .
– Install coil springs ⇒ page 243 .
– Install wheels and tighten bolts or nuts ⇒ page 320 .
– Raise vehicle.
– Remove clip -1-.
Note
2. Subframe 173
BlueMotion vehicles

WARNING


Note


Note

aged.

tighten to 20 Nm.
– Lower subframe 10 cm using engine and gearbox jack - V.A.G
1383 A- .
subframe, for example using a felt-tip pen.

1 - Nut - T10263/5-
2 - Washer , from -T10263-
3 - Tube - T10263/6-
5 - Nut - T10263/5-
6 - Spindle - T10263/4-
– Press out bonded rubber bush by operating the pump.
Note
The outer ring of the bush shears off when the bonded rubber
bush is pressed out. This occurs with a loud bang.
– The bonded rubber bush must be removed from the tube -

T10356/6- once the bush has been pressed out.
– Clamp tube - T10356/6- on the intended surfaces in a vice.
– Insert a screwdriver between tube - T10356/6- and bonded
rubber bush and lever bush out of tube -arrow-. If necessary,
apply a drift to bush and drive out with light hammer blows.
2. Subframe 175
Distinguishing features of bonded rubber bushes

I - Front bonded rubber bush
II - Rear bonded rubber bush
The front bonded rubber bushes have two notches on the upper
side -arrows- and differ to the rear slightly in height ⇒ Electronic
parts catalogue “ETKA” .
The bonded rubber bush must be installed in a certain direction;
note mark on subframe.
– Insert bonded rubber bush -1- in subframe so that the nose

and the plate -arrows- face perpendicular to direction of travel.
– Apply thrust piece - T10263/3- -2- so that flattened sides also
face perpendicular to direction of travel.

shown.
1 - Nut - T10263/5-
6 - Nut - T10263/5-
7 - Spindle - T10263/4-
– Carefully operate pump to press bonded rubber bush in until
collar lies »flush« on subframe.
– Install rear silencer of exhaust system ⇒ Rep. gr. 26 ; Exhaust
pipes/silencers; Removing and installing rear silencer .
– Install coil springs ⇒ page 243 .
– Install rear wheels and tighten bolts or nuts ⇒ page 320 .
Specified torques
♦ Use new bolts

2.4.3 Repairing subframe, four-wheel drive,

from week 22/2012
Renewing front bonded rubber bush ⇒ page 177
Renewing rear bonded rubber bush ⇒ page 183
Renewing front bonded rubber bush

equipment required
V.A.G 1383 A-
T10205/13-
2. Subframe 177
Note
♦ When a bonded rubber bush is defective, the bonded rubber

bush on the opposite side must also be renewed; allocation ⇒
Electronic Parts Catalogue “ETKA.” .
♦ Before replacing a defective bonded rubber bush, check the
other bonded rubber bushes.
♦ If cracks or other damage is visible, these bonded rubber
bushes must be renewed also.
♦ To renew bonded rubber bushes, the subframe must be low‐
ered at the front or the rear. The removal of the subframe is
not required.
♦ Mark position of bonded rubber bushes in relation to subframe
before removing.

– Raise vehicle.
– Remove wheels.
– Remove spring ⇒ page 243 .
haust system; Removing and installing parts of the exhaust
system .
body.
– Remove track rods ⇒ page 213 .
– Pull out retaining clip -1- on both sides of vehicle.
Note
BlueMotion vehicles


WARNING

– Position engine and gearbox jack - V.A.G 1383 A- with uni‐

versal gearbox support - V.A.G 1359/2- beneath subframe and
secure with strap.
Note

vehicle.
– Fix position of subframe using 2 locating pins - T10096- and

tighten to 20 Nm.
Note

aged.
– Replace subframe securing bolts on both sides one after the

other with locating pins - T10096- and tighten to 20 Nm.
2. Subframe 179

subframe with e.g. a felt-tip pen -1-.
Note
Make a mark -1- on subframe centred on cut-out in bonded rubber

bush -2-.
– Lever anti-twist device -1- off bonded rubber bush near re‐
taining lug using, for example, a screwdriver -2-.
– Lower subframe approx. 100 mm using engine and gearbox
jack - V.A.G 1383 A- .
– Unclip brake line -1- from clip -arrow- on left side.
Note
The clip will be destroyed and must be renewed.
– Fit special tools as shown in illustration.

1 - Hexagon nut - T10263/5-

3 - Subframe
4 - Tube - T10356/2- , side with recess faces subframe.
5 - Thrust plate - T10205/1-
8 - Threaded spindle - T10263/4-
Note
♦ The collar of the outer ring of the bonded rubber bush will be sheared off by the mounting when the bush is
pulled out. This occurs with a loud bang.
♦ After the bush has been pulled out, it must be removed from the tube - T10356/2- with light hammer blows.
2. Subframe 181

– As an assembly aid, draw a line -1- on the vertical rib of the
bonded rubber bush.
– Coat outer edge of bonded rubber bush with assembly paste.

shown.

2 - Thrust piece - T10356/7- - the marking -A- faces towards sub‐
frame

3 - Subframe
4 - Align bonded rubber bush on mark, made for this purpose (the
marks must align with one another)
5 - Thrust piece - T10356/8- - the flattened sides must engage in
cover of bonded rubber bush -arrows-.
– Check position of bonded rubber bush, realign if necessary
and preload bonded rubber bush using special tools.
Note
♦ Ensure that the hose from the hydraulic cylinder - VAS 6178-
to the foot pump - VAS 6179- is routed between the trailing
arm and the fuel tank while pressing in the bush.
♦ Ensure that the bonded rubber bush does not cant at the start
of the pressing action. Otherwise, the outer ring could be dam‐
aged.

Specified torques
♦ Use new bolts
Renewing rear bonded rubber bush
2. Subframe 183

equipment required
V.A.G 1383 A-
T10205/13-

Note
♦ When a bonded rubber bush is defective, the bonded rubber

bush on the opposite side must also be renewed; allocation ⇒
Electronic Parts Catalogue “ETKA.” .
♦ Before replacing a defective bonded rubber bush, check the
other bonded rubber bushes.
♦ If cracks or other damage is visible, these bonded rubber
bushes must be renewed also.
♦ To renew bonded rubber bushes, the subframe must be low‐
ered at the front or the rear. The removal of the subframe is
not required.
♦ Mark position of bonded rubber bushes in relation to subframe
before removing.

– Raise vehicle.
– Remove wheels.
– Remove spring ⇒ page 243 .
haust system; Removing and installing parts of the exhaust
system .
– Pull out retaining clip -1- on both sides of vehicle.
Note
BlueMotion vehicles
2. Subframe 185

WARNING

– Position engine and gearbox jack - V.A.G 1383 A- with uni‐

versal gearbox support - V.A.G 1359/2- beneath subframe and
secure with strap.
Note

vehicle.
– Fix position of subframe using locating pins - T10096- .
Note

aged.
– Replace subframe securing bolts on both sides one after the

other with locating pins - T10096- and tighten to 20 Nm.


subframe with e.g. a felt-tip pen -1-.
Note
Make a mark -1- on subframe centred on cut-out in bonded rubber

bush -2-.
– Lever anti-twist device -1- off bonded rubber bush near re‐
taining lug using, for example, a screwdriver -2-.
– Lower subframe approx. 100 mm using engine and gearbox
jack - V.A.G 1383 A- .
– Unclip brake line -1- from clip -arrow- on left side.
Note
The clip will be destroyed and must be renewed.
– Fit special tools as shown in illustration.
2. Subframe 187

3 - Subframe
4 - Tube - T10356/6- , side with recess faces subframe.
Note
♦ The collar of the outer ring of the bonded rubber bush will be sheared off by the mounting when the bush is
pulled out. This occurs with a loud bang.
♦ After the bush has been pulled out, it must be removed from the tube - T10356/6- with light hammer blows.


– As an assembly aid, draw a line -1- on the vertical rib of the
bonded rubber bush.
– Coat outer edge of bonded rubber bush with assembly paste.

shown.

2 - Thrust piece - T10356/7- - the marking -B- faces towards sub‐
frame
2. Subframe 189
3 - Subframe
4 - Align bonded rubber bush on mark, made for this purpose (the
marks must align with one another)
5 - Thrust piece - T10356/8- - the flattened sides must engage in
cover of bonded rubber bush -arrows-.
– Check position of bonded rubber bush, realign if necessary
and preload bonded rubber bush using special tools.
Note
Ensure that the bonded rubber bush does not cant at the start of
the pressing action. Otherwise, the outer ring could be damaged.

Specified torques
♦ Use new bolts

3 Anti-roll bar
⇒ “3.1 Assembly overview - anti-roll bar”, page 191
⇒ “3.2 Removing and installing anti-roll bar”, page 192
3.1 Assembly overview - anti-roll bar

⇒ “3.1.1 Assembly overview - anti-roll bar, front-wheel drive”,
page 191
⇒ “3.1.2 Assembly overview - anti-roll bar, four-wheel drive”, page
192
3.1.1 Assembly overview - anti-roll bar, front-wheel drive
1 - Anti-roll bar
❑ Take different running
gear designs into ac‐
count ⇒ page 358 .
⇒ page 192 .
2 - Mounting
❑ Always renew mount‐
ings/bushes on both
sides of vehicle
3 - Clamp
4 - Bolt
❑ Tighten evenly.
6 - Nut
❑ 45 Nm
❑ Self-locking
❑ When tightening, coun‐
terhold on multi-point
socket of bolt
7 - Bolt
8 - Coupling rod
❑ Connects anti-roll bar to
trailing arm and wheel
bearing housing
9 - Subframe
3. Anti-roll bar 191

3.1.2 Assembly overview - anti-roll bar, four-wheel drive

1 - Anti-roll bar
⇒ page 194 .
2 - Mounting
❑ Always renew mount‐
ings/bushes on both
sides of vehicle
3 - Clamp
4 - Bolt
❑ Tighten evenly.
6 - Nut
❑ 45 Nm
❑ Self-locking
❑ When tightening, coun‐
terhold on multi-point
socket of bolt
7 - Bolt
8 - Coupling rod
bearing housing
9 - Subframe
3.2 Removing and installing anti-roll bar

⇒ “3.2.1 Removing and installing anti-roll bar, front-wheel drive”,
page 192
⇒ “3.2.2 Removing and installing anti-roll bar, front-wheel drive”,
page 194
3.2.1 Removing and installing anti-roll bar,

front-wheel drive


Removing
Note
The following procedure is for the left side of the vehicle. The
procedure for the right side of the vehicle is identical.
– Remove nut -1- and pull coupling rod -2- from anti-roll bar.
Note
Do not loosen bolt -arrow- for track rod -3-.
– Remove bolts -arrows- for anti-roll bar clamp.

– Remove anti-roll bar.
Installing
– Insert anti-roll bar into vehicle.

– Evenly tighten bolts -arrows- for anti-roll bar clamp.
– Connect coupling rod -2- to anti-roll bar and tighten nut -1-.
Specified torques
♦ Use new bolts
♦ Tighten threaded connections only when vehicle is in
the normal running position

♦ Use new nut
3.2.2 Removing and installing anti-roll bar,

front-wheel drive


Removing
Note
The following procedure is for the left side of the vehicle. The
procedure for the right side of the vehicle is identical.
Note
Do not loosen bolt -arrow- for track rod -3-.

If the upper bolt of the anti-roll bar clamp on the right side of the
vehicle cannot be removed, then additional work must be per‐
formed ⇒ page 195 .
For the right side of the vehicle only (depending on equipment)
BlueMotion vehicles

– Now strap vehicle to lifting platform arms on both sides of ve‐

hicle using tensioning straps - T10038- .
WARNING


– Raise wheel hub with support - T10149- and engine and gear‐
box jack - V.A.G 1383 A- far enough that bolts of right anti-roll
bar clamp are accessible.
Continuation for both sides of vehicle:
– Remove anti-roll bar.
Installing
– Install anti-roll bar in vehicle.
– Evenly tighten bolts -arrows- for anti-roll bar clamp.

– Lower wheel suspension again using engine and gearbox jack
- V.A.G 1383 A- and remove support - T10149- from wheel
hub.
– Remove tensioning strap - T10038- .
– Install wheel and tighten. ⇒ page 320
Specified torques
♦ Use new bolts


♦ Use new nut

4 Suspension link, track rod

⇒ “4.1 Assembly overview - transverse link”, page 198
⇒ “4.2 Removing and installing upper transverse link”,
page 203
⇒ “4.3 Removing and installing lower transverse link”, page 207
⇒ “4.4 Removing and installing track rod”, page 211
4.1 Assembly overview - transverse link

⇒ “4.1.1 Assembly overview - transverse link, track rod, front-
wheel drive”, page 198
⇒ “4.1.2 Assembly overview - transverse link, track rod, four-
4.1.1 Assembly overview - transverse link, track rod, front-wheel drive
1 - Eccentric bolt
❑ For camber adjustment
❑ Check wheel alignment
whenever this compo‐
nent is loosened
⇒ page 347 .
2 - Nut
❑ M12 x 1.5
❑ 95 Nm
❑ Self-locking
❑ Always tighten threaded
connections in unladen
position ⇒ page 9
3 - Eccentric washer
❑ Inner hole with lug
4 - Eccentric bolt
❑ For track adjustment
nent is loosened
⇒ page 347 .
6 - Nut
❑ M12 x 1.5
❑ 95 Nm
❑ Self-locking
position ⇒ page 9
Note
♦ To tighten nuts, set torque

wrench - V.A.G 1332- to 80 Nm.

♦ This torque setting only applies

in conjunction with 18 mm tool
insert - T10179- .
7 - Subframe
❑ Repairing ⇒ page 162 .
8 - Mounting for rear silencer
9 - Bolt
❑ M12 x 1.5 x 110
10 - Lower transverse link
11 - Nut
❑ M12 x 1.5 x 75
❑ Self-locking
❑ Always tighten threaded connections in unladen position ⇒ page 9
12 - Bolt
13 - Threaded rivet
❑ M6
14 - Spreader rivet
15 - Stone deflector
16 - Hexagon bolt
❑ M6 x 12
❑ 8 Nm
17 - Nut
❑ Self-locking
18 - Washer
19 - Bolt
❑ M14 x 1.5 x 115
20 - Washer
21 - Upper transverse link
22 - Washer
23 - Nut
❑ Self-locking
4. Suspension link, track rod 199


25 - Washer
26 - Bolt
❑ M14 x 1.5 x 115
27 - Track rod
❑ Forwards closed (left and right track rods differ)
❑ It is permitted to install mixed types.
28 - Bolt
❑ M12 x 1.5 x 95
29 - Bolt
❑ M12 x 1.5 x 90
30 - Nut
❑ Self-locking

4.1.2 Assembly overview - transverse link, track rod, four-wheel drive

1 - Eccentric bolt
nent is loosened
⇒ page 347 .
❑ Do not turn more than
90° in either direction
(i.e. from minimum to
maximum adjustment
position).
2 - Nut
❑ M12 x 1.5
❑ 95 Nm
❑ Self-locking
❑ Can be loosened and
tightened up to 5 times
for adjustment work.
4 - Eccentric bolt
nent is loosened
⇒ page 347 .
❑ Do not turn more than
90° in either direction
(i.e. from minimum to
maximum adjustment
position).
6 - Nut
❑ M12 x 1.5
❑ 95 Nm
❑ Self-locking
❑ Can be loosened and tightened up to 5 times for adjustment work.
Note
♦ To tighten nuts, set torque

wrench - V.A.G 1332- to 80 Nm.
♦ This torque setting only applies
in conjunction with 18 mm tool
insert - T10179- .

7 - Subframe
8 - Bolt
❑ M12 x 1.5 x 125
10 - Nut
❑ Self-locking
11 - Bolt
❑ M12 x 1.5 x 75
12 - Threaded rivet
❑ M6
13 - Spreader rivet
14 - Stone deflector
15 - Hexagon bolt
❑ M6 x 12
❑ 8 Nm
16 - Nut
❑ Self-locking
17 - Washer
18 - Bolt
❑ M14 x 1.5 x 115
19 - Washer
20 - Upper transverse link
21 - Washer
22 - Nut
❑ Self-locking
24 - Washer
25 - Bolt
❑ M14 x 1.5 x 115

26 - Track rod
❑ Forwards closed (left and right track rods differ)
27 - Bolt
❑ M12 x 1.5 x 125
28 - Bolt
❑ M12 x 1.5 x 95
29 - Nut
❑ Self-locking
4.2 Removing and installing upper trans‐

verse link
⇒ “4.2.1 Removing and installing upper transverse link, front-
⇒ “4.2.2 Removing and installing upper transverse link, four-
4.2.1 Removing and installing upper trans‐

verse link, front-wheel drive

Removing
– Raise vehicle.
– Remove wheel.

– Detach wire -arrow A- for speed sensor from upper suspen‐

sion link.
– Mark position of eccentric bolt -arrow- in relation to subframe,

for example using a felt-tip pen.
– Remove upper transverse link.
Installing
– Insert upper suspension link into vehicle and tighten bolts
hand-tight.
Transverse link may be bolted only when dimension “a” has been
attained ⇒ page 11 .
– Tighten new nut -arrow- to specified torque only.
– To do so, use insert tool 18 mm - T10179- .

On use of insert tool 18 mm - T10179- , tighten nuts to 80 Nm.
– Observe mark made for position of eccentric bolt relative to
subframe.

– Tighten bolt -1- for upper transverse link.
Note
Ensure that a washer is installed between the bolt and the wheel
bearing housing.
– Attach wire -arrow A- for speed sensor to upper suspension

link.
– Install coil spring ⇒ page 241 .
– Perform wheel alignment ⇒ page 347 .
Specified torques
Upper transverse link to wheel bearing housing 130 Nm + 90° further
♦ Use new nuts and bolts
Upper transverse link to subframe 95 Nm

♦ Use new nut ♦ To tighten nuts, set torque wrench - V.A.G
1332- to 80 Nm.
the normal running position ♦ Applies only in conjunction with insert tool,
18 mm - T10179-
4.2.2 Removing and installing upper trans‐

verse link, four-wheel drive

Removing
– Raise vehicle.
– Remove wheel.

– Detach wire -arrow A- for speed sensor from upper suspen‐

sion link.

– Remove upper transverse link -1-.
Installing
– Insert upper suspension link into vehicle and tighten bolts
hand-tight.

– Observe mark made for position of eccentric bolt -arrow- rel‐
ative to subframe.

– Tighten bolt -1- for upper transverse link.
Note
Ensure that a washer is installed between the bolt and the wheel
bearing housing.
– Attach wire -arrow A- for speed sensor to upper suspension

link.
Specified torques
Upper transverse link to subframe 95 Nm

♦ Use new nut ♦ To tighten nuts, set torque wrench - V.A.G
1332- to 80 Nm.
the normal running position ♦ Applies only in conjunction with insert tool,
18 mm - T10179-
4.3 Removing and installing lower trans‐

verse link
⇒ “4.3.1 Removing and installing lower transverse link, front-
⇒ “4.3.2 Removing and installing lower transverse link, four-wheel
drive”, page 209
4.3.1 Removing and installing lower trans‐

verse link, front-wheel drive


Removing
– Raise vehicle.
– Remove wheel.
– Remove bolt -arrow- for lower transverse link -1-.
Vehicles with dynamic headlight range control
– Remove bolts -1- from lower transverse link.

– Remove lower transverse link.
Installing
– Insert lower transverse link into vehicle and hand-tighten bolts.

ative to subframe.
– Install bolts -1- in lower transverse link.

– Tighten bolt -arrow- for lower transverse link -1-.

Specified torques
Lower transverse link to wheel bearing housing 90 Nm + 90° further
Lower transverse link to subframe 95 Nm

♦ Use new nut
Rear left vehicle level sender - G76- to lower transverse 5 Nm

link
4.3.2 Removing and installing lower trans‐

verse link, four-wheel drive

Removing
– Raise vehicle.
– Remove wheel.
– Remove coil spring ⇒ page 243 .


– Disconnect and lower rear part of exhaust system.
– Remove lower transverse link.
Installing
– Insert lower transverse link into vehicle and hand-tighten bolts.

ative to subframe.
– Reinstall rear section of exhaust system.
– Install bolts -1- in lower transverse link.


Specified torques
Lower transverse link to wheel bearing housing 90 Nm + 90° further

♦ Use new nut

link
4.4 Removing and installing track rod

⇒ “4.4.1 Removing and installing track rod, front-wheel drive”,
page 211
⇒ “4.4.2 Removing and installing track rod, four-wheel drive”,
page 213
4.4.1 Removing and installing track rod, front-

wheel drive

Removing

– Raise vehicle.
– Remove wheel.
– Remove bolt -arrow- for track rod -3-.
– Remove nut -arrow- and remove bolt towards rear.

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

The track rod may be bolted only when distance “a” has been

– Tighten bolts -arrows- for anti-roll bar clamp.
– Tighten bolt -arrow- for track rod -3-.
Note
Ensure that a washer is installed between the nut and the wheel
bearing housing.
Specified torques
Track rod to wheel bearing housing 130 Nm + 90° further
Track rod to subframe 90 Nm + 90° further


♦ Use new bolts

♦ Use new nut
4.4.2 Removing and installing track rod, four-

wheel drive


Removing
– Raise vehicle.
– Remove wheel.
– Remove bolt -arrow- for track rod -3-.


If the upper bolt of the anti-roll bar clamp on the right side of the
vehicle cannot be removed, then additional work must be per‐
formed ⇒ page 215 .
BlueMotion vehicles

WARNING


– Raise wheel hub with support - T10149- and engine and gear‐
box jack - V.A.G 1383 A- far enough that bolts of right anti-roll
bar clamp are accessible.

– Remove nut -arrow- and remove bolt towards rear.

– Remove track rod -1-.
Installing
– Install track rod on vehicle and tighten bolts hand tight.
Note
Note different versions of track rods: downwards open or forwards

closed.
– Insert track rod -1- into vehicle and hand-tighten bolts.

– Tighten bolts -arrows- for anti-roll bar clamp.
– Tighten bolt -arrow- for track rod -3-.
Note
Ensure that a washer is installed between the nut and the wheel
bearing housing.

