Service

Workshop Manual
Golf Variant 2007 ➤
Jetta 2005 ➤
Running gear, axles, steering
Edition 07.2010

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Service Department. Technical Information

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

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

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Technical information should always be available to the foremen and mechanics, because their
careful and constant adherence to the instructions is essential to ensure vehicle road-worthiness and
safety. In addition, the normal basic safety precautions for working on motor vehicles must, as a
matter of course, be observed.

All rights reserved.

No reproduction without prior agreement from publisher.

Copyright © 2010 Volkswagen AG, Wolfsburg MEX5R005420

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00 - Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

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1 Checklist for evaluating running gear of accident vehicles . . . . . . . . . . . . . . . . . . . . . . . . . . 1

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2 General information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

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40 - Front suspension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

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1 Appraisal of accident vehicles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

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2 Repairing front suspension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
2.1 Overview - front axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

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2.2 Raising wheel suspension to unladen position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
3 Subframe, anti-roll bar, suspension links . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

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3.1 Assembly overview: subframe, anti-roll bar, suspension links . . . . . . . . . . . . . . . . . . . . . . 9
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3.2 Assembly overview: front left vehicle level sender G78 . . . . . . . . . . . . . . . . . . . . . . . . . . 14

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3.3 Removing and installing front left vehicle level sender G78 . . . . . . . . . . . . . . . . . . . . . . . . 14

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3.4 Repairing thread in longitudinal member . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

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3.5 Fixing position of subframe and brackets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

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3.6 Lowering subframe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

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3.7 Removing and installing subframe without steering box . . . . . . . . . . . . . . . . . . . . . . . . . . 21

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3.8 Removing and installing subframe with steering box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
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3.9 Repairing subframe (front-wheel drive) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
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3.10 Repairing subframe (four-wheel drive) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
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3.11 Checking swivel joint . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
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3.12 Removing and installing swivel joint . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

3.13 Removing and installing suspension link with mounting bracket . . . . . . . . . . . . . . . . . . . . 38
3.14 Removing and installing suspension link with mounting bracket (left side for vehicles with
DSG or automatic gearboxes) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
3.15 Renewing bonded rubber bush for suspension link . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
3.16 Renewing mounting bracket with suspension link bush . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
3.17 Removing and installing anti-roll bar . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
4 Assembly overview: wheel bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
4.1 Removing and installing wheel bearing unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
4.2 Removing and installing wheel bearing housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
5 Assembly overview: suspension strut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
5.1 Removing and installing suspension strut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
5.2 Repairing suspension strut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
6 Removing and installing drive shafts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
6.1 Loosening and tightening drive shaft hexagon bolt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
6.2 Loosening and tightening 12-point flange bolt securing drive shaft . . . . . . . . . . . . . . . . . . 71
6.3 Removing and installing drive shaft with constant velocity joint . . . . . . . . . . . . . . . . . . . . . . 72
6.4 Removing and installing left drive shaft with (push-on) constant velocity slip joint . . . . . . 74
6.5 Removing and installing right drive shaft with (push-on) constant velocity slip joint . . . . . . 78
6.6 Removing and installing drive shafts with triple roller joint AAR2600i . . . . . . . . . . . . . . . . 81
6.7 Removing and installing drive shafts with triple roller joint AAR3300i . . . . . . . . . . . . . . . . 83
6.8 Removing and installing intermediate shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
7 Repairing drive shaft - overview of drive shafts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
7.1 Heat shields for drive shafts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
8 Assembly overview: drive shaft with VL90 or VL100 constant velocity joint . . . . . . . . . . . . 90
8.1 Dismantling and assembling drive shaft with VL90 or VL100 constant velocity joint . . . . . . 92
8.2 Checking outer constant velocity joint . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
8.3 Checking inner constant velocity joint . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
9 Assembly overview: drive shaft with VL107 constant velocity joint (bolt-on) . . . . . . . . . . . . 100
9.1 Dismantling and assembling drive shaft with VL107 constant velocity joint . . . . . . . . . . . . 102
9.2 Repairing intermediate shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107

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 Golf Variant 2007 ➤ , Jetta 2005 ➤
Running gear, axles, steering - Edition 07.2010