Specified torques
Track rod to wheel bearing housing 130 Nm + 90° further
Track rod to subframe 90 Nm + 90° further


♦ Use new bolts

♦ Use new nut

5 Suspension strut, shock absorber,

spring
⇒ “5.1 Assembly overview - suspension strut, shock absorber,
spring”, page 218
⇒ “5.2 Removing and installing shock absorbers”, page 224
⇒ “5.3 Repairing shock absorber”, page 233
⇒ “5.4 Removing and installing spring”, page 241
5.1 Assembly overview - suspension strut,

shock absorber, spring
⇒ “5.1.1 Assembly overview - suspension strut, shock absorber,
spring, basic version, front-wheel drive”, page 218
spring, basic version, four-wheel drive”, page 220
spring, adaptive chassis control DCC, front-wheel drive”,
page 222
spring, adaptive chassis control DCC, four-wheel drive”,
page 223
5.1.1 Assembly overview - suspension strut, shock absorber, spring, basic ver‐
sion, front-wheel drive

1 - Lower spring seat

❑ End of coil spring turned
to stop
2 - Assembly aid
❑ Not necessary to rein‐
stall once removed
3 - Coil spring
⇒ page 241 .
Note
♦ Note information for conversion

to Nivomat under all circumstan‐
ces ⇒ page 220 .
to heavy-duty running gear un‐
der all circumstances
⇒ page 220 .
4 - Upper spring seat

5 - Bolt
❑ 180 Nm
6 - Bolt
7 - Shock absorber
⇒ page 224 .
❑ Take different running gear designs into account ⇒ page 358 .
Note

ces ⇒ page 220 .
⇒ page 220 .
8 - Washer
5. Suspension strut, shock absorber, spring 219

Converting to Nivomat
Observe the following important points when converting the rear
axle to Nivomat
♦ Only convert vehicles with standard running gear. Other run‐
ning gears must not be converted to Nivomat.
♦ The Nivomat shock absorber and the respective coil spring
must be fitted to both sides of the vehicle ⇒ electronic parts
catalogue “ETKA”
♦ A vehicle alignment check must be performed after exchang‐
ing the shock absorbers and coil springs. The camber on the
rear axle must be set to 1°45'.
Further information for the Nivomat can be found in ⇒ Self-study
programme No. 357 ; The Nivomat .
Converting to heavy-duty running gear
DANGER!
The vehicle must be restricted to a maximum speed of 210 km/

h at the engine control unit when converting the vehicle to
heavy-duty running gear. Speeds above 210 km/h can cause
damage to the drive shafts. Use ⇒ Vehicle diagnostic tester to
carry out Guided Function “Limiting maximum speed”.
5.1.2 Assembly overview - suspension strut, shock absorber, spring, basic ver‐
sion, four-wheel drive


to stop
2 - Assembly aid
❑ Not necessary to rein‐
stall once removed
3 - Coil spring
❑ Note different running
gear versions
⇒ page 358 , vehicle
data sticker.
⇒ page 243 .
Note

ces ⇒ page 221 .
⇒ page 222 .

5 - Bolt
❑ 180 Nm
6 - Bolt
❑ M10 x 35
7 - Shock absorber
❑ Take different running gear designs into account ⇒ page 358 .
8 - Washer
Converting to Nivomat
Observe the following important points when converting the rear
axle to Nivomat
♦ Only convert vehicles with standard running gear. Other run‐
ning gears must not be converted to Nivomat.
♦ The Nivomat shock absorber and the respective coil spring
must be fitted to both sides of the vehicle ⇒ electronic parts
catalogue “ETKA”
♦ A vehicle alignment check must be performed after exchang‐
ing the shock absorbers and coil springs. The camber on the
rear axle must be set to 1°45'.

Further information for the Nivomat can be found in ⇒ Self-study

programme No. 357 ; The Nivomat .
Converting to heavy-duty running gear
DANGER!
The vehicle must be restricted to a maximum speed of 210 km/

h at the engine control unit when converting the vehicle to
heavy-duty running gear. Speeds above 210 km/h can cause
damage to the drive shafts. Use ⇒ Vehicle diagnostic tester to
carry out Guided Function “Limiting maximum speed”.
5.1.3 Assembly overview - suspension strut, shock absorber, spring, adaptive

chassis control DCC, front-wheel drive

to stop
2 - Coil spring
gear types into account
⇒ page 358
⇒ page 241 .
4 - Bracket
❑ For rear body accelera‐
tion sender - G343-
5 - Body acceleration sender,
rear - G343-
⇒ page 303 .
❑ Note installation posi‐
tion on bracket
⇒ page 223
6 - Bolt
❑ 5 Nm
7 - Bolt
❑ 180 Nm
8 - Bolt
❑ M10 x 35
9 - Shock absorber with rear left/right shock absorber damper adjustment valve - N338/N339-
❑ Take different running gear types into account ⇒ page 358 .

10 - Washer
Installation position rear body acceleration sender - G343- on

bracket
Retaining lug -1- must engage in recess in rear body acceleration
sender - G343- -arrow-.
5.1.4 Assembly overview - suspension strut, shock absorber, spring, adaptive

chassis control DCC, four-wheel drive

to stop
2 - Coil spring
❑ Note different running
gear versions
⇒ page 358 , vehicle
data sticker.
⇒ page 243 .
4 - Bracket
❑ For rear body accelera‐
tion sender - G343-
rear - G343-
⇒ page 305 .
❑ Note installation posi‐
tion on bracket
⇒ page 224
6 - Bolt
❑ 5 Nm
7 - Bolt
❑ 180 Nm

8 - Bolt
❑ M10 x 35
9 - Shock absorber
❑ Note different running gear versions ⇒ page 358 , vehicle data sticker.
10 - Washer
Installation position rear body acceleration sender - G343- on

bracket
Lug of bracket -1- must engage in recess in rear body acceleration
sender - G343- -arrow-.
5.2 Removing and installing shock absorb‐

ers
⇒ “5.2.1 Removing and installing shock absorbers, basic version,
front-wheel drive”, page 224
⇒ “5.2.2 Removing and installing shock absorbers, basic version,
four-wheel drive”, page 226
⇒ “5.2.3 Removing and installing shock absorbers, adaptive chas‐
sis control DCC, front-wheel drive”, page 228
⇒ “5.2.4 Removing and installing shock absorbers, adaptive chas‐
sis control DCC, four-wheel drive”, page 230
5.2.1 Removing and installing shock absorb‐

ers, basic version, front-wheel drive


Removing
– Raise vehicle.
– Remove wheel.
– Remove rear wheel housing liner ⇒ General body repairs,
exterior; Rep. gr. 66 ; Wheel housing liner; Removing and
installing wheel housing liner .
– Remove bolts -1- for shock absorber -2-.

– Remove shock absorber.
Installing
The shock absorber may be bolted to the wheel bearing housing
only when dimension “a” has been attained ⇒ page 11 .
– Install shock absorber -2- and tighten bolts -1-.

– Tighten bolt -arrow-.

– Install rear wheel housing liner ⇒ General body repairs, ex‐
terior; Rep. gr. 66 ; Wheel housing liner; Removing and
Specified torques
Shock absorber to body 50 Nm + 45° further
♦ Use new bolts

♦ Use new bolt

ers, basic version, four-wheel drive

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

– Remove bolts -1- for shock absorber -2-.

Installing
– Install shock absorber -2- and tighten bolts -1-.

– Install rear wheel housing liner ⇒ General body repairs, ex‐
terior; Rep. gr. 66 ; Wheel housing liner; Removing and
Specified torques
♦ Use new bolts


ers, adaptive chassis control DCC,
front-wheel drive

Removing
– Raise vehicle.
– Remove wheel.
Only for left shock absorber
– Unscrew rear left vehicle level sender - G76- from lower trans‐
verse link.
– Disconnect connector and pull cable off shock absorber.

– Remove bolts from shock absorber.

– Pull rear body acceleration sender - G343- off shock absorber
mount.

Installing
Note installation position of shock absorber.

The rear left/right shock absorber damper adjustment valve -
N338/N339- must point to the rear outwards to the wheel.
– Put rear body acceleration sender - G343- on shock absorber

mount.
– Place bracket from rear onto shock absorber mount so that
retaining lugs -1- engage in recesses in shock absorber
mount.
– Turn bracket forwards so it makes contact with shock absorber
mount.
Lug -arrow- is used for calibrating bracket for rear body acceler‐
ation sender - G343- .

– Install shock absorber and tighten bolts.


– Push plug onto rear left/right shock absorber damper adjust‐
– Screw rear left vehicle level sender - G76- onto lower trans‐
verse link.
– Install wheel housing liner ⇒ General body repairs, exterior;
Specified torques
♦ Use new bolts

♦ Use new bolt

link

ers, adaptive chassis control DCC, four-
wheel drive

Removing
– Raise vehicle.
– Remove wheel.


– Unscrew rear left vehicle level sender - G76- from lower trans‐
verse link.
– Disconnect connector and pull cable off shock absorber
– Remove bolts from shock absorber.

– Pull rear body acceleration sender - G343- off shock absorber
mount.

Installing
Note installation position of shock absorber.

The rear left/right shock absorber damper adjustment valve -
N338/N339- must point to the rear outwards to the wheel.

– Put rear body acceleration sender - G343- on shock absorber

mount.
– Place bracket from rear onto shock absorber mounting so that
retaining lugs -1- engage in recesses in shock absorber
mounting.
– Turn bracket forwards so it makes contact with shock absorber
mount.
Lug -arrow- is used for calibrating bracket for rear body acceler‐
ation sender - G343- .

– Install shock absorber and tighten bolts.

– Push plug onto rear left/right shock absorber damper adjust‐
– Screw rear left vehicle level sender - G76- onto lower trans‐
verse link.
– Install wheel housing liner ⇒ General body repairs, exterior;
Specified torques
♦ Use new bolts

♦ Use new bolt

link

5.3 Repairing shock absorber

⇒ “5.3.1 Repairing shock absorbers, basic version, front-wheel
drive”, page 233
⇒ “5.3.2 Repairing shock absorbers, basic version, four-wheel
drive”, page 234
⇒ “5.3.3 Repairing shock absorbers, adaptive chassis control
DCC, front-wheel drive”, page 236
⇒ “5.3.4 Repairing shock absorbers, adaptive chassis control
DCC, four-wheel drive”, page 238
5.3.1 Repairing shock absorbers, basic version, front-wheel drive
1 - Shock absorber
⇒ page 224 .
2 - Protective tube
3 - Bump stop
4 - Shock absorber mounting
5 - Nut
❑ 25 Nm
❑ Loosening and tighten‐
ing ⇒ page 234
6 - Cover

Dismantling and assembling shock absorber

Special tools and work‐
shop equipment re‐
quired
♦ Torque wrench -
V.A.G 1332-

T10001-
Loosening and tighten‐

ing threaded connection
for shock absorber
mounting
1- Commercially
available ratchet
handle
2- Socket - T10001/9-
3- Ratchet handle -
T10001/11-
4- Socket - T10001/1-
Specified torque
Shock absorber mounting to shock absorber 25 Nm
♦ Use new nut
5.3.2 Repairing shock absorbers, basic version, four-wheel drive

1 - Shock absorber
⇒ page 226 .
2 - Protective tube
3 - Bump stop
5 - Nut
❑ 25 Nm
ing ⇒ page 236
6 - Cover


quired
♦ Torque wrench -
V.A.G 1332-

T10001-

for shock absorber
mounting
1 - Commercially availa‐
ble ratchet handle
2 - Socket - T10001/9-
3 - Ratchet handle -
T10001/11-
4 - Socket - T10001/1-
Specified torque
♦ Use new nut
5.3.3 Repairing shock absorbers, adaptive chassis control DCC, front-wheel

drive

1 - Shock absorber with rear

left/right shock absorber
damper adjustment valve -
N338/N339-
⇒ page 228 .
2 - Deflector cap
3 - Protective tube
4 - Bump stop
6 - Nut
❑ 25 Nm
ing ⇒ page 238
7 - Cover


quired
♦ Torque wrench -
V.A.G 1332-

T10001-

for shock absorber
mounting
1- Commercially
available ratchet
handle
2- Socket - T10001/9-
3- Ratchet handle -
T10001/11-
4- Socket - T10001/1-
Specified torque
♦ Use new nut
5.3.4 Repairing shock absorbers, adaptive chassis control DCC, four-wheel drive


left/right shock absorber
damper adjustment valve -
N338/N339-
⇒ page 230 .
2 - Protective cap
3 - Protective tube
4 - Bump stop
6 - Nut
❑ M10 x 1.0
❑ 25 Nm
ing ⇒ page 240
7 - Cover


quired
♦ Torque wrench -
V.A.G 1332-

T10001-

for shock absorber
mounting
1 - Commercially availa‐
ble ratchet handle
2 - Socket - T10001/9-
3 - Ratchet handle -
T10001/11-
4 - Socket - T10001/1-
Specified torque
♦ Use new nut

5.4 Removing and installing spring

⇒ “5.4.1 Removing and installing spring, front-wheel drive”, page
241
⇒ “5.4.2 Removing and installing spring, four-wheel drive”,
page 243
5.4.1 Removing and installing spring, front-

wheel drive
♦ Suspension strut clamp - V.A.G 1752-
♦ Spring retainer - V.A.G 1752/3A-
♦ Adapter - V.A.G 1752/9- , not illustrated

Removing
– Raise vehicle.
– Remove wheel.

– Insert spring compressor -3-.

1- Spring retainer - V.A.G 1752/3A-
2- Adapter - V.A.G 1752/9-
WARNING
Ensure that coil spring is correctly seated in spring retainers -

V.A.G 1752/3A- -2-.
– Compress coil springs until they can be removed.
Note
Use a spanner or a reversible ratchet handle to compress spring

compressor.
Installing
– Check that the lower spring plate is not damaged.
– If necessary, replace the lower spring plate.
– Place lower plate onto bottom of coil spring.

End of spring -arrow- must lie against stop on bottom spring seat.
– Mount spring together with spring plate.
– The bottom spring seat has a pin.
– Insert this pin in holes in lower transverse link -arrow-.

– Insert upper spring seat into upper end of spring.

– The bead of the spring seat -arrow- must lie against the coil
spring correctly.
– Release tension on coil spring while locating upper spring seat
on lug on body.
– Remove spring tensioner .
5.4.2 Removing and installing spring, four-

wheel drive
♦ Suspension strut clamp - V.A.G 1752-
♦ Spring retainer - V.A.G 1752/3A-
♦ Adapter - V.A.G 1752/9- , not illustrated

Removing
– Raise vehicle.
– Remove wheel.

– Insert spring compressor -3-.

1- Spring retainer - V.A.G 1752/3A-
2- Adapter - V.A.G 1752/9-
WARNING
Ensure that coil spring is correctly seated in spring retainers -

V.A.G 1752/3A- -2-.
– Compress coil springs until they can be removed.
Note
Use a spanner or a reversible ratchet handle to compress spring

compressor.
Installing
– Check that the lower spring plate is not damaged.
– If necessary, replace the lower spring plate.
– Place lower plate onto bottom of coil spring.

End of spring -arrow- must lie against stop on bottom spring seat.
– Mount spring together with spring plate.
– The bottom spring seat has a pin.
– Insert this pin in holes in lower transverse link -arrow-.

– Insert upper spring seat into upper end of spring.

– The bead of the spring seat -arrow- must lie against the coil
spring correctly.
– Release tension on coil spring while locating upper spring seat
on lug on body.
– Remove spring tensioner .

6 Wheel bearing, trailing arm

⇒ “6.1 Assembly overview - wheel bearing, trailing arm”,
page 246
⇒ “6.2 Removing and installing wheel bearing housing”,
page 251
⇒ “6.3 Removing and installing wheel bearing unit”, page 258
⇒ “6.4 Renewing bonded rubber bush for wheel bearing housing”,
page 263
⇒ “6.5 Removing and installing trailing arm with mounting brack‐
et”, page 270
⇒ “6.6 Repairing trailing arm”, page 276
6.1 Assembly overview - wheel bearing,

trailing arm
⇒ “6.1.1 Assembly overview - wheel bearing housing, wheel bear‐
ing unit, trailing arm, front-wheel drive”, page 246
⇒ “6.1.2 Assembly overview - wheel bearing housing, wheel bear‐
ing unit, trailing arm, four-wheel drive”, page 249
6.1.1 Assembly overview - wheel bearing housing, wheel bearing unit, trailing
arm, front-wheel drive

1 - Cover
3 - Coupling rod
bearing housing
4 - Bolt
❑ Observe tightening se‐
quence
5 - Trailing arm
⇒ page 270 .
6 - Bolt
❑ 8 Nm
7 - Rear right speed sensor -
G44- / rear left speed sensor -
G46-
❑ Can be tested in Guided
Fault Finding using
⇒ Vehicle diagnostic
tester.
❑ Before inserting sensor,
clean inner surface of
hole and coat with lubri‐
cating paste - G 000
650- .
⇒ page 251 .
10 - Washer
❑ Chamfer of washer must face outwards.
❑ The washer or a wheel bearing pre-seal has been fitted ⇒ page 248
11 - Nut
❑ 45 Nm
12 - Brake disc
13 - Bolt
❑ 4 Nm
14 - Dust cap
❑ Pressing off and driving in ⇒ page 258
A proper seal can be achieved only by installing a new grease cap.
15 - Bolt
❑ Loosen and tighten using bit - T10162 A-
❑ 200 Nm + 180° further
6. Wheel bearing, trailing arm 247

16 - Wheel hub with wheel bearing
❑ ABS sensor ring is installed in wheel bearing.
The wheel bearing and wheel hub are assembled as one unit
This wheel bearing unit is maintenance-free and does not require adjustment. Adjustments and repairs are not
possible!
17 - Bolt
❑ 12 Nm
18 - Splash plate
19 - Bolt
21 - Bolt
Wheel bearing pre-seal -1-
Caution
When installing the wheel bearing pre-seal -1-, make sure that
the hole -arrow- is centred on the speed sensor -2-.

6.1.2 Assembly overview - wheel bearing housing, wheel bearing unit, trailing
arm, four-wheel drive
1 - Cover
3 - Coupling rod
bearing housing
4 - Bolt
❑ Observe tightening se‐
quence ⇒ page 275 .
5 - Trailing arm
⇒ page 273 .
6 - Drive shaft
❑ Assembly overview
⇒ page 281 .
⇒ page 283 .
❑ M14 x 1.5 x 45
⇒ page 255 .
9 - Rear right speed sensor -
G44- / rear left speed sensor -
G46-
❑ Can be tested in Guided
Fault Finding using ⇒ Vehicle diagnostic tester.
❑ Before inserting sensor, clean inner surface of hole and coat with lubricating paste - G 000 650- .
10 - Hexagon socket head bolt
❑ M6 x 16
❑ 8 Nm
12 - Nut
❑ M12 x 25
❑ 40 Nm
❑ Self-locking

13 - Brake disc
14 - Bolt
❑ 4 Nm
15 - Bolt
WARNING
There
ture ⇒ page 251 .
When
ing installed.
The
torque must also be
used.
The
The
ing and tightening
⇒ page 288 .

16 - Wheel hub with wheel bearing
❑ ABS sensor ring is installed in wheel bearing.
The wheel bearing and wheel hub are assembled in one housing.
This wheel bearing unit is maintenance- and play-free. Adjustments and repairs are not possible!
17 - Bolt
❑ M6 x 12
❑ 12 Nm
18 - Splash plate
19 - Bolt
❑ M12 x 1.5 x 80
21 - Bolt
❑ M10 x 35



housing
⇒ “6.2.1 Removing and installing wheel bearing housing, front-
⇒ “6.2.2 Removing and installing wheel bearing housing, four-
6.2.1 Removing and installing wheel bearing

housing, front-wheel drive

Removing
– Raise vehicle.
– Remove wheel.
– Remove wheel bearing unit ⇒ page 258
– Take off cover.
– Remove ABS speed sensor out of wheel bearing housing.

– Remove bolt for track rod -1-, upper transverse link -2- and
lower transverse link -3- from wheel housing -4-.
– Remove coupling rod -arrow- from wheel bearing housing.
– Hold wheel bearing housing and unscrew bolts -arrows-.

– Remove coupling rod -1- from trailing arm.
Installing
Threaded connection for trailing arm and wheel bearing housing

may be tightened only after all other components (particularly the
spring and shock absorber) of respective wheel suspension have
been installed. To tighten, wheel suspension must be in extended
position. Only then do trailing arm and wheel bearing housing
move to the necessary position -arrows-.
It is essential to follow specified sequence of work steps below!

– Install bolts for track rod -1-, upper transverse link -2- and low‐
er transverse link -3-, but do not tighten.
– Attach coupling rod -arrow- to wheel bearing housing -4- hand-
tight.
– Screw in bolts -arrows- and fit coupling rod -1- to trailing arm.
– Tighten bolt -arrow- for shock absorber.

Bolt connections on wheel bearing housing may be tightened only
when dimension “a” has been obtained ⇒ page 11 .
– Tighten bolt for track rod -1-, upper transverse link -2- and
lower transverse link -3-.
– Tighten nut for coupling rod -arrow-.

– Tighten bolts -arrow-.
Vehicles with wheel bearing pre-seal
Caution
When installing the wheel bearing pre-seal -1-, make sure that
the hole -arrow- is centred on the speed sensor -2-.

– Fit cover plate.
– Install wheel bearing unit ⇒ page 258
– Install ABS speed sensor in wheel bearing housing.
– Install brake disc.
– Install brake carrier with brake caliper ⇒ Brake systems; Rep.
gr. 46 ; Rear brake; Assembly overview - rear brake .
Specified torques
Wheel bearing housing to lower suspension link 90 Nm + 90° further

Wheel bearing housing to track rod 130 Nm + 90° further

Trailing arm to wheel bearing housing 90 Nm + 45° further

♦ Use new bolts
Coupling rod to wheel bearing housing. 40 Nm

♦ Use new nut
Splash plate to wheel bearing housing 12 Nm

ABS speed sensor to wheel bearing housing 8 Nm


♦ Use new bolt
Brake disc to wheel bearing housing. 4 Nm

housing, four-wheel drive

Removing
– Raise vehicle.
– Remove wheel.
– Remove brake carrier with brake caliper and tie to body using
wire ⇒ Brake systems; Rep. gr. 46 ; Rear brake; Assembly
overview - rear brake .
– Remove ABS speed sensor from wheel bearing housing.

– Unscrew bolts -arrows- and remove splash plate -1-.
– Remove bolt for track rod -1-, upper transverse link -2- and
lower transverse link -3- from wheel housing -4-.
– Unbolt coupling rod from wheel bearing housing -arrow-.
– Remove coupling rod -1- from trailing arm.

– Hold wheel bearing housing and unscrew bolts -arrows-.
– Take out wheel bearing housing.
Installing
ing:
Position: threaded connection between trailing arm and wheel

bearing housing

– Fit trailing arm to wheel bearing housing with bolts -arrows-

but do not tighten yet.
– Attach coupling rod -1- to trailing arm but do not tighten nut
yet.
hub.
– Tighten trailing arm bolts -arrows- to specified torque, ensur‐
ing that components are positioned as required ⇒ page 256 .
– Bolt coupling rod -1- to wheel bearing housing and anti-roll bar.
The threaded connections on the wheel bearing housing may be
tightened only when the dimension between the centre of wheel
hub and lower edge of wheel housing has been attained
⇒ page 14 .
Caution


Specified torques



Wheel bearing housing to track rod 150 Nm + 90° further

♦ Use new bolts
Coupling rod to wheel bearing housing. 40 Nm

♦ Use new nut

ABS speed sensor to wheel bearing housing 8 Nm
bing”
♦ Use new bolt
ribbing”
♦ Use new bolt

unit
⇒ “6.3.1 Removing and installing wheel bearing unit, front-wheel
drive”, page 258
⇒ “6.3.2 Removing and installing wheel bearing unit, four-wheel
drive”, page 261
6.3.1 Removing and installing wheel bearing unit, front-wheel drive


equipment required
♦ Hub grease cap puller - VW
637/2-
♦ Fitting sleeve - 3241-
1332-
1410-
♦ Tool insert - T10162 A-

Removing
– Raise vehicle.
– Remove wheel.
– Loosen grease cap from seat by tapping lightly on the claw of
the hub grease cap puller - VW 637/2- -1-.

– Pry off grease cap.

1- Hub grease cap puller - VW 637/2-
Note
Hang brake caliper from body.
– Remove bolt for brake disc and remove brake disc.
– Unscrew bolt -1- using socket - T10162 A- -2-.
Caution
Do not use an impact driver when removing bolt -1- with socket
- T10162 A- -2-!
– Pull wheel hub/wheel bearing unit -2- from stub axle.

Installing
– Carefully push wheel hub/wheel bearing unit -2- onto stub

axle.
Caution
Ensure that the wheel hubs/wheel bearing unit does not cant!
– Screw in new bolt -1- and tighten to specified torque.

Note
♦ First tighten bolt to specified torque setting using torque

wrench.
♦ Use a rigid spanner for turning further by angle.
Caution
Do not use an impact driver when tightening bolt -1- with socket
- T10162 A- -2-!
– Drive in dust cap.

1- Drift sleeve - 3241/4-
Always renew removed grease caps.
Damaged grease caps may allow moisture to enter the bearing.
Therefore, always use the tool shown in the illustration.
Specified torques
♦ Use new bolt

unit, four-wheel drive


Removing
– Raise vehicle.
– Remove wheel.
– Remove drive shaft ⇒ page 283
Note
Do not suspend brake caliper by brake hose.

– Pull wheel hubs/wheel bearing unit from wheel bearing hous‐
ing.
Installing
ing:
Caution



Specified torques
♦ Use new bolt
6.4 Renewing bonded rubber bush for

wheel bearing housing
⇒ “6.4.1 Renewing bonded rubber bush for wheel bearing hous‐
ing, front-wheel drive”, page 263
⇒ “6.4.2 Renewing bonded rubber bush for wheel bearing hous‐
ing, four-wheel drive”, page 266
6.4.1 Renewing bonded rubber bush for wheel bearing housing, front-wheel drive


equipment required
♦ Assembly tool - 3346-
♦ Carrier - 3390-
1332-

Removing
– Raise vehicle.
– Remove wheel.
– Remove wheel bearing unit ⇒ page 258
– Take off cover.


– Position tools as shown in figure.

1- Nut - 3346/3-
2- Carrier - 3390-
3- Sleeve - 3350-
4- Nut (commercially available)
5- Spindle - 3346/2-
– Pull out bonded rubber bush by turning spindle.
Installing
Pulling in bonded rubber bush

1- Nut - 3346/3-
2- Thrust piece - 3346-
4- Fitting sleeve - 3378-
6- Spindle - 3346/2-
– Pull in bonded rubber bush by turning spindle.
Note
♦ Do not use lubricant.

♦ Insert bearing carefully so it does not cant.

– Install wheel bearing unit ⇒ page 258


Specified torques

6.4.2 Renewing bonded rubber bush for wheel bearing housing, four-wheel drive


equipment required
♦ Carrier - 3390-
1332-

Removing
– Raise vehicle.
– Remove wheel.
Note
Do not suspend brake caliper by brake hose.

– Unscrew bolts -arrows- and remove splash plate -1-.


1- Nut - 3346/3-
2- Carrier - 3390-
3- Sleeve - 3350-
5- Spindle - 3346/2-
– Pull out bonded rubber bush by turning spindle.
Installing
Pulling in bonded rubber bush


1- Nut - 3346/3-
2- Thrust piece - 3346-
4- Fitting sleeve - 3378-
6- Spindle - 3346/2-
– Pull in bonded rubber bush by turning spindle.
Note
♦ Do not use lubricant.

♦ Insert bearing carefully so it does not cant.


Specified torques


6.5 Removing and installing trailing arm with

mounting bracket
⇒ “6.5.1 Removing and installing trailing arm with mounting brack‐
et, front-wheel drive”, page 270
⇒ “6.5.2 Removing and installing trailing arm with mounting brack‐
et, four-wheel drive”, page 273
6.5.1 Removing and installing trailing arm with

mounting bracket, front-wheel drive

Removing
– Raise vehicle.
– Remove wheel.
– Remove mounting bracket -1- by pushing out inner pins of riv‐
ets -arrows A-.
– Unbolt coupling rod -2- from trailing arm.

BlueMotion vehicles
underbody cover .

– Remove trailing arm with mounting bracket.
If the trailing arm is to be renewed, the mounting bracket must be
removed from the longitudinal member.
– Clamp trailing arm in a vice so that mounting bracket -1- lies

against vice -arrow-.
The position of the mounting bracket relative to the trailing arm
must then be adjusted ⇒ page 271 .
Determining position of mounting bracket in relation to trailing arm
Measure dimension -a- from middle of bolt to outer edge of

mounting bracket.
Dimension -a- is 57.5 ± 1 mm.
1- Mounting bracket
2- Trailing arm
– Tighten bolt when dimension -a- is set.
Installing


bearing housing
– Position trailing arm and mounting bracket on wheel bearing

housing with bolts -arrows- but do not tighten yet.
yet.
– Raise wheel suspension using engine and gearbox jack -
V.A.G 1383 A- until mounting bracket contacts body.
– Tighten bolts -arrows B- on position of old imprint.

– Mount line -1- on mounting bracket -arrows A-.
hub.
– Tighten trailing arm bolts -arrows B- to specified torque. Make

sure components are in required position when doing this
⇒ page 272 .
– Tighten nut for coupling rod -2- on wheel bearing housing.
– Attach mounting bracket -1- by pushing in inner pins of rivets
-arrows A-.


Specified torques
♦ Use new bolts
Trailing arm to mounting bracket 90 Nm + 90° further

♦ Use new bolt

♦ Use new bolts
Coupling rod to trailing arm. 40 Nm

♦ Use new nut
6.5.2 Removing and installing trailing arm with

mounting bracket, four-wheel drive


Removing
– Raise vehicle.
– Remove wheel.
– Unbolt coupling rod -2- from trailing arm.
BlueMotion vehicles
underbody cover .

– Remove trailing arm with mounting bracket.
If the trailing arm is to be renewed, the mounting bracket must be
removed from the longitudinal member.

The position of the mounting bracket relative to the trailing arm
must then be adjusted ⇒ page 274 .
Determining position of mounting bracket in relation to trailing arm

Measure dimension -a- from middle of bolt to outer edge of

mounting bracket.
Dimension -a- is 57.5 ± 1 mm.
1- Mounting bracket
2- Trailing arm
– Tighten bolt when dimension -a- is set.
Installing

bearing housing
– Position trailing arm and mounting bracket on wheel bearing

housing with bolts -arrows- but do not tighten yet.
yet.
– Raise wheel suspension using engine and gearbox jack -
V.A.G 1383 A- and support - T10149- until mounting bracket
contacts body.
– Tighten bolts -arrows B- on position of old imprint.

– Mount line -1- on mounting bracket -arrows A-.
hub.

– Tighten bolts -arrows B- for trailing arm to specified torque,

observing required position of components ⇒ page 275 .
– Tighten nut for coupling rod -2- on wheel bearing housing.
– Attach mounting bracket -1- by pushing in inner pins of rivets
-arrows A-.

Specified torques
♦ Use new bolts
Trailing arm to mounting bracket 90 Nm + 90° further

♦ Use new bolt

♦ Use new bolts
Coupling rod to trailing arm. 40 Nm

♦ Use new nut
6.6 Repairing trailing arm

⇒ “6.6.1 Repairing trailing arm, front-wheel drive”, page 276
⇒ “6.6.2 Repairing trailing arm, four-wheel drive”, page 278
6.6.1 Repairing trailing arm, front-wheel drive


equipment required
♦ Removal tool - 3372-

– Remove trailing arm ⇒ page 270 .


1- Tube - T10230/3-
2- Thrust piece - T10230/10-
3- Removal tool - 3372-
Position bonded rubber bush as follows:

1- Make a connecting line between the gap -arrow A- and the
recess -arrow-, e.g. with a straightedge.
2- Locate the bonded rubber bush such that the upper right lug
-1- is to the left of the line.
3- The lower left lug -2- must then be to the right of the con‐
necting line.
Note
Take great care to ensure that the installation position of the bon‐
ded rubber bush is correct relative to the bush in the trailing arm.

1- Tube - T10230/5-
2- Thrust plate - T10230/12- (chamfer must face bonded rub‐
ber bush)
– Press bonded rubber bush in flush.
– Attach mounting bracket to trailing arm ⇒ page 271 .
– Install trailing arm ⇒ page 271 .
6.6.2 Repairing trailing arm, four-wheel drive


equipment required
♦ Removal tool - 3372-

– Remove trailing arm ⇒ page 273 .


1- Tube - T10230/3-
2- Thrust piece - T10230/10-
Position bonded rubber bush as follows:

1- Make a connecting line between the gap -arrow A- and the
recess -arrow-, e.g. with a straightedge.
2- Locate the bonded rubber bush such that the upper right lug
-1- is to the left of the line.
3- The lower left lug -2- must then be to the right of the con‐
necting line.
Note
Take great care to ensure that the installation position of the bon‐
ded rubber bush is correct relative to the bush in the trailing arm.

1- Tube - T10230/5-
2- Thrust plate - T10230/12- (chamfer must face bonded rub‐
ber bush)
– Press bonded rubber bush in flush.
– Attach mounting bracket to trailing arm ⇒ page 274 .
– Install trailing arm ⇒ page 273 .

7 Drive shaft
⇒ “7.1 Assembly overview - drive shaft”, page 281
⇒ “7.3 Loosening and tightening drive shaft bolt”, page 287
⇒ “7.4 Dismantling and assembling drive shaft”, page 290
⇒ “7.5 Checking inner constant velocity joint”, page 293
7.1 Assembly overview - drive shaft

plete unit
ing plastic hammer
2 - Bolt
WARNING
There
ture ⇒ page 283 .
When
ing installed.
The
torque must also be
used.
The
The
ing and tightening
⇒ page 288 .

3 - Drive shaft
4 - Clamp
7. Drive shaft 281

5 - Boot
6 - Clamp
7 - Dished spring
❑ With inner splines
8 - Retaining ring
10 - Clamp
11 - Locking plate
❑ M8 x 48
❑ 40 Nm
13 - Retaining ring
❑ Remove and install with circlip pliers - VW 161 A-
14 - Seal
16 - Dished spring
❑ With inner splines


7.2 Removing and installing jointed shaft

Caution

Removing
7. Drive shaft 283

Caution

instructions:
– Remove wheel.
– Remove bolts -arrows- for lower suspension link -1- and track
rod -2- from wheel bearing housing.

– Loosen drive shaft at gearbox flange.
– Swing wheel bearing housing out and pull drive shaft out of
inner splines.

serted.

7. Drive shaft 285


Note
– Remove drive shaft.

Installing
ing:
agonally to 10 Nm.
– Tighten multi-point socket head bolts in diagonal sequence to
40 Nm.
– Tighten bolt for drive shaft at wheel hub:
Caution


The threaded connections on the wheel bearing housing may be
tightened only when the dimension measured between the centre
of wheel hub and lower edge of wheel housing before work was
started has been attained ⇒ page 14 .
Specified torques
bing”
♦ Use new bolt
ribbing”
♦ Use new bolt


Drive shaft to flange shaft of rear final drive 40 Nm
♦ Use new bolts ♦ Initially tighten diagonally to 10 Nm
7.3 Loosening and tightening drive shaft

bolt
head bolt with ribbing”, page 287
head bolt without ribbing”, page 288

bolt, twelve-point head bolt with ribbing
♦ Socket, 24 mm - T10361A-
7. Drive shaft 287


Caution

instructions:


Note
aged.


bolt, twelve-point head bolt without rib‐
bing

♦ Socket, 24 mm - T10361A-

Caution

instructions:

7. Drive shaft 289


Note
aged.

7.4 Dismantling and assembling drive shaft

equipment required
♦ Tube - VW 416 B-

♦ Circlip pliers - VW 161 A-

1331-
1332-
Dismantling
Drive off outer constant velocity joint
– Fold back boot.
– Drive constant velocity joint off drive shaft using drift -A-.
The drift must be positioned exactly on the triple roller star of the
constant velocity joint.
Driving joint on
7. Drive shaft 291


– Drive joint protective boot off joint using a drift.
– Remove both clamps and slide boot towards outer joint.
Assembling
Installation position of dished spring on inner and outer joints

1- Dished spring
– Press joint on to stop.
– Install retaining ring.
Note
Chamfer on internal circumference of ball hub (splines) must face

contact shoulder on drive shaft.


O-type clip.
cant pliers).
Note
♦ Because a stainless steel boot clamp is required due to the

hard material of the joint boot (compared to rubber), it is pos‐
sible to tighten the clamp only with clamp tensioner - V.A.G
1682- .
♦ Use torque wrench -C- with adjustment range 5 … 50 Nm, (e.g.
torque wrench - V.A.G 1331- ).
force for the clip will not be attained although the correct torque
is applied.
7.5 Checking inner constant velocity joint

Removing
soiled, and to check the running surfaces and the balls for wear
and damage.
– Press out joint body in direction of arrow.
– Press balls out of cage.
Note
The ball hub and joint body are paired. Do not interchange them.
7. Drive shaft 293

– Tip ball hub out of ball cage via ball track -arrows-.
– Check joint body, ball hub, ball cage and balls for pitting and
traces of seizing.
Excessive circumferential backlash in the joint is noticeable dur‐
ing load change jolts. In this case the joint must be replaced.
Smoothing and traces of wear of the balls are no reason to renew
the joint.
Installing
– Insert hub into cage via the two chamfers. The hub can be
installed in any position. Press balls into cage.
The ball hub has two different distances between the ball tracks:
a smaller one and a larger one.
– Insert hub complete with cage and balls into joint body, making
sure that a smaller gap -b- faces open side of joint body.
– Also make sure that chamfer on inner circumference of ball
hub is visible after swinging it into place.
– Swing ball hub into place by swinging hub out of cage as

shown in figure -arrows-.

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

-arrow-.
– Checking function of constant velocity joint
The constant velocity joint is correctly assembled if the ball hub
can be moved by hand backwards and forwards over its entire
range of axial movement.
7. Drive shaft 295

43 – Self-levelling suspension
1 Electronically controlled damping
system
⇒ “1.1 Overview of fitting locations - electronically controlled
damping system”, page 296
⇒ “1.2 Cable routing - front axle”, page 298
⇒ “1.3 Cable routing - rear axle”, page 300
⇒ “1.4 Removing and installing electronically controlled damping
control unit”, page 300
⇒ “1.5 Re-adapting reference position (default position)”,
page 301
⇒ “1.6 Removing and installing front body acceleration senders”,
page 301
⇒ “1.7 Removing and installing rear body acceleration sender”,
page 303
⇒ “1.8 Removing and installing bracket for body acceleration
sender”, page 306
⇒ “1.9 Shock absorber damping adjustment button”, page 308
1.1 Overview of fitting locations - electronically controlled damping system
Caution
The body acceleration senders are not allowed to be swapped

over.
296 Rep. gr.43 - Self-levelling suspension

1 - Shock absorber damping

adjustment button - E387-
❑ Location: in front of gear
lever in centre console
❑ Explanations
⇒ page 308
right shock absorber damper
adjustment valve - N339- .
front-wheel drive
⇒ page 228
four-wheel drive
⇒ page 230
3 - Electronically controlled
damping control unit - J250-
❑ Location: behind lug‐
gage compartment trim
on right side.
⇒ page 300 .
❑ If the electronically con‐
trolled damping control
unit - J250- is renewed,
the basic setting of the
adaptive chassis control
DCC must be per‐
formed. ⇒ page 301
rear - G343-
❑ Location: on rear left
shock absorber mount
front-wheel drive
⇒ page 303
❑ Removing and installing four-wheel drive ⇒ page 305
5 - Shock absorber with rear left shock absorber damper adjustment valve - N338- .
❑ Removing and installing front-wheel drive ⇒ page 228
6 - Rear left vehicle level sender - G76-
❑ Removing and installing front-wheel drive ⇒ page 317
❑ If the rear left vehicle level sender - G76- is removed and installed, the basic setting of the adaptive
chassis control DCC must be performed ⇒ page 301
Basic setting of headlights ⇒ Vehicle diagnostic tester
7 - Front left body acceleration sender - G341-

8 - Shock absorber with front left shock absorber damper adjustment valve - N336-
❑ Removing and installing suspension strut ⇒ page 59
❑ Repairing suspension strut ⇒ page 50
9 - Front left vehicle level sender - G78- and front right vehicle level sender - G289-
❑ If the rear left vehicle level sender - G78- and front right vehicle level sender - G289- are removed and
installed, the basic setting of the adaptive chassis control DCC must be performed ⇒ page 301
1. Electronically controlled damping system 297

Basic setting of headlights ⇒ Vehicle diagnostic tester
10 - Shock absorber with front right shock absorber damper adjustment valve - N337-
❑ Removing and installing suspension strut ⇒ page 59
❑ Repairing suspension strut ⇒ page 50
11 - Front right body acceleration sender - G342-
1.2 Cable routing - front axle

⇒ “1.2.1 Cable routing left front axle, left”, page 298
⇒ “1.2.2 Cable routing right front axle, right”, page 299
1.2.1 Cable routing left front axle, left
Note
♦ Always check the cable routing.

♦ Always make sure all cables are correctly hooked into the brackets provided, and are not twisted.
1 - Cable for front left shock

absorber damper adjustment
valve - N336-
❑ Cable must be hooked
into bracket on shock
absorber -arrow-
2 - Cable for front left speed
sensor - G47-
3 - Brake pad wear indicator
wire.

1.2.2 Cable routing right front axle, right
Note

1 - Cable for front right shock

absorber damper adjustment
valve - N337-
absorber -arrow-
2 - Cable for front right speed
sensor - G45-

1.3 Cable routing - rear axle
Note

1 - Cable for rear left/right

shock absorber damper ad‐
justment valve - N338/N339-
absorber -arrow-
2 - Cable for rear right/left
speed sensor - G44/G46-
1.4 Removing and installing electronically

controlled damping control unit
Removing
Location: behind luggage compartment trim on right side.
– Switch off all electrical consumers.
– Pull out ignition key.
– Remove right luggage compartment side trim ⇒ General body
repairs, interior; Rep. gr. 70 ; Luggage compartment trims;

Removing and installing side panel trim for luggage compart‐

ment .
– Remove electronically controlled damping control unit - J250-
-1- from the stowage compartment
– Release connector -2- and pull off.
Installing
ing:
– Perform basic setting of adaptive chassis control DCC
⇒ page 301 .
1.5 Re-adapting reference position (default

position)
– Connect ⇒ Vehicle diagnostic tester and select “Guided Fault
Finding”.
Running gear
Wheel damping electronic control unit
Functions
Basic setting
Follow instructions on screen to perform basic setting.
1.6 Removing and installing front body ac‐

celeration senders
⇒ “1.6.1 Removing and installing front body acceleration sender,
left”, page 301
⇒ “1.6.2 Removing and installing front body acceleration sender,
right”, page 302
1.6.1 Removing and installing front body ac‐

celeration sender, left

Removing
– Remove wiper arms ⇒ Electrical system; Rep. gr. 92 ; Wind‐
screen wiper system; Removing and installing wiper arms .

– Remove left plenum chamber cover ⇒ General body repairs,

exterior; Rep. gr. 50 ; Plenum chamber bulkhead; Removing
and installing plenum chamber cover .
– Release connector and pull off.
– Unscrew bolts and remove front left body acceleration sender
- G341- .
Installing
Caution
The front body acceleration senders must never be swapped

over with the rear body acceleration senders , assignment in
⇒ Electronic parts catalogue “ETKA” .
– Note installation position of front left body acceleration sender

- G341- on bracket.
Lug of bracket -1- must engage in recess in front left body accel‐
eration sender - G341- -arrow-
Note
Specified torques
Front left body acceleration sender - G341- to bracket 5 Nm
1.6.2 Removing and installing front body ac‐

celeration sender, right

Removing
– Remove wiper arms ⇒ Electrical system; Rep. gr. 92 ; Wind‐
screen wiper system; Removing and installing wiper arms .