10 Assembly overview: drive shaft with VL107 constant velocity slip joint (push-on) . . . . . . . . 109
10.1 Dismantling and assembling drive shaft with VL107 (push-on) constant velocity slip joint
........................................................................ 110
10.2 Checking outer constant velocity joint . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112
11 Assembly overview: drive shaft with triple roller joint AAR2600i . . . . . . . . . . . . . . . . . . . . 114
11.1 Dismantling and assembling drive shaft with triple roller joint AAR2600i . . . . . . . . . . . . . . 115
12 Assembly overview: drive shaft with triple roller joint AAR3300i . . . . . . . . . . . . . . . . . . . . 120
12.1 Dismantling and assembling drive shaft with triple roller joint AAR3300i . . . . . . . . . . . . . . 122

42 - Rear suspension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127

1 Appraisal of accident vehicles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127
2 Repairing rear suspension (front-wheel drive) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128
2.1 Overview - rear axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128
2.2 Rear axle in unladen position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129
3 Assembly overview: subframe, transverse link, track rod (front-wheel drive) . . . . . . . . . . 132
3.1 Removing and installing rear axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134
3.2 Vehicle level sender for vehicles with automatic headlight range control . . . . . . . . . . . . . . 139
3.3 Renew vehicle level sender in vehicle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139
3.4 Removing and installing upper transverse link . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140
3.5 Removing and installing lower transverse link . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 142
3.6 Removing and installing track rod . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143
4 Assembly overview: wheel bearing housing, trailing arm (front-wheel drive) . . . . . . . . . . . . 147
4.1 Removing and installing wheel bearing housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 148
4.2 Renewing bonded rubber bush for wheel bearing housing . . . . . . . . . . . . . . . . . . . . . . . . 152
4.3 Removing and installing wheel bearing/wheel hub unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . 155
4.4 Removing and installing trailing arm with mounting bracket . . . . . . . . . . . . . . . . . . . . . . . . 157
4.5 Repairing trailing arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 161
5 Assembly overview: shock absorber, coil spring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 164
5.1 Removing and installing coil spring . . . . . . . . . . . . . . . . . . a.g.en. A. G. ..V.o.lks. w. a.g.en. A. G. d. o. . . . . . . . 164
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5.2 Removing and installing shock absorbers . . . . . . . .b.y V. o.lk. . . . . . . . . . . . . . . . . . . . . n.o.t g. u. . . 166
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5.3 Repairing shock absorber . . . . . . . . . . . . . . . . .or.is.e . . . . . . . . . . . . . . . . . . . . . . . . . . . . . r.a.nte168
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6 Assembly overview: anti-roll bar . . . . . . . . .ss.a.u . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 170 ra
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6.1 Removing and installing anti-roll bar . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 170
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BlueMotion (front-wheel drive) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 173
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7.1 Removing and installing shield . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 174 ility
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8 Repairing rear suspension (four-wheel drive) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 176 h re

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8.1 Overview - rear axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 176

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8.2 Rear axle in unladen position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 178

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9 Assembly overview: subframe, final drive (four-wheel drive) . . . . . . . . . . . . . . . . . . . . . . . . 180

9.1 Removing and installing rear axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 180
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9.2 Repairing subframe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 186

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10 Assembly overview: transverse link, track rod (four-wheel drive) . . . . . . . . . . . . . . . . . . . . 193

10.1 Overview - rear left vehicle level sender G76 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 196
10.2 Renew vehicle level sender in vehicle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 196
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10.3 Removing and installing upper transverse link . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 197

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10.4 Removing and installing lower transverse link . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 199

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10.5 Removing and installing track rod . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201

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11 Assembly overview: wheel bearing housing, trailing arm (four-wheel drive) . . . . . . . . . . . . 204
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11.1 Removing and installing wheel bearing housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 205

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11.2 Renewing bonded rubber bush for wheel bearing housing . . . . . . . . . . . . . . . . . . . . . . . . 208
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11.3 Removing and installing wheel bearing/wheel hub unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . 210
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11.4 Removing and installing trailing arm with mounting bracket . . . . . . . . . . . . . . . . . . . . . . . . 211 cop Vo
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11.5 Repairing trailing arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 215
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 Golf Variant 2007 ➤ , Jetta 2005 ➤
Running gear, axles, steering - Edition 07.2010

12 Assembly overview: shock absorber, coil spring (four-wheel drive) . . . . . . . . . . . . . . . . . . 218

12.1 Removing and installing coil spring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 218
12.2 Removing and installing shock absorbers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 220
12.3 Repairing shock absorber . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 222
13 Assembly overview: anti-roll bar (four-wheel drive) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 225
13.1 Removing and installing anti-roll bar . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 225
14 Assembly overview: drive shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 228
14.1 Loosening and tightening 12-point flange bolt securing drive shaft . . . . . . . . . . . . . . . . . . 229
14.2 Removing and installing drive shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 230
14.3 Dismantling and assembling drive shaft . . . . . . . . . a. g.e.n .AG . .. V. o.lk.s.w.ag. e.n.A.G. d.o. . . . . . . . . . . . . . 232
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14.4 Checking outer constant velocity joint . . . . . .y V. o. . . . . . . . . . . . . . . . . . . . . .no. t .gu. . . . . . . . .
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14.5 Checking inner constant velocity joint . .or.is.ed. . . . . . . . . . . . . . . . . . . . . . . . . . . . .ra.nt.e . . . . . 237
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44 - Wheels, tyres, vehicle geometry . . s. s. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 240
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1 Appraisal of accident vehicles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 240

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2 Torque settings for wheels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 241
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3 Fitting wheel and tyre . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 242

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3.1 General information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 242

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3.2 Fittings instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 242

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4 Removing and fitting tyres (wheels with tyre pressure monitoring) . . . . . . . . . . . . . . . . . . 244

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4.1 Notes on safety and conditions for removing and fitting tyres (wheels with tyre pressure
monitoring) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 244

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4.2 Wheel change . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 244
4.3 Pressing tyre off wheel rim . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 245

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4.4 Removing tyre from wheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 246

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4.5 Fitting tyre to wheel rim . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 246

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5 Removing and fitting tyres with run-flat properties to wheel rims . . . . . . . . . . . . . . . . . . . . 248
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5.1 Notes on safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 248
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5.2 Fittings instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 248

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5.3 Pressing tyre off wheel rim . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 250

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5.4 Removing tyre from wheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 250

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5.5 Fitting tyre to wheel rim . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 252

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6 Tyre pressure monitor display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 254
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6.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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254
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6.2 System fault in the ABS system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Prote
cted AG.
agen
255
6.3 Perform basic setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 255
7 Tyre pressure monitor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 257
7.1 Button behaviour . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 257
7.2 Assembly overview: tyre pressure sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 259
7.3 Removing and installing tyre pressure sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 259
8 Wheel alignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 261
8.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 261
8.2 Test prerequisites . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 263
8.3 Test preparations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 263
8.4 Specifications for wheel alignment Jetta from 2006, Golf Variant from 2008 . . . . . . . . . . . . 264
8.5 Specifications for wheel alignment Jetta from 2005, Golf Variant from 2008, Bora
SportWagen from 2009 (North America) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 265
8.6 Specifications for wheel alignment Bora from 2006 (Mexico) . . . . . . . . . . . . . . . . . . . . . . 266
8.7 Specifications for wheel alignment, Jetta from 2006 (India) . . . . . . . . . . . . . . . . . . . . . . . . 267
8.8 Overview - wheel alignment procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 268
8.9 Correcting front axle camber . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 270
8.10 Adjusting camber on rear axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 271
8.11 Adjusting toe at rear axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 273
8.12 Adjusting front axle toe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 273

Contents iii
 Golf Variant 2007 ➤ , Jetta 2005 ➤
Running gear, axles, steering - Edition 07.2010