– Remove left and right plenum chamber cover ⇒ General body

repairs, exterior; Rep. gr. 50 ; Plenum chamber bulkhead;
Removing and installing plenum chamber cover .
– Unscrew nuts and remove front right body acceleration sender
- G342- .
Installing
Caution
The front body acceleration senders must never be swapped

over with the rear body acceleration senders , assignment in
– Note installation position of front right body acceleration send‐

er - G342- on the bracket.
Lug of bracket -1- must engage in recess in front right body ac‐
celeration sender - G342- -arrow-
Note
Specified torques
Front right body acceleration sender - G342- to bracket 5 Nm
1.7 Removing and installing rear body ac‐

celeration sender
⇒ “1.7.1 Removing and installing rear body acceleration sender,
front-wheel drive”, page 303
⇒ “1.7.2 Removing and installing rear body acceleration sender,
four-wheel drive”, page 305
1.7.1 Removing and installing rear body ac‐

celeration sender, front-wheel drive


Removing
– Raise vehicle.
– Remove wheel.
– Remove rear left wheel housing liner ⇒ General body repairs,
– Unscrew bolts and remove rear body acceleration sender -
G343- .
Installing
Caution
The rear body acceleration sender must never be swapped

over with the front body acceleration senders , assignment in
– Note installation position of rear body acceleration sender -

G343- on the bracket.
Retaining lug -1- must engage in recess in front right body accel‐
– Install rear left wheel housing liner ⇒ General body repairs,
Specified torques
Rear body acceleration sender - G343- to bracket 5 Nm

1.7.2 Removing and installing rear body ac‐

celeration sender, four-wheel drive

Removing
– Raise vehicle.
– Remove wheel.
– Remove rear left wheel housing liner ⇒ General body repairs,
– Unscrew bolts and remove rear body acceleration sender -
G343- .
Installing
Caution
The rear body acceleration sender must never be swapped

over with the front body acceleration senders , assignment in
– Note installation position of rear body acceleration sender -

G343- on the bracket.
– Install rear left wheel housing liner ⇒ General body repairs,
Specified torques
Rear body acceleration sender - G343- to bracket 5 Nm

1.8 Removing and installing bracket for

body acceleration sender
♦ Drift - VW 222 A-
♦ Drill bit with ∅ 11 mm

Removing
– Remove front left body acceleration sender - G341-
⇒ page 301
– Remove front right body acceleration sender - G342-
⇒ page 302
– Unscrew and remove bolts for bracket and remove bracket
from shock absorber turret.
Installing
Caution
The body acceleration senders are not allowed to be swapped

over, assignment in ⇒ Electronic parts catalogue “ETKA” .
– Clean shock absorber turret.

Front left body acceleration sender - G341-
– Screw front left body acceleration sender - G341- onto brack‐
et.

– Note installation position of front left body acceleration sender

- G341- on bracket.
Lug of bracket -1- must engage in recess in front left body accel‐
eration sender - G341- -arrow-
Note
Front right body acceleration sender - G342-

– Screw front right body acceleration sender - G342- onto brack‐
et.
– Note installation position of front right body acceleration send‐

er - G342- on the bracket.
Note

– Pull off bonding surface seal on bracket or attach double-sided
adhesive tape
– Fix bracket using a drill bit with ∅ 11 mm and drift - VW 222

A- .
Note
The holes in the bracket must line up with the holes in the shock
absorber turret.
– Screw in bolts one after another until finger-tight and then

tighten to specified torque.
– Push plug onto body acceleration sender
Specified torques
♦ Use new bolts

1.9 Shock absorber damping adjustment

button
The shock absorber damping adjustment button - E387- is located
on the right next to the gear lever in the centre console.
The shock absorber damping adjustment button - E387- sets the
system to three different modes:
♦ Standard
♦ Sport
♦ Comfort
The operating sequence is -Normal- > -Sport- > -Comfort- >
-Normal- > …
In the shock absorber damping adjustment button - E387- , the
fields -S- and -C- are back-lit with a yellow function LED when
selection of the corresponding mode is active.
When -Normal- mode is selected, the shock absorber damping
adjustment button - E387- is not illuminated.

2 Vehicle level senders

⇒ “2.1 Assembly overview - front vehicle level senders”,
page 309
⇒ “2.2 Assembly overview - rear vehicle level senders”,
page 310
⇒ “2.3 Removing and installing front vehicle level senders”, page
314
⇒ “2.4 Removing and installing rear vehicle level senders”,
page 316
2.1 Assembly overview - front vehicle level senders
Note
♦ The front left/right vehicle level sender - G78/G289- is only available as a replacement part complete with
coupling rod and upper and lower retaining plates.
♦ Replace with subframe installed.
1 - Subframe
2 - Bolt
❑ M6 x 16
❑ 9 Nm
3 - Front left vehicle level send‐
er - G78- and front right vehicle
level sender - G289-
❑ Complete with attach‐
ments
❑ Lever -arrow- must face
outwards
⇒ page 314 .
❑ If the rear left vehicle
level sender - G78- and
front right vehicle level
sender - G289- are re‐
moved and installed, the
basic setting of the
DCC must be performed
⇒ page 301
❑ Following renewal, ba‐
sic settings for headlight
must be performed.
Basic setting of headlights
⇒ Vehicle diagnostic tester
4 - Suspension link
5 - Nut
❑ 9 Nm
❑ Self-locking
2. Vehicle level senders 309

2.1.1 Assembly overview: front left/right vehi‐

cle level sender - G78/G289- for adap‐
tive chassis control DCC
2.2 Assembly overview - rear vehicle level
senders
⇒ “2.2.1 Assembly overview - rear vehicle level senders, basic
version, front-wheel drive”, page 310
⇒ “2.2.2 Assembly overview - rear vehicle level senders, basic
version, four-wheel drive”, page 312
⇒ “2.2.3 Assembly overview - rear vehicle level senders, adaptive
chassis control DCC, front-wheel drive”, page 313
⇒ “2.2.4 Assembly overview - rear vehicle level senders, adaptive
chassis control DCC, four-wheel drive”, page 314
2.2.1 Assembly overview - rear vehicle level senders, basic version, front-wheel
drive
Note
The rear left vehicle level sender - G76- is only available as a replacement part complete with coupling rod and
upper and lower retaining plates.

1 - Bolt
❑ M5 x 20
❑ 5 Nm
2 - Pop rivet nut
3 - Subframe
4 - Rear left vehicle level send‐
er - G76-
ments
outwards
⇒ page 316 .
must be performed.
Checking basic setting of
headlights ⇒ Vehicle diagnos‐
tic tester

2.2.2 Assembly overview - rear vehicle level senders, basic version, four-wheel
drive
Note
The rear left vehicle level sender - G76- is only available as a replacement part complete with coupling rod and
upper and lower retaining plates.
1 - Bolt
❑ M5 x 20
❑ 5 Nm
2 - Pop rivet nut
3 - Subframe
er - G76-
ments
outwards
⇒ page 317 .
must be performed.
Checking basic setting of
headlights ⇒ Vehicle diagnos‐
tic tester

2.2.3 Assembly overview - rear vehicle level senders, adaptive chassis control
DCC, front-wheel drive
Note
♦ The vehicle level sender is available as a replacement part only complete with coupling rod and upper and
lower retaining plates.
♦ Renewing without removing subframe ⇒ page 317 .
1 - Subframe
2 - Bolt
❑ M5 x 20
❑ 5 Nm
er - G76-
ments
outwards
⇒ page 317 .
level sender - G76- is re‐
⇒ page 301
must be performed.

2.2.4 Assembly overview - rear vehicle level senders, adaptive chassis control
DCC, four-wheel drive
Note
♦ The vehicle level sender is available as a replacement part only complete with coupling rod and upper and
lower retaining plates.
♦ Renewing without removing subframe ⇒ page 318 .
1 - Subframe
2 - Bolt
❑ M5 x 20
❑ 5 Nm
er - G76-
ments
outwards
⇒ page 318 .
level sender - G76- is re‐
⇒ page 301
must be performed.
2.3 Removing and installing front vehicle

level senders


Removing
Note
♦ To remove front left vehicle level sender - G78- , steering must

be turned to right lock to ensure clearance between suspen‐
sion link and anti-roll bar.
♦ To remove front right vehicle level sender - G289- , steering
must be turned to left lock to ensure clearance between sus‐
pension link and anti-roll bar.
– Separate connector.
– Remove bolt and nut.
– Take out vehicle level sender.
Installing
Note
♦ Lever on vehicle level sender must face towards outside of

vehicle.
♦ Thread of vehicle level sender must be screwed into front hole
in suspension link. Lug of bracket for vehicle level sender must
engage in rear hole in order to guarantee correct installation
position.

⇒ page 301
– Carry out basic setting of headlights ⇒ Vehicle diagnostic test‐
er
Specified torques
Bolt to subframe 9 Nm
Nut 9 Nm
♦ Use new nut

2.4 Removing and installing rear vehicle

level senders
⇒ “2.4.1 Removing and installing rear vehicle level senders, front-
⇒ “2.4.2 Removing and installing rear vehicle level senders, four-
⇒ “2.4.3 Removing and installing rear vehicle level senders, adap‐
tive chassis control DCC, front-wheel drive”, page 317
⇒ “2.4.4 Removing and installing rear vehicle level senders, adap‐
tive chassis control DCC, four-wheel drive”, page 318
2.4.1 Removing and installing rear vehicle

level senders, front-wheel drive
Note
Removing and installing rear left vehicle level sender - G76- for
adaptive chassis control DCC, front-wheel drive ⇒ page 317


Removing
– Remove subframe bolts -3-.
– Remove rear left vehicle level sender - G76- .
Installing
The lever of rear left vehicle level sender - G76- must point to
outer side of vehicle.
– Perform basic setting of headlights following replacement
⇒ Vehicle diagnostic tester.
Specified torques
link and subframe


level senders, four-wheel drive
Note
Removing and installing rear left vehicle level sender - G76- for
adaptive chassis control DCC, four-wheel drive ⇒ page 318
Removing
– Remove subframe bolts -3-.
Installing
The lever of rear left vehicle level sender - G76- must face outside
of vehicle.
– Perform basic setting of headlights following replacement
Specified torques
link and subframe

level senders, adaptive chassis control
DCC, front-wheel drive


Removing
– Remove bolts.
Installing
Lever on vehicle level sender must face towards outside of vehi‐
cle.
⇒ page 301
er
Specified torques
Bolt to subframe/lower transverse link 5 Nm

level senders, adaptive chassis control
DCC, four-wheel drive


Removing
– Remove bolts.
Installing
Lever on vehicle level sender must face towards outside of vehi‐
cle.
⇒ page 301
er
Specified torques
Bolt to subframe/lower transverse link 5 Nm

44 – Wheels, tyres, vehicle geometry

1 Wheels, tyres
⇒ “1.1 Torque settings for wheel bolts”, page 320
⇒ “1.2 Tyres with run-flat properties”, page 320
⇒ “1.3 Pressing tyre off wheel rim”, page 322
⇒ “1.4 Removing tyre from wheel”, page 323
⇒ “1.5 Installing tyre”, page 324
⇒ “1.6 Wheel change”, page 324
⇒ “1.7 Tyre sealant”, page 328
⇒ “1.8 Tyre sealant disposal”, page 328
⇒ “1.9 Models with breakdown set”, page 328
1.1 Torque settings for wheel bolts

Wheel bolt to wheel hub for all vehicles
Specified torque: 120 Nm.
– Before fitting wheel, protect wheel centring seat against cor‐
rosion ⇒ page 324 .
♦ Position of anti-theft wheel bolts for steel wheels
⇒ page 328 .
♦ Install anti-theft wheel bolts with master set for wheel bolts .
1.2 Tyres with run-flat properties

♦ As an option, the Passat can be equipped with self-sealing
Continental tyres.
♦ This technology, referred to as ContiSeal, is a system that has
been developed to allow the car to continue to be driven even
if a nail or screw has penetrated the tyre: if screws or nails
penetrate the tyre, a protective layer on the inside of the tyre
running surface immediately seals the resulting holes.
♦ This means no air can escape. The sealing function is effective
for almost all air leaks induced by objects up to 5 millimetres
in diameter.
Note
These may not be fitted in combination with other tyre types, e.g.
run-flat tyres and “normal” tyres.
320 Rep. gr.44 - Wheels, tyres, vehicle geometry

Explanation for mobility tyres

♦ ContiSeal is a preventative sealing compound installed by the
manufacturer Continental as an integral component of the pro‐
duction process.
♦ ContiSeal is a self-adhesive, viscous sealing compound that
is applied in an even coat from shoulder to shoulder on the
inside of the running surface.
♦ The sealing compound represents an integral component of
the mobility tyre.
♦ A mobility tyre can be identified by a special logo on the outside
of the sidewall.
Caution
The sealing compound is not intended as a permanent tyre

repair following a puncture.
1. Wheels, tyres 321

♦ If a foreign body with a diameter up to 5 mm punctures the

running surface of a mobility tyre, the function of the sealing
compound is to surround the object and to prevent any possi‐
ble air loss by effecting an almost immediate seal.
♦ The sealing compound is designed to seal the majority of
puncture types caused by foreign bodies up to 5 mm in diam‐
eter.
♦ ContiSeal significantly reduces the frequency of flat tyres, but
it is not intended to allow the tyre to be operated with reduced
pressure or when flat (without air).
♦ In all other respects, mobility tyres display the same properties
as tyres without the ContiSeal sealing compound.
Handling mobility tyres
♦ When handling mobility tyres, take particular care to maintain
cleanliness during work and also when storing tyres.
♦ The sealing compound on the inside of the running surface of
the tyre is not protected and is therefore very susceptible to
any type of contamination.
♦ We recommend storing each tyre individually in a sufficiently
large plastic bag or similar.
♦ As with any other tyre, mobility tyres should be regularly
checked for signs of cuts, penetrations and loss of inflation
pressure.
♦ This inspection should be conducted at least once or twice a
month, and always prior to each long trip.
♦ Penetrations or damage that is not attended to in good time
can lead to a loss of inflation pressure and/or failure of the tyre.
♦ Mobility tyres with damage by cuts and/or penetrations must
be inspected immediately.
♦ It is necessary to decide whether the tyre must be taken out
of use and scrapped.
♦ Removing and installing the mobility tyre involves the same
procedure as a normal tyre.
1.3 Pressing tyre off wheel rim

New wheels with a modified contour have been introduced for all
vehicles as of model year 2005.
The tyre fitting unit must be fitted with the tyre fitting head de‐
signed for these wheels.
WARNING
Otherwise there is a danger that the wheel will be damaged.
If the tyre fitting unit has not yet been modified, please contact the
manufacture of the unit.
Notes on safety and conditions for removing and fitting tyres
(wheels with tyre pressure monitoring)
• It is extremely important to adhere to the instructions and
warnings in the following descriptions.
• Check whether the tyre pressure sensor should also be re‐
placed ⇒ Vehicle diagnostic tester.

Note
♦ Ensure that the tyre does not contact the tyre pressure sensor
during removal or fitting.
♦ The tyre pressure sensor must not come into contact with wa‐
ter or be blown upon with compressed air when the wheel rim
is cleaned.
– Remove air from tyre by screwing out the nickel-plate valve

element.
– When pressing off a tyre using tyre fitting equipment with a
press-off plate, always ensure that the tyre valve/ tyre pres‐
sure sensor -arrow- is directly opposite the bead breaker -1-.
The bead breaker must be positioned no more than 2 cm from
wheel rim flange.
– Remove balancing weights and rough dirt from wheel.
– Press both tyre beads off all round and liberally coat tyre and
wheel rim flange with tyre assembly paste -arrow-.
1.4 Removing tyre from wheel

Tyres which have been filled or sealed using tyre sealant must be
drained before removal.
Caution
♦ Avoid eye and skin contact with tyre sealant.

♦ It is a health hazard and may cause eye irritation and al‐
lergies.
♦ During this work, wear protective gloves and safety gog‐
gles.
– Place the wheel on an even surface.

– Unscrew and remove the valve insert of tyre valve.

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

area of tyre.
– Hold wheel over a suitable container and drain sealant.
– Remove tyre from rim.
– Clean wheel rim with, for example, a moist cloth.
1.5 Installing tyre

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

⇒ “1.6.1 Wheel change, protecting wheel centring seat against
corrosion”, page 324
⇒ “1.6.2 Wheel change, installation requirements”, page 325
⇒ “1.6.3 Wheel change, installation instructions for wheel
change”, page 326
⇒ “1.6.4 Wheel change, wheel installation”, page 327
⇒ “1.6.5 Wheel change, position of anti-theft wheel bolts for steel
wheels”, page 328
1.6.1 Wheel change, protecting wheel cen‐

tring seat against corrosion
Applies to alloy and steel wheels
When changing a wheel, wheel centring seat should be waxed
using wax spray to prevent corrosion between wheel centring seat
and rim ⇒ Electronic Parts Catalogue “ETKA” .
– Remove wheel.
– Thoroughly clean wheel centring seat on wheel hub and the
centring ring of the wheel rim.

– Apply wax to centring area -arrow- with a brush.

Ensure that only centring ring -arrow- but not contact surface of
wheel rim has been waxed. Otherwise, the brakes will be soiled,
which would reduce the braking efficiency.
WARNING
Wheel bolts, contact surfaces of wheel hub and wheel rim and
wheel hub threads must not be waxed. Never treat wheel se‐
curing bolts with lubricant or corrosion protection materials!
1.6.2 Wheel change, installation require‐

ments
Warming cold tyres to minimum installation temperature
Note
This instruction also applies to ultra-high performance tyres

(height/width ratio smaller than/same as 45 % and speed symbol
greater than/same as V).
WARNING
The minimum installation temperature of a tyre should be be‐

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

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

• Once the condensation process has ended, the condensation

should be dried with a cloth so that the further warming proc‐
ess is not delayed due to a temperature drop caused by
evaporation.
Warming times:
♦ Assuming a minimum room temperature of 19 °C and a tyre
temperature of 0 °C or more, a tyre should be kept at least at
19 °C for at least 2 hours
♦ Assuming a minimum room temperature of 19 °C and a tyre
temperature of below 0 °C, a tyre should be kept at least at 19
°C for at least 2.5 hours
Warming recommendations:
♦ If possible, tyres should be stored in the workshop 1 day before
they are fitted (order preparation)
♦ Store on an insulated base, pallet or the like, as high up as
possible
♦ Position the tyres individually to allow the warm air to “circu‐
late” around them effectively
♦ Wipe off condensation
♦ Never heat with a radiator or hot air blower!
1.6.3 Wheel change, installation instructions

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

This is important to ensure that the wheel bolts and the wheels
are properly secured.
Note
On vehicles with tyre pressure indicator, the tyre pressure indi‐

cator has to be recalibrated any time one or more wheels are
removed or fitted ⇒ page 332 .
– Check to ensure that contact surfaces -arrows- on brake disc

are free of corrosion and dirt.

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

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

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

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

must be renewed.
1.6.4 Wheel change, wheel installation

– Preserving wheel centring seat ⇒ page 324 .
1- When fitting the wheel, pull in all wheel bolts uniformly by
hand.
2- Tighten wheel bolts in diagonal sequence to 30 Nm.
3- Lower vehicle onto the floor and tighten all wheel bolts with
the torque wrench to the prescribed torque in diagonal se‐
quence ⇒ page 320 .
WARNING
Do not use an impact screwdriver to screw in the bolts.

1.6.5 Wheel change, position of anti-theft

wheel bolts for steel wheels
Caution
Adherence to position of anti-theft wheel bolts to tyre valve on

steel wheels is vital.
Anti-theft wheel bolts may only be fitted on right or left -arrows- of

valve -1- on steel wheels.
Secure installation of hub cap on steel wheel is only possible if
anti-theft wheel bolts are installed in this position.
1.7 Tyre sealant

The tyre sealant in the bottle has a limited shelf-life.
The bottle therefore has an expiry date -arrow-.
Renew tyre sealant when the expiry date is reached (the tyre
sealant must not be older than 4 years).
If the bottle has been opened, e.g. to repair a tyre, then it must
also be renewed.
Observe regulations for disposal.
1.8 Tyre sealant disposal

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

Depending on equipment level, vehicles are equipped with a
breakdown set.

Breakdown set is located in luggage compartment. It consists of

a compressor and a bottle of tyre sealant.