8.13 Basic setting for steering angle sender G85 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 274

8.14 Vehicle data sticker . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 275
9 Wheels, tyres . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 276
9.1 Models with breakdown setn A.G.. V . o. lk. s.w.a.ge. n.A.G. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 276
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9.2 Tyre sealant . . . . V.o.lk.sw. a. . . . . . . . . . . . . . . . o. e.s.no. t.g. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 276
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9.3 Removing a tyre ed . . . . . . . . . . . . . . . . . . . . . . . . . . . . r.an. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
b
276
ris tee
9.4 Fitting a newaut tyre . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . o. r .a . . . . . . . . . . . . . . . . . . . . . . . .
ho
277
9.5 Tyre sealant
ss disposal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .c . . . . . . . . . . . . . . . . . . . . . . . . 277

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le

9.6 Alloy wheels with metal valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 277

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10 Instructions for changing or fitting wheels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 279
erm

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10.1 Fitting wheels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 280

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11 Protecting wheel centring seat against corrosion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 281

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12 Rough running due to wheels/tyres - causes and rectification . . . . . . . . . . . . . . . . . . . . . . 282

spec
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12.1 Causes of rough running . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 282

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12.2 Balancing wheels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 282
12.3 Conducting a road test before balancing wheels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 282

rrectne
12.4 Balancing wheels on stationary wheel balancing machine . . . . . . . . . . . . . . . . . . . . . . . . 283
12.5 Vibration control system VAS 6230 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 285

s
12.6 Finish balancer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 285

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12.7 Radial and lateral runout of wheels and tyres . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 286

f inform
12.8 Checking radial and lateral runout on wheels and tyres with tyre gauge V.A.G 1435 . . . . 286
mer

12.9 Checking radial and lateral runout on wheel rim . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 287

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12.10 Matching . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 288
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12.11 Flat spots caused by storage or handling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 289
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48 - Steering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 291
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1 Appraisal of accident vehicles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 291
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2 General repair instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 292
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2.1 Steering box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 292
by c lksw
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2.2 Gaskets and seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 292
AG.

2.3 Nuts and bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 292

2.4 Electrical components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 293
2.5 Guided fault-finding, vehicle self-diagnosis and test instruments . . . . . . . . . . . . . . . . . . . . 293
3 Steering wheel, steering column . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 294
3.1 Removing and installing steering wheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 294
3.2 Assembly overview - steering column, Golf Variant up to model year 2009, Jetta up to model
year 2008 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 297
3.3 Removing and installing steering column, Golf Variant up to model year 2009, Jetta up to
model year 2008 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 297
3.4 Assembly overview - steering column, left-hand drive, Jetta as of model year 2009 . . . . . . 303
3.5 Removing and installing steering column, left-hand drive, Jetta as of model year 2009 . . 304
3.6 Assembly overview - steering column, right-hand drive, Jetta as of model year 2009 . . . . 311
3.7 Removing and installing steering column, right-hand drive, Jetta as of model year 2009 . . 311
3.8 Basic setting for steering angle sensor G85 steering angle sender must be checked after the
following repair work: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 318
3.9 Handling and transporting steering column, Golf Variant up to model year 2009, Jetta up to
model year 2008 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 318
3.10 Handling and transporting steering column, Jetta as of model year 2009 . . . . . . . . . . . . . . 320
3.11 Checking steering column for damage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 321
3.12 Removing and installing mounting bracket, Golf Variant up to model year 2009, Jetta up to
model year 2008 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 321
3.13 Removing and installing strut, Golf Variant up to model year 2009, Jetta up to model year
2008 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 323
4 Electromechanical steering box up to model year 2008 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 325
4.1 Assembly overview - electromechanical steering box, left-hand drive vehicle (2nd generation)
up to model year 2008 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 325

iv Contents
 Golf Variant 2007 ➤ , Jetta 2005 ➤
Running gear, axles, steering - Edition 07.2010

4.2 Assembly overview - electromechanical steering box, right-hand drive vehicle (2nd
generation) up to model year 2008 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 327
4.3 Removing and installing steering box, left-hand drive vehicle (2nd generation) up to model
year 2008 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 328
4.4 Removing and installing steering box, right-hand drive vehicle (2nd generation) up to model
year 2008 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 336
5 Electromechanical steering boxswfrom AG. Volkswagen AG d . . . . . . . . . . . . . . . . . . . . . . . . . . . .
agen model year 2009 oes 345
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5.1 Assembly overview - electromechanical
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steering box, left-hand gu drive vehicle (3rd generation)
a
from model year 2009oris. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .ra.n.te. . . . . . . . . . . . . . . . . . . .
e 345
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5.2 Assembly overview s au- electromechanical steering box, right-hand drive r a vehicle (3rd
c
generation) from model
s year 2009 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 346