2 Tyre pressure monitoring system

⇒ “2.1 Overview of fitting locations - tyre pressure monitor sys‐
tem”, page 330
⇒ “2.2 System description - tyre pressure monitoring system”,
page 331
⇒ “2.3 Assembly overview - tyre pressure sensor”, page 333
⇒ “2.4 Removing and installing tyre pressure monitor control unit”,
page 335
⇒ “2.5 Removing and installing bracket for tyre pressure monitor
control unit”, page 335
⇒ “2.6 Removing and installing tyre pressure sensor”, page 336
⇒ “2.7 Changing tyres on vehicles with tyre pressure monitoring
system”, page 341
⇒ “2.8 Removing and installing metal valve body”, page 345
2.1 Overview of fitting locations - tyre pressure monitor system
1 - Front right tyre pressure

sensor - G223-
for Technical Support
variant ⇒ page 336
for Production variant
⇒ page 338
2 - Rear right tyre pressure
sensor - G225-
⇒ page 338
3 - Tyre pressure monitor con‐
trol unit - J502-
⇒ page 335 .
❑ Location: right rear
mounting bracket
4 - Bracket for tyre pressure
monitor control unit - J502-
⇒ page 335 .
5 - Rear left tyre pressure sen‐
sor - G224-
⇒ page 338
6 - Front left tyre pressure sensor. - G222-
❑ Removing and installing for Technical Support variant ⇒ page 336

❑ Removing and installing for Production variant ⇒ page 338
2.2 System description - tyre pressure mon‐

itoring system
⇒ “2.2.1 System description - tyre pressure monitoring system,
tyre pressure monitor display”, page 331
⇒ “2.2.2 System description - tyre pressure monitoring system,
tyre pressure monitoring system (TPMS) with autolocation”, page
332
2.2.1 System description - tyre pressure mon‐

itoring system, tyre pressure monitor
display
General notes:
The tyre pressure monitor display system is part of the software
in the ABS control unit - J104- . The system is used to detect slow
tyre pressure loss from a wheel. Event memory entries for the tyre
pressure monitor display are stored in the ABS control unit -
J104- . The tyre pressure monitor display compares the wheel
speeds and consequently the rolling circumferences of the indi‐
vidual wheels with the help of the ABS speed sensors.
After the following work or modifications, the tyre pressure mon‐
itor display button - E492- must be pressed and held until a
confirmation is sounded.
♦ Change in tyre pressure
♦ Changing one or more wheels
♦ Interchanging wheels, e.g. from front to rear
♦ Removing and fitting one or more wheels
A change in a wheel's rolling circumference will be indicated by
the tyre pressure monitor warning lamp - K220- lighting up in the
dash panel insert. A tyre's rolling circumference may change as
a result of:
♦ Insufficient tyre inflation pressure.
♦ Structural tyre damage.
♦ One-sided loading of vehicle
♦ Increased load on one axle, e.g. due to towing a trailer
♦ Use of snow chains.
♦ Temporary spare wheel installed
♦ Wheel renewal.
2. Tyre pressure monitoring system 331

System fault in the ABS system

If a fault in the ABS is displayed by the ESP and TCS warning
lamp - K155- or the traction control system warning lamp - K86- ,
then the tyre pressure monitor warning lamp - K220- -arrow- will
also light up. However, no fault will be stored in the system for the
tyre monitor display.
The warning lamp cannot be extinguished by pressing the TPM
button - E492- . In this case, please carry out the following steps:
– Connect ⇒ Vehicle diagnostic tester and select “Guided Fault
Finding” ⇒ Vehicle diagnostic tester.
Running gear
Brake system
01- self-diagnosis-capable system TRW 450
03 - anti-lock braking system ABS/EDL/TCS/ESP
03 - functions
Adapting J104 with tyre pressure monitor display

Perform basic setting
Basic setting must be performed after every modification to the
wheels.
• Ignition must be switched on.
• Handbrake of vehicle must be applied.
Following each wheel change, the SET button must be actuated

whilst the ignition is switched on and the vehicle is stationary until
an audible signal is sounded. The audible signal confirms basic
setting.
The audible signal confirms basic setting.
2.2.2 System description - tyre pressure mon‐

itoring system, tyre pressure monitoring
system (TPMS) with autolocation
♦ As in the past, the system is based on sensors in the tyre which
transmit the air pressure to the tyre pressure monitor control
unit - J502- .
♦ The “autolocation” function enables the system to display tyre
pressures and warnings with accurate positioning in the dash
panel insert after covering a short distance.
♦ The “Intelligent Antenna” is a combination of a tyre pressure
monitor control unit and a central receiver antenna.
♦ No manual programming procedure is necessary after wheel
electronics have been renewed or tyre sets changed. The Tyre
Pressure Monitoring System automatically identifies new tyre
pressure sensors and programs these as soon as driving com‐
mences.

Further detailed information on the Tyre Pressure Monitoring

System (TPMS) with autolocation is available in ⇒ Self-study pro‐
gramme No. 488 ; The Passat 2011 .
2.3 Assembly overview - tyre pressure sen‐

sor
⇒ “2.3.1 Assembly overview - tyre pressure sensor, version 1”,
page 333
⇒ “2.3.2 Assembly overview - tyre pressure sensor, version 2”,
page 334
2.3.1 Assembly overview - tyre pressure sensor, version 1
Note
♦ Version 1 has been replaced by version 2.

♦ Only the version 2 parts are available; refer to ⇒ Electronic Parts Catalogue “ETKA” .
♦ It is permissible to combine version 1 and version 2 parts.
1 - Valve cap
2 - Nut
❑ Separate part of
⇒ Item 7 (page 333) .
❑ 4 Nm
3 - Washer
⇒ Item 7 (page 333) .
4 - Wheel rim
❑ Fitting tyre ⇒ page 324 .
5 - Sealing ring
⇒ Item 7 (page 333) .
6 - Valve core
❑ Always renew when
changing tyre
Note
Do not use brass valve cores; in‐

stead, use only nickel-plated (silver)
valve cores (because of corrosion).
7 - Metal valve
❑ Supplied as spare part
complete with bolt
⇒ page 345 .
8 - Bolt
❑ Torx bolt (Technical
Support variant)
❑ Separate part of ⇒ Item 7 (page 333) .

❑ 4 Nm
❑ Square-head bolt with flat head (Production variant)
9 - Tyre pressure sensor
❑ Front left tyre pressure sensor. - G222-
❑ Front right tyre pressure sensor - G223-
❑ Rear left tyre pressure sensor - G224-
❑ Rear right tyre pressure sensor - G225-
❑ Removing and installing for Technical Support variant ⇒ page 336
❑ Removing and installing for Production variant ⇒ page 338
Note
The tyre pressure sensors have a

lifetime of approx. 10 years.
2.3.2 Assembly overview - tyre pressure sensor, version 2
1 - Tyre pressure sensor

❑ Front left tyre pressure
sensor. - G222-
❑ Front right tyre pressure
sensor - G223-
❑ Rear left tyre pressure
sensor - G224-
❑ Rear right tyre pressure
sensor - G225-
⇒ page 340
2 - Bolt
❑ Square-head bolt with
flat head
❑ Is supplied as a replace‐
ment part complete with
the tyre pressure sensor
⇒ Electronic parts cata‐
logue “ETKA”
3 - Metal valve
❑ Is supplied as a replace‐
ment part complete with
the tyre pressure sensor
⇒ Electronic parts cata‐
logue “ETKA”
4 - Valve core
❑ Always renew when
changing tyre
5 - Rim
6 - Union nut
❑ 4 Nm
♦ When tightening, do not
use metal valve as a coun‐
terhold.
♦ The result of a disc being placed in the union nut is that the metal valve is first screwed onto the tyre pressure
sensor when the nut is tightened. The tyre pressure sensor is screwed onto the rim after the disc breaks.

❑ Always renew after removing
7 - Valve cap
2.4 Removing and installing tyre pressure

monitor control unit
Location:
The tyre pressure monitor control unit - J502- is fitted to the right
rear mounting bracket.
Removing
– Switch off ignition.
– If fitted, remove rear right floor trim ⇒ General body repairs,
exterior; Rep. gr. 66 ; Underbody cover; Assembly overview
- underbody cover .
– Unscrew bolts for lower spoiler of rear bumper cover ⇒ Gen‐
eral body repairs, exterior; Rep. gr. 63 ; Rear bumper; As‐
sembly overview - rear bumper .
– Press spoiler downwards slightly.
– Press lug -arrow- slightly upwards and withdraw tyre pressure
monitor control unit - J502- -2- from bracket.
Installing
2.5 Removing and installing bracket for tyre

pressure monitor control unit
Removing
– Remove tyre pressure monitor control unit - J502-
⇒ page 335 .
– Remove rear bumper cover ⇒ General body repairs, exterior;
Rep. gr. 63 ; Rear bumper; Assembly overview - rear bumper .

– Unclip cable -1- from bracket -2-.

– Press 4 lugs -arrows- inwards simultaneously and withdraw
bracket -2- slightly from metal panel.
– Press lugs -3- out of panel and withdraw bracket -2-.
Installing
– All the lugs of the bracket -2- must be properly engaged.
2.6 Removing and installing tyre pressure

sensor
⇒ “2.6.1 Removing and installing tyre pressure sensor, version 1,
customer service version”, page 336
⇒ “2.6.2 Removing and installing tyre pressure sensor, version 1,
production version”, page 338
⇒ “2.6.3 Removing and installing tyre pressure sensor, version 2”,
page 340
2.6.1 Removing and installing tyre pressure

sensor, version 1, customer service ver‐
sion


Removing
Note

♦ Only the version 2 parts are available; refer to ⇒ Electronic
Parts Catalogue “ETKA” .
– Remove tyre from wheel ⇒ page 343

Before proceeding any further, check to determine which variant
is installed.
I - Technical Support variant
In the Technical Support variant the tyre pressure sensor is at‐
tached to the valve with a bolt with an internal Torx head -1-.
If the Technical Support variant is installed, the following repair
procedure must be used ⇒ page 337 .
II - Production variant
In the Production variant the tyre pressure sensor is attached to
the valve with a square-head bolt with a flat head -2-.
If the Production variant is installed, the following repair procedure
must be used ⇒ page 339 .
– Unscrew bolt -arrow- for tyre pressure sensor -1-.

– Counter hold on metal valve (for example using 2 mm twist
drill).
Installing
Caution
♦ Before installing tyre pressure sensor , clean valve hole.

– Press tyre pressure sensor -1- against wheel rim and tighten
-arrow-.
drill).
Note
♦ After fitting, carry out a visual inspection and check that it is

securely seated. The tyre pressure sensor -1- must be bolted
such that there is no play, and its support feet must be located
in the drop centre of the rim.
♦ Once fitted, retightening of the screw connection to the speci‐
fied torque is not permitted.
Specified torques
Tyre pressure sensor to metal valve 4 Nm

sensor, version 1, production version

Removing
Note

♦ Only the version 2 parts are available; refer to ⇒ Electronic
Parts Catalogue “ETKA” .
– Remove tyre from wheel ⇒ page 343

Before proceeding any further, check to determine which variant

is installed.
I - Technical Support variant
In the Technical Support variant the tyre pressure sensor is at‐
tached to the valve with a bolt with an internal Torx head -1-.
If the Technical Support variant is installed, the following repair
procedure must be used ⇒ page 337 .
II - Production variant
In the Production variant the tyre pressure sensor is attached to
the valve with a square-head bolt with a flat head -2-.
If the Production variant is installed, the following repair procedure
must be used ⇒ page 339 .
– Unscrew nut -1- anticlockwise until tyre pressure sensor -2-

can be removed.
Note
♦ When turning nut -1- the entire valve also turns.

♦ The tyre pressure sensor must always be renewed together
with the metal valve as a single unit ⇒ Electronic parts cata‐
logue “ETKA” .
– Remove metal valve ⇒ page 345 .

Installing
Note
♦ The tyre pressure sensor must always be renewed together

with the metal valve as a single unit ⇒ Electronic parts cata‐
logue “ETKA” .
♦ The new metal valve is offered as a repair kit together with a
new bolt.
– Install metal valve ⇒ page 345 .
Caution

– Press tyre pressure sensor -1- against wheel rim and tighten
with new bolt -arrow-.
drill).
Note
♦ After fitting, carry out a visual inspection and check that it is

securely seated. The tyre pressure sensor -1- must be bolted
such that there is no play, and its support feet must be located
in the drop centre of the rim.
♦ Once fitted, retightening of the screw connection to the speci‐
fied torque is not permitted.
Specified torques
Tyre pressure sensor to metal valve 4 Nm

sensor, version 2
Removing
– Remove tyre from rim ⇒ page 343 .
– Turn nut -1- anti-clockwise until tyre pressure sensor -2- can
be removed.
Note
When the nut -1- is turned, the valve turns as well.
Installing
Caution
♦ Always renew the complete metal valve.


– Secure tyre pressure sensor loosely to metal valve -3- using

square-head bolt -5-.
Note
When doing this, ensure the metal valve is not bolted tight on the
sensor.
– Insert metal valve into valve hole in rim.
Caution
♦ When tightening, do not use metal valve as a counterhold.

♦ The result of a washer being placed in the union nut -2- is
that the metal valve is first screwed onto the tyre pressure
sensor when the nut is tightened. The tyre pressure sen‐
sor is screwed onto the rim after the disc breaks.
– Bolt new union nut onto metal valve. While doing so, the metal
valve will turn and is bolted to tyre pressure sensor .
– Tighten union nut until rupture disc breaks.
– Install tyre on rim ⇒ page 343 .
Specified torques
♦ ⇒ “2.3.2 Assembly overview - tyre pressure sensor, version 2”,
page 334
2.7 Changing tyres on vehicles with tyre

pressure monitoring system
⇒ “2.7.1 Notes and conditions for changing tyres on vehicles with
tyre pressure monitoring system”, page 341
⇒ “2.7.2 Changing tyres on vehicles with tyre pressure monitoring
system, wheel change”, page 342
system, pressing tyre off wheel rim”, page 343
system, removing tyre from wheel rim”, page 343
system, installing tyre”, page 344
2.7.1 Notes and conditions for changing tyres

on vehicles with tyre pressure monitor‐
ing system
• It is extremely important to adhere to the instructions and
warnings in the following descriptions.
• Check whether the tyre pressure sensor should also be re‐
placed ⇒ Vehicle diagnostic tester.

Note
♦ Ensure that the tyre does not contact the tyre pressure sensor
during removal or fitting.
♦ The tyre pressure sensor must not come into contact with wa‐
ter or be blown upon with compressed air when the wheel rim
is cleaned.
2.7.2 Changing tyres on vehicles with tyre

pressure monitoring system, wheel
change
If the wheels are changed (e.g. switch from summer to winter
tyres), the tyre pressure sensors transmit data as soon as the
speed of the new wheels exceeds 25 km/h. The ID numbers of
the new tyre pressure sensors are automatically detected and
entered by the control unit.
The acceleration data are additionally checked against the vehi‐
cle speed. This process takes approx. 7 minutes.
The tyre pressure monitoring control unit - J502- must first switch
to learning mode before it can automatically train the tyre pres‐
sure sensors.
To do this, the vehicle must remain stationary for 20 minutes.
Following the detection of a flat tyre, this time is 5 minutes.
If the stationary time is not adhered to and the control unit is
therefore not yet in learning mode, the system records a radio
fault. Only after a stationary time of 20 minutes are the tyre pres‐
sure sensors trained automatically.
Note
♦ When changing wheels, note that only Volkswagen-approved

wheel and tyre combinations with the tyre inflation pressure
specified in the tank flap may be installed.
♦ If unapproved wheel and tyre combinations are installed, they
must possess a certificate from the responsible technical in‐
spection authority (in Germany, TÜV) for the respective vehi‐
cle, and a second wheel set must be learned via the ⇒ Vehicle
diagnostic tester ⇒ page 342 .
♦ Learning is also necessary if the tyre inflation pressure devi‐
ates from the tyre inflation pressure specified in the tank flap
⇒ page 342 .
Tyre sets with other specified tyre inflation pressures

If a vehicle is fitted with tyres requiring nominal tyre inflation pres‐
sures other than those specified on the tank flap sticker, these
tyres (second wheel set) can also be monitored with the TPM
system.
Nominal tyre inflation pressures for the second wheel set must be
specified to the system with the ⇒ Vehicle diagnostic tester.
The tyre pressure sensors for the wheels of the second wheel set
are not automatically detected and trained by the TPM system
(unlike the tyre pressure sensors for the wheel set with Volkswa‐
gen-approved wheel and tyre combinations).
The following work has to be performed to switch to the second
wheel set:

♦ Read ID numbers (IDs) of the tyre pressure sensors prior to

installation.
♦ Switch the TPM to wheel set 2.
♦ Enter the necessary nominal tyre pressures and the IDs of the
tyre pressure sensors in the system.

pressure monitoring system, pressing
tyre off wheel rim
Caution
♦ Comply with the notes on safety and conditions

⇒ page 341
– Remove air from tyre by screwing out the nickel-plate valve

element.
– When pressing off a tyre using tyre fitting equipment with a
press-off plate, always ensure that the tyre valve/ tyre pres‐
sure sensor -arrow- is directly opposite the bead breaker -1-.
The bead breaker must be positioned no more than 2 cm from
wheel rim flange.
– Remove balancing weights and rough dirt from wheel.
– Press both tyre beads off all round and liberally coat tyre and
wheel rim flange with tyre assembly paste -arrow-.

pressure monitoring system, removing
tyre from wheel rim
Caution

⇒ page 341
♦ The assembly head must never be within area -a- of tyre
valve/tyre pressure sensor, or the assembly head will
damage the tyre pressure sensor .

Fitting tyre
– Position wheel on tyre assembly unit so that the tyre valve/
tyre pressure sensor is located in front of assembly head.
– Position assembly head near tyre valve/ tyre pressure sensor
so that an assembly lever can be inserted approx. 30° next to
the tyre valve/ tyre pressure sensor .
– Lever tyre bead over assembly finger on assembly head using
assembly lever then remove assembly lever.
– Run tyre mounting device clockwise until upper bead lies com‐
pletely above wheel rim flange.
– Position wheel on tyre assembly unit so that the tyre valve/
tyre pressure sensor is located in front of assembly head.
Note
♦ Check that the tyre pressure sensor is not loose or damaged.

If the screwed connection is loose, replace the union nut, the
valve core, the seal, the sealing washer and the valve cap with
new parts from the repair set ⇒ Electronic parts catalogue
“ETKA” .
♦ If the tyre pressure sensor is damaged, then replace the com‐
plete item ⇒ page 336 .

pressure monitoring system, installing
tyre
Caution

⇒ page 341
Note
When a tyre is changed, it is recommended that the set of seals

for the tyre pressure sensor be changed as well.
– Liberally apply tyre assembly paste to wheel rim flanges, tyre

beads and inner side of the upper tyre beads.
The inside of the tyre must be fitted first.

– Turn wheel on tyre fitting unit so that tyre valve with tyre pres‐
sure sensor -arrow- is directly opposite assembly head.
– Press tyre into drop centre in -direction of arrow- between tyre
valve with tyre pressure sensor and assembly head.
– Allow the tyre fitting unit to turn in a clockwise direction.
– Stop the fitting of lower bead before reaching tyre valve/ tyre
pressure sensor to prevent damage to tyre pressure sensor .
The tyre bead will now slide over the wheel rim flange. The wheel
rim may be turned only until the assembly head is just before the
tyre valve/ tyre pressure sensor .
– Check to ensure that tyre bead is seated correctly on assembly
head and run tyre fitting machine clockwise.
– Stop the fitting of upper bead before reaching tyre valve/ tyre
pressure sensor to prevent damage to tyre pressure sensor .
The tyre bead will now slide over the wheel rim flange. The wheel
rim may be turned only until the assembly head is just before the
tyre valve/ tyre pressure sensor .
– Fill tyres to a maximum tyre pressure of 3.3 bar (bead seating
pressure).
Caution
Never increase the inflation pressure when the tyre bead does
not lie completely against the wheel rim flange.
This would lead to damage to the tyre and/or the wheel rim.
– Release air if the tyre beads do not lie completely against the
edge of the disc wheel. Press tyre bead off again and liberally
coat wheel rim flange with tyre assembly paste.
– Fill tyres to a maximum tyre pressure of 3.3 bar (bead seating
pressure).
– If the tyre beads seat perfectly against the shoulder of the
wheel rim, increase inflation pressure to 4 bar to »seat« the
tyre.
– Screw in new nickel-plated valve core and fill tyre to the pre‐
scribed tyre pressure.
– Then, balance the wheel.
2.8 Removing and installing metal valve

body


Removing
– Removing tyre pressure sensor ⇒ page 336 .
– Remove nut -1- from metal valve.
drill) -arrow-.
Installing
Caution
♦ Tighten nut for metal valve to specified torque. Retighten‐

ing is impermissible, as the seal may otherwise be dam‐
aged.
– Tighten nut -1- of metal valve.

drill) -arrow-.
– Installing tyre pressure sensor ⇒ page 336 .
Specified torques
Hexagon nut to metal valve 4 Nm

3 Wheel alignment
⇒ “3.1 Notes for wheel alignment”, page 347
⇒ “3.2 Necessity of wheel alignment”, page 347
⇒ “3.3 Test prerequisites”, page 348
⇒ “3.4 Test preparations”, page 349
⇒ “3.5 Specified values for wheel alignment”, page 350
⇒ “3.6 Wheel alignment procedure”, page 353
⇒ “3.7 Adjusting camber at front wheels”, page 354
⇒ “3.8 Adjusting camber on rear axle”, page 355
⇒ “3.9 Adjusting toe at rear axle”, page 357
⇒ “3.10 Adjusting front axle toe”, page 357
⇒ “3.11 Vehicle data sticker”, page 358
⇒ “3.12 Steering angle sender - basic setting”, page 359
3.1 Notes for wheel alignment

Wheel alignment must be performed only using a VW/AUDI-ap‐
proved wheel alignment unit!
Whenever wheels are aligned, both the front and rear axles must
be measured.
Otherwise, the steering rack may not be centred!
– Perform all measurements with wheel alignment computer.
All the information required to perform alignment can be found in
the wheel alignment computer.
Current data »updates« are located in VW ServiceNet.
⇒ VW ServiceNet; Systems; Wheel alignment computer soft‐
ware; Beissbarth
ware; Hunter
ware; Corghi
ware; John Bean
Note
♦ Wheel alignment should not be checked before the vehicle has

completed 1,000 to 2,000 km because the coil springs must
settle.
♦ When making adjustments, adhere to the relevant specifica‐
tions as closely as possible.
3.2 Necessity of wheel alignment

Wheel alignment is necessary if:
♦ The vehicle does not handle properly.
♦ Vehicle has been involved in an accident and components
have been renewed.
♦ Axle components are removed or renewed.
3. Wheel alignment 347

♦ Tyres wear on one side.

Components have been renewed
Front axle component was Alignment necessary Rear axle component re‐ Alignment necessary
renewed. newed
Yes No Yes No
Lower suspension link X Lower transverse link X
Bonded rubber bush X 1) Upper transverse link X
for suspension link
Wheel bearing housing X Track rod X
Track rod/track rod ball joint X Wheel bearing housing X
Steering box X Subframe X
Subframe X Coil spring X
Suspension strut X Shock absorber X
Anti-roll bar X 1) Anti-roll bar X
Trailing arm X
1) Prerequisite: the positions of the subframe and brackets were
fixed before the parts were removed ⇒ page 42
Components removed and installed

Front axle component re‐ Alignment necessary Rear axle component re‐ Alignment necessary
moved and reinstalled moved and reinstalled
Yes No Yes No
Lower suspension link X 2) Lower transverse link X
Wheel bearing housing X Upper transverse link X
Track rod/track rod ball X Track rod X
joint
Steering box X Wheel bearing housing X
Subframe X 2) Subframe X 3)
Suspension strut X Coil spring X
Anti-roll bar X 2) Shock absorber X
Anti-roll bar X
Trailing arm X
2) Prerequisite: the positions of the subframe and brackets were
fixed before the parts were removed ⇒ page 42
3)Prerequisite: the position of the subframe was fixed before the
part was removed ⇒ page 159 or ⇒ page 161 .
3.3 Test prerequisites

• Check suspension, wheel bearing, steering and steering link‐
age for excessive play and damage.
• Tread depth difference of no more than 2 mm on one axle.
• Tyres inflated to correct pressure.
• Vehicle unladen.
• Fuel tank must be full.
• Spare wheel and vehicle tools are stowed in correct locations.

• The fluid reservoir for the windscreen/headlight washer sys‐

tem must be full.
• When checking wheel alignment, ensure that sliding plates
and turn tables are not touching end stop.
Please note!
• The test equipment must be properly adjusted and attached
to the vehicle; observe device manufacturer's operating in‐
structions.
If necessary, contact the manufacturer for familiarisation with the
proper use of the wheel alignment equipment.
Wheel alignment platforms and wheel alignment units and com‐
puters can lose their calibration over a period of time.
Wheel alignment platforms and alignment units and computers
should be checked and adjusted as necessary during inspection
and maintenance at least once per year!
– Treat these highly sensitive units carefully and conscientious‐
ly!
3.4 Test preparations

equipment required
♦ Wheel alignment computer
- V.A.G 1813- or VW/Audi-
approved wheel alignment
units
♦ Brake pedal depressor -
V.A.G 1869/2-
♦ Tool insert - T10179-
T10001-

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

Otherwise, the result of the measurement will be incorrect.
If runout compensation is not performed, it is not possible to adjust
toe-in correctly!
Observe information provided by the manufacturer of the wheel
alignment unit.
– Carry out wheel runout compensation.
– Apply brake pedal depressor - V.A.G 1869/2- .
– Use brake pedal depressor to depress brake pedal.
3.5 Specified values for wheel alignment

These specifications apply to all engines.
♦ Explanations regarding PR numbers ⇒ page 358 .
The ride heights shown in the table refer to dimension -a-.
Front axle Standard running Standard running Standard running

gear gear with Nivomat gear with adaptive
chassis control DCC
PR numbers G02/G07/G11/G12/ G02/G07/G15 G41
G15
Total toe (without load) 10' ± 10′ 10' ± 10′ 10' ± 10′
Camber (in straight-ahead position) -30′ ± 30′ -30′ ± 30′ -37′ ± 30′
Maximum permissible difference be‐ max. 30' max. 30' max. 30'
tween sides
Toe-out on turns 1) at 20° left and 1°19′ ± 20′ 1°19′ ± 20′ 1°22′ ± 20′
right lock
Caster 7° 32′ ± 30′ 7° 32′ ± 30′ 7° 49′ ± 30′
tween sides
Ride height 383 ± 10 mm 383 ± 10 mm 373 ± 10 mm
1)
Toe-out on turns can be displayed as a negative value on the
wheel alignment computer, depending on the manufacturer.
Front axle Sports running gear Sports running gear Standard running
except 18" wheels with 18" wheels gear with adaptive
chassis control DCC
and 18" wheels
PR numbers G03/G08 G23, G28 G41
tween sides

Front axle Sports running gear Sports running gear Standard running
except 18" wheels with 18" wheels gear with adaptive
chassis control DCC
and 18" wheels
PR numbers G03/G08 G23, G28 G41
right lock
Caster 7° 44′ ± 30′ 7° 44′ ± 30′ 7° 49′ ± 30′
tween sides
1)
Front axle Heavy-duty running Comfort heavy-duty BlueMotion

gear running gear
PR numbers G04/G09 G05/G10/G16 G37/G38
tween sides
right lock
Caster 7° 16′ ± 30′ 7° 31′ ± 30′ 7° 44′ ± 30′
tween sides
1)
Front axle R36 R36 with adap‐ Raised running Passat Alltrack
tive chassis con‐ gear
trol DCC
PR numbers G36 G46 G19/G50/G51/ G42/G43
G52
Total toe (without load) 10' ± 10′ 10' ± 10′ 10' ± 10′ 10' ± 10′
Camber (in straight-ahead -45′ ± 30′ -45′ ± 30′ -18′ ± 30′ -14′ ± 30′
position)
Maximum permissible differ‐ max. 30' max. 30' max. 30' max. 30'
ence between sides
Toe-out on turns 1) at 20° left 1°22′ ± 20′ 1°22′ ± 20′ 1°19′ ± 20′ 1°18′ ± 20′
and right lock
Caster 8° 7′ ± 30′ 8° 7′ ± 30′ 7° 23′ ± 30′ 7° 16′ ± 30′
ence between sides
Ride height 358 ± 10 mm 358 ± 10 mm 398 ± 10 mm 403 ± 10 mm
1)

These specifications apply to all engines.

♦ Explanations regarding PR numbers ⇒ page 358
Rear axle, front-wheel drive and Standard running Standard running Standard running
4WD gear gear with Nivomat gear with adaptive
chassis control DCC
Camber -1° 20′ ± 30′ -1° 45′ ± 30′ -1° 20′ ± 30′
tween sides
Total toe (at specified camber) +10′ ± 10′ +10′ ± 10′ +10′ ± 10′
Max. permissible deviation from di‐ max. 20' max. 20' max. 20'
rection of travel
Rear axle, front-wheel drive and Sports running gear Sports running gear Standard running
4WD except 18" wheels with 18" wheels gear with adaptive
chassis control DCC
and 18" wheels
Camber -1° 20′ ± 30′ -1° 45′ ± 30′ -1° 45′ ± 30′
tween sides
rection of travel
Rear axle, front-wheel drive and Heavy-duty running Comfort heavy-duty BlueMotion
4WD gear running gear
Camber -1° 20′ ± 30′ -1° 20′ ± 30′ -1° 20′ ± 30′
tween sides
rection of travel
Rear axle, front-wheel drive R36 R36 with adap‐ Raised running Passat Alltrack
and 4WD tive chassis con‐ gear
trol DCC
Camber -1° 45′ ± 30′ -1° 45′ ± 30′ -1° 20′ ± 30′ -1° 45′ ± 30′
ence between sides
Total toe (at specified cam‐ +10′ ± 10′ +10′ ± 10′ +10′ ± 10′ +10′ ± 10′
ber)
Max. permissible deviation max. 20' max. 20' max. 20' max. 20'
from direction of travel
Ride height 358 ± 10 mm 358 ± 10 mm 388 ± 10 mm 403 ± 10 mm

3.6 Wheel alignment procedure

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

pensation.
↓
Turn steering wheel to ← Measure vehicle height. ← Fit brake pedal depressor - V.A.G
straight-ahead position 1869/2-
and lock in place 1)
↓
Check front axle camber → Is actual value within toler‐ → No
ance?
↓ ↓
↓ ← ← Yes Adjust ⇒ page 354 .
↓ ↓
↓ ← ← ← ← ←
↓
Check rear axle camber → Is actual value within toler‐ → No
ance?
↓ ↓
↓ ↓
↓ ← ← ← ← ←
↓
Check rear axle toe → Is actual value within toler‐ → No
ance?
↓ ↓
↓ ↓
↓ ← ← ← ← ←
↓
Check front axle caster → Is actual value within toler‐ → No
ance?
↓ ↓
↓ ← ← Yes Inspect axle components and
body
↓ ↓
↓ ← ← ← ← ←
↓

Check front axle toe → Is actual value within toler‐ → No

ance?
↓ ↓
End ← Yes Adjust ⇒ page 357 .
↑ ↓
↑ ← ← ← ← ←
1)If steering wheel is not centred, it must be straightened after
wheel alignment is finished. Then carry out basic setting for steer‐
ing angle sender - G85- using ⇒ Vehicle diagnostic tester.
3.7 Adjusting camber at front wheels

Note
♦ Camber correction is necessary only after body repairs. The

camber is not adjustable, but can be equalized by moving the
brackets and/or the subframe.
♦ Move subframe only to left or right, but never in or opposite to
direction of normal travel!
– Remove noise insulation ⇒ General body repairs, exterior;

sulation .
– Loosen bolts -1- for subframe -2- to body on both sides.
The camber adjustment range is limited by the tolerances within
the bores in the brackets and the subframe. If the specified value
is not reached by moving the components, these and the body
must be inspected ⇒ page 1 .
– Now camber may be adjusted to specification by moving sub‐
frame -arrows 3-.
– Tighten new bolts for subframe to body to specified torque plus
extra turn angle.
Following the movement of the subframe and, consequently, the
steering rack, clearance between the steering column universal
joint and the notch in the plenum chamber bulkhead must be
checked.

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

joint -1- and cutout in plenum chamber bulkhead -2-.

M12 x 1.5 x 90 70 Nm + 180° further
♦ Use new bolts
M12 x 1.5 x 100 70 Nm + 180° further

♦ Use new bolts
M12 x 1.5 x 110 70 Nm + 90° further

♦ Use new bolts
3.8 Adjusting camber on rear axle

♦ Ring spanner - T10179-

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

– Adjust camber by turning hexagon head of eccentric bolt
-arrow-.
Note
The maximum adjustment range is 90° to the left or right of centre.
– Tighten nut -A-.

– Check camber value again after nut -A- has been tightened.
Specified torques
Upper transverse link to subframe (vehicles with front- 95 Nm
wheel drive) ♦ To tighten nuts, set torque wrench - V.A.G
♦ Use new nut 1332- to 80 Nm
♦ Tighten threaded connections only when vehicle is in ♦ Applies only in conjunction with insert tool,
the normal running position 18 mm - T10179-


Upper transverse link to subframe (vehicles with front- 95 Nm
wheel drive) ♦ To tighten nuts, set torque wrench - V.A.G
♦ Use new nut 1332- to 80 Nm
♦ Tighten threaded connections only when vehicle is in ♦ Applies only in conjunction with insert tool,
the normal running position 18 mm - T10179-
3.9 Adjusting toe at rear axle

– Loosen nut -1-.

– Turn eccentric bolt -2- until specification is attained.
– Tighten nut again.
Specified torque
♦ Use new nut
3.10 Adjusting front axle toe


♦ Tool insert 24 mm - V.A.G 1332/11-

– Loosen lock nut -3- while counterholding on head of track rod
-2-.
– Pull spring-type clip -1- off boot.
– Adjust toe by turning left and/or right track rod.
Open jaw spanner can be positioned on hexagon of track rod.
After turning track rods, ensure that boots are not twisted.
Twisted boots wear out quickly.
– Tighten locknut with tool insert 24 mm - V.A.G 1332/11- while

counterholding track rod ball joint -1-.
– Check toe values again.
It is possible that the value will change slightly when lock nut is
tightened.
However, if the measured toe value lies within the tolerance, the
adjustment is correct.
– Fit spring-type clip to boot.
Specified torques
Track rod ball joint to track rod 70 Nm
3.11 Vehicle data sticker

Explanation of “PR numbers” on vehicle data sticker
Various types of running gear are installed depending on engine
and equipment level. These are identified by the PR numbers.
The PR numbers are critical in determining the wheel alignment
specifications.
The running gear version fitted in the vehicle is indicated on the
vehicle data sticker by the PR number for the front axle.
The vehicle data sticker can be found in the spare wheel well and
in the service booklet.

Example of a vehicle data sticker

In this example the vehicle is equipped with sports running gear
G28 -arrow-.
3.12 Steering angle sender - basic setting

If steering wheel was realigned, basic setting of steering angle
sender - G85- must be checked ⇒ Vehicle diagnostic tester!
Select “Select function/component” by pressing Go to button.

4 Rough running due to wheels/tyres -

causes and rectification
⇒ “4.1 Causes of rough running”, page 360
⇒ “4.2 Conducting a road test before balancing wheels”,
page 360 .
⇒ “4.3 Balancing wheel”, page 361
⇒ “4.4 Vibration control system”, page 365
⇒ “4.5 Checking radial and lateral runout of wheels and tyres”,
page 365
⇒ “4.6 Checking radial and lateral run-out on wheel rim”,
page 366
⇒ “4.7 Matching wheels and tyres”, page 367
⇒ “4.8 Determining flat spots on tyres”, page 368
4.1 Causes of rough running

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

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

– Balance wheels.
4.3 Balancing wheel

⇒ “4.3.1 Balancing wheel, conditions”, page 361
⇒ “4.3.2 Balancing wheel, balancing wheel on stationary wheel
balancer”, page 361
⇒ “4.3.3 Balancing wheel, balancing wheel with finish balancer ”,
page 364
4.3.1 Balancing wheel, conditions

Before you start balancing the wheels, the following requirements
must be met.
• Tyre inflation pressure must be OK.
• The tyre tread must not show one-sided wear and should be
at least 4 mm deep.
• The tyre must not show any signs of damage, for example
cuts, piercing, foreign bodies, etc.
• The wheel suspension, steering and steering linkage, includ‐
ing the shock absorbers, must be in perfect condition.
• You must have conducted a road test.
4.3.2 Balancing wheel, balancing wheel on

stationary wheel balancer
• Road test has been carried out ⇒ page 360 .
Clamp wheel into wheel balancing machine
Note
When balancing tyres, please remember that cleanliness is ab‐

solutely essential, as is the case in any other repair work you carry
out. Only then can you attain a flawless result!
Dirt and rust in the area of the contact surfaces and centre of the
wheel distort the result.
– Clean contact surface, centring element and inside of wheel
using e.g. pneumatic brush grinding set - VAS 6446- ⇒ Volks‐
wagen ServiceNet; Workshop Equipment, Catalogue before
clamping wheel on wheel balancing machine!
Note
It is very important that the correct tools for centring and clamping
the wheels are used on the wheel balancing system. Before com‐
mencing any work, find out about the respective centring system
for wheel balancing machines ⇒ Volkswagen ServiceNet; Work‐
shop Equipment, Catalogue .
4. Rough running due to wheels/tyres - causes and rectification 361

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

machine.

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

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

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

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

not run true although there are no flat spots, radial or lateral
runout may be the cause.
– Check the wheel for radial or lateral runout ⇒ page 366 .
– If radial and lateral runout are within the specified tolerance,
balance the wheel and tyre.
Note
♦ More than 60 grams of weight per tyre should not be used.

♦ If more weight is required, you may be able to achieve smooth‐
er running by "matching" the tyre and rim. Matching tyres
⇒ page 367 .
♦ The wheel balancer display should indicate 0 gram.
♦ As an alternative to match mounting, you could use the vibra‐
tion control system - VAS 6230 A- ⇒ page 365 .
– Bolt wheel onto vehicle.

– First, hand-tighten the lowest wheel bolt to about 30 Nm.
– Then, tighten the remaining wheel bolts diagonally to about
30 Nm. This process centres the wheel on the hub.
– Now use the torque wrench to firmly tighten the wheel bolts
diagonally to the prescribed torque.
Carry out road test
– After balancing the wheels and tyres, carry out a road test.

If you detect vibration during the road test, it may be due to tol‐
erance in the wheel centring.
In unfavourable circumstances, the component tolerances of
wheels and hubs could cumulate. This too can lead to vibration.
This can be alleviated using a finish balancer. ⇒ page 364
4.3.3 Balancing wheel, balancing wheel with

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

have been instructed by the manufacturer of the balancer.
♦ To balance the wheels, set the wheels of the driven axle on
the sensor platforms (only the front wheels of a front-wheel
drive vehicle, all four wheels of a four-wheel drive vehicle).
If you determine a residual imbalance greater than 20 grams

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

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

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

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

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

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

WARNING
Always tighten wheel bolts to specified tightening torque using

a torque wrench!
4.4 Vibration control system

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

wheels and tyres
⇒ “4.5.1 Checking radial and lateral runout of wheels and tyres,
tolerances”, page 365
⇒ “4.5.2 Checking radial and lateral runout on wheels and tyres
with tyre gauge”, page 366
4.5.1 Checking radial and lateral runout of

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

4.5.2 Checking radial and lateral runout on

wheels and tyres with tyre gauge
Checking lateral runout
– Preload tyre gauge approx. 2 mm.
– Fit tyre gauge to side wall of tyre.
– Turn wheel slowly.
– Make a note of the smallest and largest deflection of the indi‐
cator needle.
Note
If the difference is greater than 1.3 mm, the lateral runout is too
great.
In this case, you can reduce lateral runout by match mounting the
tyre ⇒ page 367 .
Extreme values on the tyre gauge due to small irregularities in the
rubber may be disregarded.
Checking radial runout
– Fit tyre gauge to running surface of tyre.

– Turn wheel slowly.
cator needle.
Note
If the difference is greater than 1 mm, the radial runout is too great.
In this case, you can reduce radial runout by match mounting the
tyre ⇒ page 367 .
4.6 Checking radial and lateral run-out on

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


cator needle.
S - Lateral runout
H - Radial runout
– Compare the measured values with the specifications in the
table ⇒ page 367 .
Note
Extreme values on the tyre gauge due to small irregularities may

be disregarded.
Specifications for radial and lateral runout on wheel rim

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

smooth running cannot be attained.
4.7 Matching wheels and tyres

General
When radial or lateral runout of the disc wheel and tyre coincide,
the imbalance of the wheel is amplified by the tyre.
For technical reasons, 100% true running is not possible
⇒ page 365 .
Before match mounting the used wheels which are fitted on the
vehicle, run the tyres warm. This will eliminate any flat spots
caused by storage or handling, ⇒ page 368 .
Procedure for match mounting
– Let air out of tyre.
– Press tyre beads off wheel rim flanges.
– Apply tyre assembly paste all round the tyre beads.
– Rotate tyre by 180° in relation to disc wheel.
– Pump up tyre to approx. 4 bar.
– Attach the wheel (together with tyre) to the wheel balancing
machine.
– Check wheel for true running and for radial and lateral runout .

Note
♦ If the specified values for radial and lateral runout are not ex‐
ceeded, the wheel can be balanced to 0 gram. Specified
values appear on ⇒ page 365 .
♦ If the radial and lateral runout is not within the specifications,
the tyre must be rotated again.
– Let air out and press tyre beads off the wheel rim flanges.
– Rotate tyre by 90° in relation to disc wheel (quarter of a turn).
– Pump up tyre again to 4 bar and check true running.
Note
♦ If the specified values for radial and lateral runout are not ex‐
ceeded, the wheel can be balanced to 0 gram.
♦ If the radial and lateral runout are not within the specified val‐
ues, the tyre must be rotated again.
– Press tyre off wheel rim flange again as described above.

– Rotate tyre by 180° in relation to disc wheel (half a turn).
If the radial and/or lateral runout are still not within the specified
values, check the disc wheel for radial and/or lateral runout:
⇒ page 366 .
If the measured values for radial and lateral runout of the wheel
are within the specified values, the tyre has an impermissibly high
radial or lateral runout. In this case, the tyre must be renewed.
Note
♦ After fitting the tyres there will be fitting lubricant between the
tyres and the rim flanges.
♦ You should therefore avoid severe braking and acceleration
manoeuvres for the first 100 or 200 km driven. The tyres may
otherwise rotate on the rims and the work will have been in
vain.
4.8 Determining flat spots on tyres

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

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

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

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

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

– Unbolt wheels from vehicle.
– Balancing wheels on stationary wheel balancer ⇒ page 361 .

5 Adaptive Cruise Control (ACC)

⇒ “5.1 Calibrating ACC”, page 370
5.1 Calibrating ACC

⇒ “5.1.1 Calibrating ACC during vehicle alignment”, page 370
⇒ “5.1.2 Calibrating ACC without prior vehicle alignment”,
page 372
5.1.1 Calibrating ACC during vehicle align‐

ment
– Observe instructions for your wheel alignment unit as well as
the following information!
When does calibration have to be carried out?
Calibration has to be carried if:
♦ The lock carrier has been removed and installed,
♦ The sensor for automatic distance control - G550- has been
removed and installed,
♦ Track and/or camber have been adjusted on the rear axle dur‐
ing vehicle alignment.
♦ the lock carrier was brought into service position.
Which test prerequisites have to be met for the calibration proc‐
ess?
♦ Prior vehicle alignment or wheel runout compensation.
♦ Specified tyre inflation pressure and ride height values
checked.
Alignment procedure
Start → → Were adjustments carried →

Query at end of vehicle No
alignment out on the rear axle during
alignment?
↓ ↓
Yes ← Is sufficient space available ← Yes ↓
in front of the vehicle?
⇒ page 371
↓ ↓ ↓
↓ No → Reverse vehicle onto ↓
wheel alignment unit
↓ ↓ ↓
Read measured value ← ← ← ← ← Carry out wheel runout ↓
block with ⇒ Vehicle diag‐ compensation.
nostic tester
↓ ↓
Select in ⇒ Vehicle diag‐ → Dialogue is shown in ⇒ Ve‐ → Transfer measurement ↓
nostic tester: ⇒ page 372 hicle diagnostic tester point values from ⇒ Vehi‐
cle diagnostic tester to
measurement field on -
VAS 6041/2- or -VAS
6430/2- ⇒ page 372
↓ ↓

Note dimension -a- ← Position ADC setting device ← Remove radiator grille ⇒ ↓
⇒ page 371 - VAS 6041- / setting device General body repairs, in‐
- VAS 6430- in front of ve‐ terior; Rep. gr. 66 ; Radi‐
hicle ator grille/front panel; Re‐
moving and installing radi‐
ator grille .
↓ ↓
Level ADC setting device - → Observe instructions in → Select in ⇒ Vehicle diag‐ ↓
VAS 6041- / setting device ⇒ Vehicle diagnostic tester nostic tester: ⇒ page 372
- VAS 6430- and set
straight-ahead travel
↓ ↓
Adjustment via adjuster ← Dialogue is shown in ⇒ Ve‐ ↓
screws of sensor for auto‐ hicle diagnostic tester
matic distance control -
G550- ⇒ page 371
↓ ↓
End ← ← ← ← ← ←
Space required in front of vehicle

-a- = 1145 mm ± 5 mm
Distance -a- is distance between mirror of sensor for automatic
distance control - G550- and measurement field of ADC setting
device - VAS 6041- / setting device - VAS 6430-
Note
If necessary to compensate height between ADC setting device

- VAS 6041- / setting device - VAS 6430- and wheel alignment
platform, use precision adapters - V.A.G 1813/12- .
Remove radiator grille ⇒ General body repairs, interior; Rep. gr.