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5.3 Removing and installing steering box, left-hand drive vehicle (3rd generation) from model

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year 2009 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 347
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5.4 Removing and installing steering box, right-hand drive vehicle (3rd generation) from model

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year 2009 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 353

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6 Differentiating between 2nd and 3rd generation steering boxes . . . . . . . . . . . . . . . . . . . . 360

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7 Repairing electromechanical 2nd and 3rd generation steering boxes . . . . . . . . . . . . . . . . 361
es, in part or in w

7.1 Removing and installing boot . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 361

t to the co
7.2 Removing and installing track rod . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 363

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Contents v
 Golf Variant 2007 ➤ , Jetta 2005 ➤
Running gear, axles, steering - Edition 07.2010

AG. Volkswagen AG d
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vi Contents
 Golf Variant 2007 ➤ , Jetta 2005 ➤
Running gear, axles, steering - Edition 07.2010

00 – Technical data
1 Checklist for evaluating running gear
of 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 box
♦ Visual examination for tears in boots AG. Volkswagen AG d
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♦ Examine electrical and hydraulic lines dand by hoses for chafing,
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connections and steering c
gear for leaks.

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♦ Check steering box and lines for secure seating

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♦ Check for flawless function from lock to lock by moving the

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steering from stop to stop. In the process, the steering wheel

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must turn with a constant force without resistance.

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Visual inspection and functional check of running gear
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• Adhere to the sequence of the following inspection steps!
♦ Exam all components shown in the assembly overviews for

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deformation, cracks and other damage.
♦ Renew damaged parts
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♦ Align wheels on a VOLKSWAGEN AG-approved wheel align‐

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Visual and functional check of wheels and tyres

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♦ Check tyre inflation pressure; see tyre inflation pressure stick‐
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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.
Generally, in case of doubt:
• Whenever a safety risk cannot be excluded, the tyre(s) must
be renewed.

1. Checklist for evaluating running gear of accident vehicles 1

 Golf Variant 2007 ➤ , Jetta 2005 ➤
Running gear, axles, steering - Edition 07.2010

Entire vehicle
Check other vehicle systems as well, for example:
♦ Brake system including ABS
♦ Visual and functional examination of exhaust system and pas‐
senger protection
Specifications for testing and adjusting can be found in the re‐
spective workshop manual in ELSA.
The examination for accident vehicles described here refers to
the running gear and does not purport to be a complete exami‐
nation of the entire vehicle.
Electronic vehicle systems
Safety-relevant systems like, for example, ABS/EDL; airbags;
electronically regulated suspension systems; electromechanical
or electrohydraulic steering and other driver assist systems, must
be read with the vehicle diagnostic, testing and information sys‐
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Following repairs,
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again to be ssure that complete function has been restored.
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2 Rep. gr.00 - Technical data

 Golf Variant 2007 ➤ , Jetta 2005 ➤
Running gear, axles, steering - Edition 07.2010

2 General information
Information concerning wheels, tyres and snow chains can be
found in „Wheel and Tyre Guide“ ⇒ Wheels, tyres, wheel align‐
ment; Rep. gr. 44 .

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2. General information 3
 Golf Variant 2007 ➤ , Jetta 2005 ➤
Running gear, axles, steering - Edition 07.2010

40 – Front suspension
1 Appraisal of accident vehicles
A checklist for evaluating running gear of accident vehicles can
be found under ⇒ page 1 .

AG. Volkswagen AG d
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4 Rep. gr.40 - Front suspension

 Golf Variant 2007 ➤ , Jetta 2005 ➤
Running gear, axles, steering - Edition 07.2010

2 Repairing front suspension

2.1 Overview - front axle

AG. Volkswagen AG d
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♦ It is not permitted to carrys aout welding and straightening operations on load-bearing or wheel-guiding sus‐
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♦ Always renew self-locking nuts.