66 ; Radiator grille/front panel; Removing and installing radiator
grille .
Designation of adjuster screws of sensor for automatic distance

control - G550-
1- Adjuster screw for horizontal or measured value block 6-2
⇒ page 372
2- Adjuster screw for vertical or measured value block 6-3
⇒ page 372
3- Must not be rotated - serves only as point of rotation
5. Adaptive Cruise Control (ACC) 371

Explanation of axes and display in vehicle diagnostic tester

Y - Measured value block 6-2
Z - Measured value block 6-3
Example:
The value 0.1 corresponds to 4 mm on -VAS 6041/2- or -VAS
6430-
The display in ⇒ Vehicle diagnostic tester shows a value of 0.6
for measured value block 6-2 and a value of -1.0 for measured
value block 6-3.
These values then reveal a measurement point -arrow-, which
consists of the following values:
-a- = 24 mm
-b- = -40 mm
Select on ⇒ Vehicle diagnostic tester:
♦ Running gear
♦ Proximity control
♦ 01 - System capable of self-diagnosis
♦ Functions
♦ Adaptation to adjustment on wheel alignment unit
5.1.2 Calibrating ACC without prior vehicle

alignment
– Observe instructions for your wheel alignment unit as well as
the following information!
When does calibration have to be carried out?
Calibration has to be carried if:
♦ The lock carrier has been removed and installed,
♦ The sensor for automatic distance control - G550- has been
removed and installed,
♦ Track and/or camber have been adjusted on the rear axle dur‐
ing vehicle alignment.
♦ the lock carrier was brought into service position.
Which test prerequisites have to be met for the calibration proc‐
ess?
♦ Prior vehicle alignment or wheel runout compensation.
♦ Specified tyre inflation pressure and ride height values
checked.
Alignment procedure
Start → Is sufficient space available in → No

front of the vehicle?
⇒ page 373
↓ ↓

Yes Reverse vehicle onto wheel

alignment unit
↓ ↓
Read measured value block ← Carry out wheel runout compen‐ ← ← ←
with ⇒ Vehicle diagnostic test‐ sation.
er
↓
Select in ⇒ Vehicle diagnostic → Dialogue is shown in ⇒ Vehicle → Transfer measurement point
tester: ⇒ page 374 diagnostic tester values from ⇒ Vehicle diag‐
nostic tester to measurement
field on -VAS 6041/2- or -VAS
6430- ⇒ page 374
↓
Note dimension -a- ← Position ADC setting device - ← Remove radiator grille ⇒
⇒ page 373 VAS 6041- / setting device - General body repairs, interior;
VAS 6430- in front of vehicle Rep. gr. 66 ; Radiator grille/
front panel; Removing and in‐
stalling radiator grille .
↓
Level ADC setting device - → Observe instructions in ⇒ Vehi‐ → Select in ⇒ Vehicle diagnostic
VAS 6041- / setting device - cle diagnostic tester tester: ⇒ page 374
VAS 6430- and set straight-
ahead travel
↓
Designation of adjuster screws ← Dialogue is shown in ⇒ Vehi‐
of sensor for automatic distance cle diagnostic tester
control - G550- ⇒ page 374
↓
End
Space required in front of vehicle

-a- = 1145 mm ± 5 mm
Distance -a- is distance between mirror of sensor for automatic
distance control - G550- and measurement field of ADC setting
device - VAS 6041- / setting device - VAS 6430- .
Note
If necessary to compensate height between ADC setting device

- VAS 6041- / setting device - VAS 6430- and wheel alignment
platform, use precision adapters - V.A.G 1813/12- .
Remove radiator grille ⇒ General body repairs, interior; Rep. gr.

66 ; Radiator grille/front panel; Removing and installing radiator
grille .
5. Adaptive Cruise Control (ACC) 373

Designation of adjuster screws of sensor for automatic distance

control - G550-
1- Adjuster screw for horizontal or measured value block 6-2
⇒ page 374
2- Adjuster screw for vertical or measured value block 6-3
⇒ page 374
3- Must not be rotated - serves only as point of rotation
Explanation of axes and display in vehicle diagnostic tester

Y - Measured value block 6-2
Z - Measured value block 6-3
Example:
The value 0.1 corresponds to 4 mm on -VAS 6041/2- or -VAS
6430-
The display in ⇒ Vehicle diagnostic tester shows a value of 0.6
for measured value block 6-2 and a value of -1.0 for measured
value block 6-3.
These values then reveal a measurement point -arrow-, which
consists of the following values:
-a- = 24 mm
-b- = -40 mm
Select on ⇒ Vehicle diagnostic tester:
♦ Running gear
♦ Proximity control
♦ 01 - System capable of self-diagnosis
♦ Functions
♦ Adaptation to adjustment on wheel alignment unit

6 Front camera for driver assist sys‐

tems
⇒ “6.1 Calibrating front camera for driver assist systems”,
page 375
6.1 Calibrating front camera for driver assist

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

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

In this case, clean the affected area.
♦ The field of view of the camera is fogged over.
The camera aperture must be cleaned manually if there is heavy
contamination on the inside of the windscreen in the field of view
of the camera. To do this, the control unit and lens hood must be
removed and the windscreen cleaned using cleaning solution.
Remove control unit and lens hood ⇒ Electrical system; Rep. gr.
96 ; Lane change assist; Assembly overview - lane change assist .
Correct calibration is a basic precondition for the driver assistance
system's -242- front camera to function without faults.
The driver assistance system's -242- front camera must be reca‐
librated if:
♦ “No or incorrect basic setting/adaptation” entry stored in the
event memory.
♦ The driver assistance system's front camera - R242- was re‐
placed.
♦ Windscreen has been renewed or removed.
♦ Rear axle toe setting has been adjusted.
♦ Modifications have been made to the car's running gear that
have an effect on the body height.
♦ Vehicle level senders are re-taught in vehicles with damping
control.
Note
♦ Before calibrating the driver assistance system's front camera,

read out event memory and rectify faults as necessary.
♦ The geometrical driving axis of the car must be measured in
order to calibrate the driver assistance system's front camera.
It is used as a reference position for the setting device - VAS
6430- .
♦ Calibration of the driver assistance system's front camera
must only be performed only using VW/AUDI approved wheel
alignment equipment!
♦ Calibration of the driver assistant system's front camera is only
permitted using the setting device - VAS 6430- !
6. Front camera for driver assist systems 375

♦ Setting device - VAS 6430-
♦ Wheel alignment computer

♦ ⇒ Vehicle diagnostic tester
Note
♦ The driver assistance system's front camera - R242- must be

correctly located in the holder.
♦ The field of view of the camera must be clean and clear.
♦ Before driving the vehicle onto the wheel alignment platform,
make sure there is sufficient space between the midpoint of
the hub of the front wheels and the setting device - VAS 6430- .
♦ The distance between the setting device - VAS 6430- and the
centre point of the hub of the front wheels must be 1500 mm
± 25 mm.
♦ If the available space is not adequate, move the vehicle back‐
wards on the alignment platform as required.
♦ The calibration board must be positioned centrally on the set‐
ting device.
♦ The event memory must be read before starting calibration.
Any memory entries must be deleted.
– Note testing preconditions for wheel alignment ⇒ page 348 .

– Drive car onto wheel alignment platform.
– Connect battery charger ⇒ Electrical system; Rep. gr. 27 ;
Battery; Charging battery .
– Connect ⇒ Vehicle diagnostic tester to vehicle. (Route diag‐
nostic cable through open window.)
Note
During the calibration procedure, make sure that all the car doors
remain closed and that the car's outside lighting is switched off.
– Move front wheels to straight-ahead position.

– Select calibration run for driver assistance system's -R242-
front camera.
– Mount quick-release clamps on all four wheels.
– Mount measuring transducers on wheels.
– Perform wheel runout compensation on rear wheels.
– Bounce springs.

– Measure standing height at all four wheels and make a note

of it.
Note
♦ Setting device - VAS 6430- is not allowed to be moved on

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

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

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

both sides of vehicle and setting device - VAS 6430- must
then be aligned.
♦ Distance -a- must be same on both sides of car.
♦ To guarantee correct calibration, setting device - VAS
6430- must be at right angle to lengthways axis of car.
– Mount measurement transducer -1- of front wheels onto set‐

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

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

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

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

height -2- indicated by wheel alignment computer and make a
note.
When nominal height has been reached, measuring bar -1- must
be moved upwards slightly and secured with clamping screw
-arrow-.

– Use adjuster screw -1- to level spirit level -A-.
– Move setting device - VAS 6430- sideways -arrows B- until

display on wheel alignment computer is within tolerance.
– Screw down adjuster screws -2- and -3- slightly to secure set‐
ting device - VAS 6430- against rolling away.

– Turn fine adjuster screw -1- until display on wheel alignment

computer is within tolerance.
– Use adjuster screw -1- to level spirit level -A-.
– Use adjuster screws -2- and -3- to level spirit level -B-.

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

floor.
– Check nominal height -2- again and correct if necessary.
When nominal height has been reached, measuring bar -1- must
be moved upwards slightly and secured with clamping screw
-arrow-.
Concluding work is carried out via ⇒ Vehicle diagnostic tester.
– Switch on ignition.
– On ⇒ Vehicle diagnostic tester, select “Guided Fault Finding”.
Body (Rep. Gr. 01;27;50...97)
Electrical system (Rep. Gr. (01, 27, 90…97)
01_Self-diagnosis capable systems
Front camera for driver assistance system -R242-
Camera for driver assistance systems, functions
A5 - Calibrating the control unit (Rep. Gr. 44)
Follow instructions on screen to perform calibration.
Note
The next step in Guided fault finding is to measure the body

height.

– Enter the noted standing height.

48 – Steering
1 Steering wheel
⇒ “1.1 Assembly overview - steering wheel”, page 383
⇒ “1.2 Removing and installing steering wheel”, page 383
1.1 Assembly overview - steering wheel
1 - Steering column
⇒ page 389 .
2 - Steering wheel
⇒ page 383 .
❑ Different versions possi‐
ble. Refer to ⇒ Electron‐
ic Parts Catalogue
3 - Bolt
❑ 30 Nm + 90°
1.2 Removing and installing steering wheel

1. Steering wheel 383


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

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

– Remove airbag unit ⇒ General body repairs, interior; Rep. gr.
69 ; Driver side airbag; Removing and installing airbag unit
with igniter .
– Turn wheels to straight-ahead position.
Note
The steering wheel must be removed/installed in the middle po‐

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

– Unscrew and remove bolt -1-.

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

Bolt for steering wheel 30 Nm + 90°
♦ Use new bolt
1. Steering wheel 385

2 Steering column
⇒ “2.1 Assembly overview - steering column”, page 386
⇒ “2.2 Removing and installing steering column”, page 389
⇒ “2.3 Handling and transporting steering column”, page 402
⇒ “2.4 Checking steering column for damage”, page 403
⇒ “2.5 Removing and installing ESL control unit”, page 403
2.1 Assembly overview - steering column

⇒ “2.1.1 Assembly overview - steering column, left-hand drive”,
page 386
⇒ “2.1.2 Assembly overview - steering column, right-hand drive”,
page 388
2.1.1 Assembly overview - steering column, left-hand drive
Note
♦ It is not permitted to weld or straighten load-bearing or wheel-guiding components of the suspension.


1 - Cross member for steering

column
2 - Steering column
⇒ page 389 .
3 - Bolt
❑ 20 Nm
4 - Crash bar for brake pedal
5 - Bolt
❑ 10 Nm
6 - Crash bar for clutch pedal
7 - Bolt
8 - Bolt
❑ 3 Nm
9 - Handle
10 - Electronic steering column
lock control unit - J764-
⇒ page 403 .
11 - Shear-head bolt
2. Steering column 387

2.1.2 Assembly overview - steering column, right-hand drive
Note
pension components.
1 - Assembly carrier
2 - Shear-head bolt
3 - Electronic steering column
lock control unit - J764-
⇒ page 403 .
4 - Steering column
⇒ page 395 .
5 - Bolt
6 - Crash bar for brake pedal
7 - Bolt
❑ 10 Nm
8 - Crash bar for clutch pedal
9 - Bolt
❑ 20 Nm
10 - Bolt
❑ 3 Nm
11 - Handle

2.2 Removing and installing steering col‐

umn
⇒ “2.2.1 Removing and installing steering column, left-hand drive
vehicle”, page 389
⇒ “2.2.2 Removing and installing steering column, right-hand
drive vehicle”, page 395
2.2.1 Removing and installing steering col‐

umn, left-hand drive vehicle

Removing
Only the complete steering column is supplied as a replacement
part. A repair is not possible.
Electronic steering column lock control unit - J764- can be con‐
verted ⇒ page 403 .

WARNING

♦ Mechanic(s) must electrostatically discharge himself/
themselves. This can be done by touching a suitable metal
part, for example, a water pipe, a heater pipe, a metal
frame or a lifting platform ⇒ page 5 .
Failure to comply with this precaution may lead to subsequent
failure of the electronic steering column lock control unit -
J764- !
battery .

– Pull down lever beneath steering column.
– Swing steering column down as far as possible and pull out.
– Press lever under steering column back up.
with igniter .
– Remove steering wheel ⇒ page 383 .
– Remove upper steering column cover ⇒ General body repairs,
interior; Rep. gr. 68 ; Compartments/covers; Removing and
installing upper steering column cover .
– Remove lower steering column cover ⇒ General body repairs,
installing lower steering column cover .
– Remove steering column switch ⇒ Electrical system; Rep. gr.
94 ; Steering column switch module; Removing and installing
steering column switch module .
– Remove footwell vent on driver side ⇒ Heating, air condition‐
ing system; Rep. gr. 80 ; Air duct; Assembly overview - air
duct and air distribution in passenger compartment .
– Unscrew nut -arrow- and pull earth cable off steering column.

Caution

damage.
– Pull out cable guide -1- beneath steering column. To do this,

raise lugs on both sides -arrows- slightly and pull cable guide
out of guide on steering column.

Vehicles without crash bars

– Lower steering column -2- slightly and carefully pull out up‐
wards.
Vehicles with crash bars
Clutch pedal crash bar fastening with two bolts

– Unscrew bolts and remove crash bar for clutch pedal -1-.
Clutch pedal crash bar fastening with one bolt

– Unscrew bolt -1- and, if fitted, remove crash bar for clutch
pedal -2-.
Continuation for all vehicles with crash bars
– Remove bolt -3- and remove crash bar for brake pedal -4-.

– Lower steering column slightly and carefully pull out upwards.
Caution
Take great care to ensure the steering column is handled and

transported correctly ⇒ page 402 .
Installing
– Hook steering column into installation aid on mounting brack‐
et.

– Align steering column to mounting bracket.

In the process, the pins -arrows A- of mounting bracket must be
aligned with and inserted into the holes -arrows B- of the steering
column
The correct installation position of the steering column relative to
the mounting bracket is guaranteed only in this way.

– Tighten bolts -1- for steering column -2-.

– Tighten steering column bolts -1-.
Clutch pedal crash bar fastening with two bolts

– Insert crash bar -1- and bolts and tighten.
– Insert and tighten left lower bolt for steering column.

Clutch pedal crash bar fastening with one bolt

– Fit crash bar for clutch pedal -2- and tighten bolt -1-.
– Fit crash bar for brake pedal -4- and tighten bolt -3-.
– Install cable guide -1- beneath steering column.

The lugs -arrows- must engage in the guide on both sides.
– Reconnect earth cable to steering column -arrow-.
– Position universal joint -1- in direction of -arrow- onto steering

pinion.
– Insert new hexagon bolt -arrow- and tighten.

– Install footwell trim -2- and secure with bolts -1-.

– Reconnect all connections and earth cable on steering col‐
umn.
– Install footwell vent below steering column ⇒ Heating, air con‐
ditioning system; Rep. gr. 80 ; Air duct; Assembly overview -
air duct and air distribution in passenger compartment .
– Install steering column switch ⇒ Electrical system; Rep. gr.
– Install lower steering column cover ⇒ General body repairs,
– Install upper steering column cover ⇒ General body repairs,
– Install steering wheel ⇒ page 383 .
– Install airbag unit on driver side ⇒ General body repairs, in‐
terior; Rep. gr. 69 ; Driver side airbag; Removing and installing
airbag unit with igniter .
– Carry out basic setting for steering angle sender - G85- using
Basic setting for steering angle sender must be checked after the
following procedures:
♦ When vehicle steering angle sensor - G85- is removed or re‐
newed,
♦ If steering column was removed or renewed;
♦ After removal or replacement of steering rack;
♦ If steering wheel was repositioned.
Specified torques
♦ Use new bolt
Steering column to mounting bracket 20 Nm

♦ Use new bolt
Crash bar with 2 bolts to steering column 10 Nm
2.2.2 Removing and installing steering col‐

umn, right-hand drive vehicle


Removing
Only the complete steering column is supplied as a replacement
part. A repair is not possible.
Electronic steering column lock control unit - J764- can be con‐
verted ⇒ page 403 .
WARNING

♦ Mechanic(s) must electrostatically discharge himself/
themselves. This can be done by touching a suitable metal
part, for example, a water pipe, a heater pipe, a metal
frame or a lifting platform ⇒ page 5 .
Failure to comply with this precaution may lead to subsequent
failure of the electronic steering column lock control unit -
J764- !
battery .

– Pull down lever beneath steering column.
– Swing steering column down as far as possible and pull out.
– Press lever under steering column back up.


with igniter .
– Remove steering wheel ⇒ page 383 .
– Remove upper steering column cover ⇒ General body repairs,
– Remove lower steering column cover ⇒ General body repairs,
– Remove steering column switch ⇒ Electrical system; Rep. gr.
– Remove footwell vent on driver side ⇒ Heating, air condition‐
ing system; Rep. gr. 80 ; Air duct; Assembly overview - air
duct and air distribution in passenger compartment .
– Unscrew nut -arrow- and pull earth cable off steering column.
– Unscrew nut -1-.

– Pull out pin -2- and remove clip complete.
– Slide footwell trim -3- upwards in -direction of arrow- and re‐
move.
– Remove bolt -1- for universal joint and pull universal joint -2-
off steering rack.
Caution

damage.

– Pull out cable guide -1- beneath steering column. To do this,

raise lugs on both sides -arrows- slightly and pull cable guide
out of guide on steering column.

– Lower steering column -2- slightly and carefully pull out up‐
wards.
Vehicles with manual gearboxes

– Remove bolt -1- on left under steering column and remove
crash bar -2- for clutch pedal.
– Unscrew bolts -1- and remove crash bar for brake pedal -2-.


– Lower steering column slightly and carefully pull out upwards.
Caution

Installing
– Hook steering column into installation aid on mounting brack‐
et.
– Align steering column to mounting bracket.

In the process, the pins -arrows A- of mounting bracket must be
aligned with and inserted into the holes -arrows B- of the steering
column
The correct installation position of the steering column relative to
the mounting bracket is guaranteed only in this way.

– Tighten bolts -1- for steering column -2-.

– Tighten steering column bolts -1-.

Vehicles with manual gearboxes

– Insert crash bar -2- for clutch pedal and tighten bolt -1-.
– Insert bolt -3- and tighten.

– Insert crash bar for brake pedal -2- and tighten bolts -1-.
– Install cable guide -1- beneath steering column.

The lugs -arrows- must engage in the guide on both sides.
– Reconnect earth cable to steering column -arrow-.

– Fit universal joint -2- onto steering rack pinion and tighten bolt
-1-.
– Install footwell trim -3- and push down counter to

-direction of arrow-.
– Screw on nut -1-.
– Insert entire clip -2- and push pin in completely.
– Reconnect all connections and earth cable on steering col‐
umn.
– Install footwell vent below steering column ⇒ Heating, air con‐
ditioning system; Rep. gr. 80 ; Air duct; Assembly overview -
air duct and air distribution in passenger compartment .
– Install steering column switch ⇒ Electrical system; Rep. gr.
– Install lower steering column cover ⇒ General body repairs,
– Install upper steering column cover ⇒ General body repairs,
– Install steering wheel ⇒ page 383 .
– Install airbag unit on driver side ⇒ General body repairs, in‐
terior; Rep. gr. 69 ; Driver side airbag; Removing and installing
airbag unit with igniter .
Basic setting for steering angle sender must be checked after the
following procedures:
♦ When vehicle steering angle sensor - G85- is removed or re‐
newed,
♦ If steering column was removed or renewed;
♦ After removal or replacement of steering rack;
♦ If steering wheel was repositioned.
Specified torques
♦ Use new bolt
Steering column to mounting bracket 20 Nm

♦ Use new bolt
Crash bar with 2 bolts to steering column 10 Nm

2.3 Handling and transporting steering col‐

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

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

♦ Transport steering column with two hands
♦ Grasp steering column at top of column tube and in area of
upper universal joint
♦ The clamping lever -1- must always point upwards during
transport, to ensure that the jointed shaft does not contact the
steering column lock -2-
Improper handling of steering column

Transportation using the following parts leads to primary steering
column damage:
1- Clamping lever
2- Weight compensation springs
3- Deformation element

Improper handling of steering column with safety risks

Following handling will damage the steering lock -1-:
♦ Transporting the steering column by the drive shaft with one
hand
♦ Bending the joint more than 90° and striking/knocking against
the steering column lock
♦ Lying/placing jointed shaft on steering column lock
♦ Lying/placing steering column on steering column lock
2.4 Checking steering column for damage

Visual check
– Check all steering column parts for damage.
Checking function
– Check that steering column turns smoothly and easily.
– Check whether steering column can be moved in the longitu‐
dinal direction and vertically.
2.5 Removing and installing ESL control

unit
♦ Socket - T10424-
Removing
– Remove steering column ⇒ page 389 .
Caution


– Carefully clamp steering column -1- in vice with protective

jaws.
– Carefully swivel universal joint -2- downwards.
– Loosen lower shear bolt -arrow- with socket - T10424- .