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♦ Always renew corroded nuts and bolts.

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♦ Bonded rubber bushes can be twisted only to a limited extent. Therefore, tighten the bolted connections of

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components with bonded rubber bushes only when the wheel bearing housing is raised to unladen position

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⇒ page 6 .

spec
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I - Assembly overview: sub‐
frame, anti-roll bar, suspen‐

rrectness of i
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l purpos

II - Assembly overview: wheel

bearing ⇒ page 55

nf
ercia

o
III - Assembly overview: sus‐

rm
m

pension strut ⇒ page 62

atio
om

n in
or c

thi
te

sd
iva

o
r
rp

cu
o

m
f

en
ng

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

2. Repairing front suspension 5

 Golf Variant 2007 ➤ , Jetta 2005 ➤
Running gear, axles, steering - Edition 07.2010

The chapter „Removing and installing drive shafts“ can be found

on ⇒ page 72 .
The chapter „Repairing drive shaft“ can be found on
⇒ page 87 .

2.2 Raising wheel suspension to unladen position

Special tools and workshop

equipment required
♦ Engine and gearbox jack -
V.A.G 1383 A-
♦ Tensioning strap -T10038-
♦ Support -T10149-

n AG. Volkswagen AG do
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss

ce
le
un

pt
an
d
itte

y li
erm

ab
ility
ot p

wit
is n

h re
ole,

spec
urposes, in part or in wh

t to the co
rrectness o
cial p

f inform
mer

atio
om

n
c

i
or

n thi
te

sd
iva

o
pr

cum
r
fo

en
ng

t.
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Cop py
t. rig
Caution
gh ht
pyri by
Vo
co lksw
by
cted agen
All bolts on running gear components with bonded rubber Prote AG.
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.

6 Rep. gr.40 - Front suspension

 Golf Variant 2007 ➤ , Jetta 2005 ➤
Running gear, axles, steering - Edition 07.2010

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 using tensioning
straps -T10038- .

WARNING

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

vehicle will slip off the lifting platform!

– Turn wheel hub until one of the wheel bolt holes is at the top.
– Attach support -T10149- to wheel hub using wheel bolt.
n AG. Volkswagen AG do
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
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a ac
ss

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nl

pt
du

an
itte

y li
erm

ab
ility
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wit
, is n

h re
hole

spec
es, in part or in w

t to the co
rrectness of i
l purpos

nform
mercia

at
om

ion
c

in t
or

his
ate

do
priv

cum
for

en
ng

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

2. Repairing front suspension 7

 Golf Variant 2007 ➤ , Jetta 2005 ➤
Running gear, axles, steering - Edition 07.2010

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: Jetta from 2006, Ride height -a- in mm
Golf Variant from 2008 1)
Standard running gear (2UA) 382 ± 10 mm
Heavy-duty running gear (2UB) 402 ± 10 mm
Sports running gear except 18" 367 ± 10 mm
wheels (2UC)
Sports running gear with 18" 367 ± 10 mm
wheels (G02/G05/G07/2UC)
Jetta BlueMotion (G13/2UC) 367 ± 10 mm
Golf Variant BlueMotion 367 ± 10 mm
(G14/2UC)

Running gear: Jetta from 2005 Ride height -a- in mm

(North America), Golf Variant
from 2008, Bora SportWagen
from 2009 (North America) 1)
Standard running gear (2UA) 382 ± 10 mm
Sports running gear (2UC) 382 ± 10 mm
Sports running gear GLI (G11) 382 ±
gen AG
. V10
olksmm
wagen AG
wa does
olks not
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Running gear: Bora from 2006 ed b Ride height -a- in mm ara
nte
1) ris
(Mexico) utho eo
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sa c
Standard running gear (2UD)
s 393 ± 10 mm
ce
e
nl

pt

Sports running gear GLI (G10) 382 ± 10 mm

du

an
itte

y li
erm

ab

Running gear: Jetta from 2006 Ride height -a- in mm

ility
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(India) 1)
wit
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Standard running gear 397 ± 10 mm

hole

spec

(G56/2UE)
es, in part or in w

t to the co

1)The type of running gear fitted to the vehicle is recorded on the

vehicle data sticker. The running gear is identified by the PR
number. Which PR. No. refers to which running gear can be found
rrectness of i

here ⇒ page 275 .

l purpos

– Raise wheel bearing housing using engine and gearbox jack

-V.A.G 1383 A- until dimension -a- is attained.
nf
ercia

orm

WARNING
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♦ Never raise or lower the vehicle while the engine and

thi
te

gearbox jack is positioned beneath the vehicle.

sd
iva

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r
rp

cu

♦ Do not leave engine and gearbox jack -V.A.G 1383 A- un‐

o

m
f

en
ng

der vehicle longer than necessary.

t.
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Cop py
t. rig
gh ht
pyri by
Vo
o
– Tighten respective nuts and bolts.
c by lksw
cted agen
Prote AG.
– Lower wheel bearing housing.
– Pull engine and gearbox jack -V.A.G 1383 A- out from under
vehicle.
– Detach support -T10149- .

8 Rep. gr.40 - Front suspension

 Golf Variant 2007 ➤ , Jetta 2005 ➤
Running gear, axles, steering - Edition 07.2010

3 Subframe, anti-roll bar, suspension

links

3.1 Assembly overview: subframe, anti-roll bar, suspension links

Caution

♦ It is not permitted to carry out welding and straightening

operations on load-bearing or wheel-guiding suspension
components.
♦ Always renew self-locking nuts.
♦ Always renew corroded nuts and bolts.

1 - Nut
❑ 65 Nm
❑ When tightening, coun‐
terhold on hexagon
socket of joint stub.
❑ Self-locking
❑ Always renew after re‐
moving.
2 - Coupling rod n AG. Volkswagen AG do
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❑ Link between anti-roll by Volk ot g
ua
bar and suspension rised ran
tee
strut utho
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sa ac
3 - Bracket s
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le
un

pt

❑ Fixing position
an
d
itte

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⇒ page 16
rm

ab
pe

❑ If bracket is renewed,
ility
ot

the wheels must be

wit
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h re

aligned ⇒ page 261

hole

spec

4 - Mounting bracket
es, in part or in w

t to the co

❑ Fixing position
⇒ page 17
❑ With bonded rubber
rrectness of i

bush
l purpos

5 - Bolt
❑ 50 Nm + 90° further
nform
ercia

❑ Always renew after re‐

m

moving.
a
com

tion in

6 - Bolt
r
te o

thi

❑ M12 x 1.5 x 90
s
iva

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rp

❑ 70 Nm + 90° further
um
fo

en
ng

❑ Always renew after re‐

t.
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op
moving.
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7 - Bolt cop Vo
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cted agen
❑ M12 x 1.5 x 90 Prote AG.

❑ 70 Nm + 90° further
❑ Always renew after removing.

3. Subframe, anti-roll bar, suspension links 9

 AG. Volkswagen AG d
agen oes
olksw not
y V gu
Golf Variant 2007 ➤ , Jetta r2005
ise
d b
➤ ara
nte
Running gear, axles, steering
autho
- Edition 07.2010 eo
ra
ss c

ce
le
8 - Front left vehicle level sender -G78-

un

pt
an
d
❑ Can be checked in guided fault finding of the vehicle diagnostic, testing and information system -VAS

itte

y li
erm
5051B- .

ab
ility
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9 - Bolt

wit
is n

h re
❑ 9 Nm
ole,

spec
urposes, in part or in wh

10 - Suspension link

t to the co
❑ Different versions of suspension links are possible (cast steel, aluminium).
❑ Allocation ⇒ Electronic parts catalogue „ETKA“

rrectne
Note

ss o
❑ If damaged, also renew swivel joint.
cial p

f inform
❑ Removing and installing ⇒ page 38 .
mer

atio
❑ Renew mounting ⇒ page 46
om

n
c

i
or

n
11 - Suspension link

thi
te

sd
a

❑ Different versions of suspension links are possible (welded steel sheet, single-shell steel sheet).
iv