– Remove swarf with brush.
Caution
No swarf must enter steering column.
– Carefully clamp steering column, rotated by 180°, in vice.

– Carefully swivel universal joint -2- downwards.
Note
Turning 180° is necessary to prevent swarf from entering steering

column from above when loosening shear bolt.
– Loosen lower shear bolt -arrow- with socket - T10424- .

– Remove swarf with brush.
– Carefully remove electronic steering column lock control unit
- J764- -1-.
Installing

– Secure electronic steering column lock control unit - J764-

-1- with new shear bolts -arrows-.
– Tighten shear bolts -arrows- evenly until bolt heads shear off.
– Install steering column ⇒ page 392 .
– If electronic steering column lock control unit - J764- has been
renewed, electronic steering column lock control unit - J764-
must be adapted ⇒ Vehicle diagnostic tester.
Guided functions
Selecting vehicle systems or functions
25 Immobilizer
Adapting ESL
Follow instructions on screen to perform adaption.


3 Steering box
⇒ “3.1 Assembly overview - steering rack”, page 406
⇒ “3.2 Removing and installing steering rack”, page 409
⇒ “3.3 Repairing steering rack”, page 424
⇒ “3.4 Removing and installing track rod”, page 429
⇒ “3.5 Removing and installing track rod ball joint”, page 432
⇒ “3.6 Removing and installing boot”, page 433
3.1 Assembly overview - steering rack

⇒ “3.1.1 Assembly overview - steering rack, left-hand drive”, page
406
⇒ “3.1.2 Assembly overview - steering rack, right-hand drive”,
page 408
3.1.1 Assembly overview - steering rack, left-hand drive
Caution

damage.

1 - Universal joint
2 - Bolt
3 - Power steering rack
❑ With power steering
control unit - J500-
❑ With electromechanical
power steering motor -
V187-
❑ With steering torque
sender - G269-
❑ Can be tested in guided
fault finding using ⇒ Ve‐
hicle diagnostic tester
⇒ page 409 .
Note
Any entries in the event memory

must be deleted before renewing
the steering rack ⇒ Vehicle diagnos‐
tic tester.

5 - Nut
❑ Tighten to 100 Nm, then
loosen (turn back) 180°
and retighten to 100 Nm
❑ Self-locking
6 - Subframe
7 - Bolt
8 - Heat shield
9 - Torx bolt
❑ 6 Nm
❑ Self-locking
10 - Wiring
3. Steering box 407

3.1.2 Assembly overview - steering rack, right-hand drive
Caution

damage.
1 - Universal joint
2 - Bolt
20 Nm + 90° further
3 - Wiring
4 - Heat shield
5 - Bolt
❑ 6 Nm
❑ Self-locking
❑ With power steering
control unit - J500-
❑ With electromechanical
power steering motor -
V187-
❑ With steering angle
sender - G85-
❑ With steering torque
sender - G269-
❑ Can be tested in guided
fault finding using ⇒ Ve‐
hicle diagnostic tester
⇒ page 417 .
Note
Any entries in the event memory

must be deleted before renewing
the steering rack ⇒ Vehicle diagnos‐
tic tester.
7 - Left wheel bearing housing Volkswagen Technical Site: http://vwts.ru http://vwts.info

8 - Nut
❑ M12 x 1.5
❑ Tighten to 100 Nm, then loosen (turn back) 180° and retighten to 100 Nm
❑ Self-locking
9 - Bolt
❑ M10 x 70

10 - Subframe
11 - Right wheel bearing housing
3.2 Removing and installing steering rack

⇒ “3.2.1 Removing and installing steering rack, left-hand drive
⇒ “3.2.2 Removing and installing steering rack, right-hand drive
3.2.1 Removing and installing steering rack, left-hand drive vehicle

equipment required
1331-
1332-
V.A.G 1383 A-

Removing
Note
Any entries in the event memory must be deleted before renewing

the steering rack ⇒ Vehicle diagnostic tester.
3. Steering box 409

– Connect ⇒ Vehicle diagnostic tester and start “Guided Fault

Finding”.
Follow the instructions on the screen.
cess”
lock engages.
– Disconnect battery ⇒ Electrical system; Rep. gr. 27 ; Battery;
Disconnecting and reconnecting battery.
Caution

damage.

– Raise vehicle.
noise insulation .

ly.
Caution
nut.

-14-.
3. Steering box 411

– Unscrew bolts -5- and -6- for steering rack.

– Fix position of subframe and brackets. ⇒ page 42
– Separate connector for extended service intervals on oil sump.
– Remove bolts -arrows- on heat shield, if fitted.

– Remove heat shield from subframe, if fitted.
– Position
engine and gearbox jack - V.A.G 1383 A- -1- under subframe.

– Remove bolts -9- and -10- and lower subframe with bracket
slightly. In the process, observe electrical wiring.
– Unscrew bolts -arrows- and remove shield -1- over steering

rack.

– Unclip all remaining cable securing points on steering rack and
subframe.
– Separate connectors -1- and -2- from steering rack.

– Lower subframe carefully with engine/gearbox jack - V.A.G
1383 A- .
– Lift steering rack down off subframe and remove it to right.
3. Steering box 413

– Put steering rack down as shown.

This prevents damage to control unit -1-.
Installing

– Check that white pressure diaphragm -arrow- is clean and un‐

damaged.
– Clean pressure diaphragm carefully if necessary.
Note
Renew steering rack if pressure diaphragm is damaged.

– Plug in connectors -1- and -2- so they audibly engage

Threaded sleeve of steering rack must be located in subframe
hole.
Note

♦ After fitting the steering rack to the universal joint ensure that
the seal is not kinked against the assembly plate on the steer‐
ing rack. The opening to the footwell must be sealed correctly.
Before inserting subframe bolts, position steering rack on sub‐

frame and insert bolts for steering rack and anti-roll bar.
sulation .
– Bolt universal joint to steering rack.
– Connect battery ⇒ Electrical system; Rep. gr. 27 ; Battery;
Disconnecting and connecting battery .
If new steering rack has been installed, adapt electromechanical
power-assisted steering using ⇒ Vehicle diagnostic tester.
– Adapt electromechanical power-assisted steering using ⇒ Ve‐
hicle diagnostic tester.
Running gear (repair group 01; 40...49)
Electromechanical power steering
01 - self-diagnosis-capable system (APA-BS)
Electromechanical steering system
Functions
Adapting electromechanical steering

After installation, position of steering wheel must be checked dur‐
ing road test.
If steering wheel is crooked or a new steering rack was installed,
wheels must be aligned.
– Check wheel alignment ⇒ page 347 .
Specified torques
♦ Use new bolts

♦ Use new bolts
3. Steering box 415


♦ Use new nut

♦ Use new nuts

link
♦ Use new nuts
Heat shield to subframe 6 Nm

♦ Bolt M6 is self-locking

♦ Use new bolts

♦ Use new bolt
Heat shield to steering rack 6 Nm



M12 x 1.5 x 90 70 Nm + 180° further
♦ Use new bolts
M12 x 1.5 x 100 70 Nm + 180° further

♦ Use new bolts
M12 x 1.5 x 110 70 Nm + 90° further

♦ Use new bolts

M10 x 35 50 Nm + 90° further
♦ Use new bolt
M10 x 75 50 Nm + 90° further

♦ Use new bolt
M12 x 1.5 x 85 60 Nm + 90° further

♦ Use new bolt

3.2.2 Removing and installing steering rack, right-hand drive vehicle

equipment required
1331-
1332-
V.A.G 1383 A-
Removing
Note
Any entries in the event memory must be deleted before renewing

the steering rack ⇒ Vehicle diagnostic tester.
– Connect ⇒ Vehicle diagnostic tester and start “Guided Fault

Finding”.
cess”
lock engages.
3. Steering box 417


– Disconnect battery ⇒ Electrical system; Rep. gr. 27 ; Battery;
Disconnecting and reconnecting battery.
– Remove footwell trim ⇒ General body repairs, interior; Rep.
gr. 68 ; Compartments/covers; Removing and installing dash
panel end trim on driver side .
– Unscrew nut -1-.
– Pull out pin -2- and remove clip complete.
– Slide footwell trim -3- upwards in -direction of arrow- and re‐
move.
– Remove bolt -1- for universal joint and pull universal joint -2-
off steering rack.
Caution

damage.

– Raise vehicle.
noise insulation .
ly.
Caution
nut.


-14-.
– Remove bolts -arrows- on heat shield, if fitted.

– Remove heat shield from subframe, if present.

3. Steering box 419

– Unscrew bolts -5- and -6- for steering rack.

– Separate connector for extended service intervals on oil sump.
– Position
engine and gearbox jack - V.A.G 1383 A- under subframe.
– Remove bolts -9- and -10- and lower subframe with bracket
slightly. Observe electrical wiring.

– Unscrew bolts -arrows- and remove shield -1- over steering

rack.

– Unclip all remaining cable securing points on steering rack and
subframe.
– Separate connectors from steering rack.

– Lower subframe carefully with engine/gearbox jack - V.A.G
1383 A- .
– Lift steering rack down off subframe and remove it to right.
3. Steering box 421

– Set steering rack down as illustrated.

This prevents damage to control unit -1-.
Installing
Threaded sleeve of steering rack must be located in subframe
hole.
Note

♦ After fitting the steering rack to the universal joint, make sure
that the seal is not kinked when lying against the assembly
plate and that the opening to the footwell is correctly sealed.
Before inserting subframe bolts, position steering rack on sub‐

frame and insert bolts for steering rack and anti-roll bar.
sulation .
– Bolt universal joint to steering rack.
– Connect battery ⇒ Electrical system; Rep. gr. 27 ; Battery;
Disconnecting and connecting battery .
If new steering rack has been installed, adapt electromechanical
power-assisted steering using ⇒ Vehicle diagnostic tester.
– Adapt electromechanical power-assisted steering using ⇒ Ve‐
hicle diagnostic tester.
Running gear (repair group 01; 40...49)
Electromechanical power steering
01 - System capable of self-diagnosis (ZF)
Electromechanical steering system
Functions
Adapting electromechanical steering
Note
If parking aid 2 is fitted in the vehicle, the power steering control

unit - J500- must be recoded ⇒ Vehicle diagnostic tester.
After installation, check position of steering wheel during road

test.
If steering wheel is crooked or a new steering rack was installed,
wheels must be aligned.

Specified torques
♦ Use new bolts

♦ Use new bolts

♦ Use new nut

♦ Use new nuts

link
♦ Use new nuts
Heat shield to subframe 6 Nm


♦ Use new bolts

♦ Use new bolt
Heat shield to steering rack 6 Nm



M12 x 1.5 x 90 70 Nm + 180° further
♦ Use new bolts
M12 x 1.5 x 100 70 Nm + 180° further

♦ Use new bolts
M12 x 1.5 x 110 70 Nm + 90° further

♦ Use new bolts

M10 x 35 50 Nm + 90° further
♦ Use new bolt
3. Steering box 423


M10 x 75 50 Nm + 90° further
♦ Use new bolt
M12 x 1.5 x 85 60 Nm + 90° further

♦ Use new bolt
3.3 Repairing steering rack

⇒ “3.3.1 Repairing steering rack, left-hand drive”, page 424
⇒ “3.3.2 Repairing steering rack, right-hand drive”, page 426
⇒ “3.3.3 Repairing steering rack, renewing bonded rubber bush
for power steering rack”, page 426
3.3.1 Repairing steering rack, left-hand drive
1 - Right track rod ball joint

❑ Marked with “A”
⇒ page 433
⇒ page 432 .
❑ Checking: ⇒ page 425
❑ Installation position
⇒ page 433
2 - Nut
❑ 70 Nm
3 - Clamp
4 - Boot
❑ Must not be twisted after
toe setting has been ad‐
justed.
⇒ page 433 .
5 - Clamp
❑ Renew.
6 - Track rod
❑ 100 Nm
⇒ page 429 .
7 - Long bonded rubber bush
❑ Left rear with centring.
9 - Long bonded rubber bush
❑ Rear right
424 Rep. gr.48 - Steering Volkswagen Technical Site: http://vwts.ru http://vwts.info

10 - Short bonded rubber bush
❑ Front left and right.
11 - Locking plate
12 - Left track rod ball joint
❑ Marked with “B” ⇒ page 433
❑ Installation position ⇒ page 433
Checking play, tightness and bellows of track rod ball joints

– Check play by moving track rods and wheels with the vehicle
raised (wheels hanging free). Play: no play
– Check tightness of bolts.
– Check that bellows are undamaged and correctly seated.
3. Steering box 425

3.3.2 Repairing steering rack, right-hand drive
1 - Right track rod ball joint

❑ Marked with “A”
⇒ page 433
⇒ page 432 .
❑ Installation position
⇒ page 433
2 - Nut
❑ 70 Nm
3 - Clamp
4 - Boot
❑ Must not be twisted after
adjusting toe.
❑ Remove steering rack to
renew.
5 - Clamp
❑ Renew.
6 - Track rod
❑ 100 Nm
⇒ page 429 .
❑ Replacement parts are
supplied pre-adjusted.
⇒ page 417 .
8 - Left track rod ball joint
❑ Marked with “B” ⇒ page 433
❑ Installation position ⇒ page 433
Checking play, tightness and bellows of track rod ball joints

– Check play by moving track rods and wheels with the vehicle
raised (wheels hanging free). Play: no play
– Check tightness of bolts.
– Check that bellows are undamaged and correctly seated.
3.3.3 Repairing steering rack, renewing bon‐

ded rubber bush for power steering rack


Removing
Note
♦ Always renew bonded rubber bushes in pairs per side of the

vehicle.
♦ Removal and installation are described for only one bonded
rubber bush. The procedure for the second bonded rubber
bush is similar.
♦ Always note allocation of bonded rubber bush to power-as‐
sisted steering rack ⇒ page 428 .
– Remove power steering rack ⇒ page 409 .

– Fit tools from above as shown in illustration.
1- Nut - T10390/3-
2- Tube - T10390/1-
– Pull out bonded rubber bush.
3. Steering box 427

Allocation of bonded rubber bush to power-assisted steering rack

1- Short bonded rubber bush for front left
2- Short bonded rubber bush for front right
3- Long bonded rubber bush for rear right
4- Long bonded rubber bush for rear left with centring
Installing
– Note allocation of bonded rubber bush to power-assisted
steering rack ⇒ page 428 .
– Coat exterior of bonded rubber bush with soapy water.
– Position the bonded rubber bushes so that the flattened areas

point inwards in parallel -arrows-.
Note
Always draw in bonded rubber bush from above from direction of

steering shaft.

1- Nut - T10390/3-
3- Tube - T10390/2-
– Draw bonded rubber bush in to stop until rubber lip has folded
over edge -arrow-.
Note
After releasing assembly tool - T10390- , bonded rubber bush

slides back slightly.
– Place lock plate -1- onto bonded rubber bushes so that edges
and flattened areas engage.
– Secure lock plate -1- in position with a cable tie -2-.
Note
Tighten cable tie as securely as possible so that lock plate does

not slip when installing power-assisted steering rack.
– Install power steering rack ⇒ page 409 .

– Remove cable tie from steering rack.

3.4 Removing and installing track rod

equipment required
♦ Ball joint puller - 3287 A-
1275-
1332-
♦ Open-end insert, 38 mm -
V.A.G 1923-
♦ Locking pliers for Phaeton
steering rack - VAS 6199-

Removing
– Turn steering wheel to straight-ahead position.
– Raise vehicle.
– Remove wheel.
– Clean outside of steering rack in vicinity of boot.
3. Steering box 429

ly.
Caution
– Open clamps and push boot back.
– Unscrew track rod.

1- Open-end spanner attachment - V.A.G 1923-
Note
♦ If the steering rack shows signs of corrosion, damage, wear or

soiling, renew the complete steering rack.
♦ Likewise, if there is no film of grease on the steering rack, the
steering rack must be renewed.
Installing track rod

ing:
Caution
Do not grease steering rack.
– Make sure that correct track rod ball joint is installed on each
side.
I - Track rod ball joint on right marked with an “A”
II - Track rod ball joint on left marked with a “B”
– Thread new clamps and rubber boot onto track rod.

– Screw track rod into track rod ball joint until dimension -a- is
attained.
Dimension -a- = 367 ± 1 mm
– Tighten track rod.

1- Open-end spanner attachment - V.A.G 1923-
– Lightly lubricate sealing surface between boot and track rod
with grease - G 052 168 A1- (from repair kit Fuchs Renolit
JP1619).
– Push rubber boot -2- onto track rod -1-, making sure that boot
is correctly positioned.
– Secure spring-type clip on rubber boot using hose clip pliers -
V.A.G 1275- .
– Lightly lubricate sealing surface between boot and steering
rack with grease - G 052 168 A1- (from repair kit Fuchs Renolit
JP1619).
– Push rubber boot onto steering rack housing as far as it will
go.
– Install new clamp, as shown in figure, with locking pliers for

Phaeton steering rack - VAS 6199- .
– If both track rods have been exchanged, “learning steering end
stops basic setting” must be carried out with ⇒ Vehicle diag‐
nostic tester.
Specified torques
Track rod to steering rack 100 Nm
3. Steering box 431

3.5 Removing and installing track rod ball

joint

Removing
– Raise vehicle.
– Remove wheel.
– Loosen nut -1-.
– Mark position of track rod ball joint on track rod.
– Loosen nut -2- on track rod ball joint but do not remove com‐
pletely.
Caution
– Push track rod off wheel bearing housing and remove nut.
– Unscrew track rod ball joint from track rod.
Installing

– Make sure that correct track rod ball joint is installed on each
side.
I - Track rod ball joint on right marked with an “A”
II - Track rod ball joint on left marked with a “B”
– Screw track rod ball joint onto track rod as far as previously
applied mark and secure with lock nut.
– Insert track rod ball joint into wheel bearing housing.
– Bolt track rod ball joint with new nut.
– Install front wheel and tighten ⇒ page 320 .
Specified torques
3.6 Removing and installing boot
3. Steering box 433


equipment required
1275-
1332-
♦ Tool insert 24 mm - V.A.G
1332/11-
♦ Locking pliers for Phaeton
steering rack - VAS 6199-

Removing
Note
♦ If boot is defective, moisture and dirt will enter steering rack.

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

– Raise vehicle.
– Remove wheel.

– Mark position of nut on track rod.

– Remove track rod ball joint ⇒ page 432 .
– Clean outside of steering rack in vicinity of boot.
No dirt must be allowed to enter the steering rack through a de‐
fective rubber boot during this operation.
– Open hose clips.
– Pull boot off steering rack housing and track rod.
Note
♦ If the steering rack shows signs of corrosion, damage, wear or

soiling, renew the complete steering rack.
♦ Likewise, if there is no film of grease on the steering rack, the
steering rack must be renewed.
Installing
Caution
Do not grease steering rack.

– Thread new clamps and rubber boot onto track rod.
– Lightly lubricate sealing surface between boot and track rod
with grease - G 052 168 A1- (from repair kit Fuchs Renolit
JP1619).
– Push rubber boot -2- onto track rod -1- as shown in figure.
– Secure spring-type clip on rubber boot using hose clip pliers -
V.A.G 1275- .
– Lightly lubricate sealing surface between boot and steering
rack with grease - G 052 168 A1- (from repair kit Fuchs Renolit
JP1619).
– Push rubber boot onto steering rack housing to stop.
– Install new clamp, as shown in figure, with locking pliers for

Phaeton steering rack - VAS 6199- .
– Screw in track rod ball joint up to mark made during removal
and install ⇒ page 432 .
– Install front wheel and tighten ⇒ page 320 .
– If both track rods have been exchanged, basic setting must be
carried out for steering angle sender - G85- ⇒ Vehicle diag‐
nostic tester.
– Then carry out basic setting of steering ⇒ Vehicle diagnostic
tester
3. Steering box 435

Specified torques

VW Passat b7 Running Gear Steering Eng

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Service

Service Department. Technical Information

42 - Rear suspension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 136

1 Rear axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 136

43 - Self-levelling suspension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 296

44 - Wheels, tyres, vehicle geometry . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 320

1 Wheels, tyres . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 320

2.5 Removing and installing ESL control unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 403

1.1 Checklist for evaluating running gear on

1. Evaluating accident vehicles 1

2 Rep. gr.00 - Technical data

2.1 Tyre types

3.1 General repair instructions

3.2 Steering box

3.3 Gaskets and seals

4 Rep. gr.00 - Technical data

3.4 Nuts and bolts

3.5 Electrical components

3.6 Lifting suspension to kerb weight posi‐

Special tools and workshop

All bolts on running gear components with bonded rubber

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

6 Rep. gr.00 - Technical data

Before the respective wheel suspension is raised, the vehicle

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

Respective nuts and bolts may be tightened only when dimension

Running gear 1) Ride height -a- in mm

♦ Never raise or lower the vehicle while the engine and

– Tighten respective nuts and bolts.

8 Rep. gr.00 - Technical data

Special tools and workshop

All bolts on running gear components with bonded rubber bushes

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

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

10 Rep. gr.00 - Technical data

Measuring dimension -a-

Running gear 1) Ride height -a- in mm

♦ Never raise or lower the vehicle while the engine and

– Tighten respective nuts and bolts.

Volkswagen Technical Site: http://vwts.ru http://vwts.info 3. Repair instructions 11

Special tools and workshop

All bolts on running gear components with bonded rubber bushes

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

12 Rep. gr.00 - Technical data

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

Measuring dimension -a-

Running gear 1) Ride height -a- in mm

♦ Never raise or lower the vehicle while the engine and

– Tighten respective nuts and bolts.

14 Rep. gr.00 - Technical data

1.1 Overview - front axle

⇒ “6.1 Overview - drive shaft”, page 99

16 Rep. gr.40 - Front suspension

2.1 Assembly overview - subframe

A mixed installation of suspension

18 Rep. gr.40 - Front suspension

Distinguishing characteristics of bonded rubber bushes for pen‐

♦ There are 2 different types of bonded rubber bushes for pen‐

2.2 Assembly overview - anti-roll bar