o
pr

cum
r

❑ Allocation ⇒ Electronic parts catalogue „ETKA“

fo

en
ng

t.
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op py
Note t. C rig
gh ht
pyri by
Vo
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by
❑ If damaged, also renew swivel joint. cted agen
Prote AG.
❑ Removing and installing ⇒ page 38 .
❑ Renew mounting ⇒ page 46
12 - Nut
❑ M12 x 1.5
❑ 60 Nm
❑ Self-locking
❑ Always renew after removing.
13 - Swivel joint
❑ Checking ⇒ page 35
❑ Removing and installing ⇒ page 36 .
❑ Renew together with suspension link if suspension link is damaged
14 - Nut
❑ For cast steel suspension link: 60 Nm
❑ For sheet steel and forged aluminium suspension link: 100 Nm
❑ Self-locking
❑ Always renew after removing.
15 - Nut
❑ 9 Nm
16 - Bolt
❑ M12 x 1.5 x 100
❑ 70 Nm + 90° further
❑ Always renew after removing.
17 - Bolt
❑ 20 Nm + 90° further
❑ Always renew after removing.
18 - Bolt
❑ M12 x 1.5 x 75
❑ 70 Nm + 90° further

10 Rep. gr.40 - Front suspension

 Golf Variant 2007 ➤ , Jetta 2005 ➤
Running gear, axles, steering - Edition 07.2010
❑ Always renew after removing.
19 - Bolt
❑ M14 x 1.5 x 70
❑ 100 Nm + 90° further
❑ Do not tighten until pendulum support is bolted to gearbox
❑ Always renew after removing.
20 - Bracket for skid plate
❑ Allocation ⇒ Electronic parts catalogue „ETKA“
21 - Bolt
Always observe size and strength class of the bolt. Different torque specifications apply.
n AG. Volkswagen AG do
❑ M10 x 75 strength class 8.8: 40 Nm and turn 90° further
olks
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❑ M10 x 75 strength class 10.9: 50 Nm and turn by further
d90° ua
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se ri tee
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ac
Caution ss

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pt
From model year 08,
du

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itte

HeliCoil inserts are in‐

y li
erm

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stalled in the pendulum

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support connection in

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the 02Q gearboxes.

h re
Identification ⇒ Rep. gr.
hole

spec
34
es, in part or in w

t to the co
Use a bolt with hardness
class 10.9 for this and all
other gearboxes.

rrectness of i
If there is no HeliCoil in‐
l purpos

sert in the 02Q gearbox,

use bolts with the

nform
ercia

strength class 8.8 and

the corresponding tor‐
m

at
que setting.
om

ion
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in t
or

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❑ Always renew after removing.

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or

22 - Bolt
f

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ng

t.
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Always observe strength class of the bolt. Different torque specifications apply. ht. Cop py
rig
rig ht
❑ M10 x 35 strength class 8.8: 40 Nm and turn 90° further py by
co Vo
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❑ M10 x 35 strength class 10.9: 50 Nm and turn 90° further
cted agen
Prote AG.

3. Subframe, anti-roll bar, suspension links 11

 Golf Variant 2007 ➤ , Jetta 2005 ➤
Running gear, axles, steering - Edition 07.2010

Caution
From model year 08,
HeliCoil inserts are in‐
stalled in the pendulum
support connection in
the 02Q gearboxes.
Identification ⇒ Rep. gr.
34 .
Use a bolt with hardness
class 10.9 for this and all
other gearboxes.
If there is no HeliCoil in‐
sert in the 02Q gearbox,
use bolts with the
strength class 8.8 and
the corresponding tor‐
que setting.

❑ Always renew after removing.

23 - Bracket to pendulum support
❑ Not an individual part
24 - Pendulum support
❑ Bolt first to gearbox and then to subframe
❑ Various versions AG. Volkswagen AG d
agen oes
olksw
❑ Allocation ⇒ byElectronic parts catalogue „ETKA“ not
V gu
ara
ed n
25 - Lower bondedris rubber bush for pendulum support tee
utho or
❑ Pressing
ss
a
out and in for vehicles with front-wheel drive ⇒ ac
page 28
ce
le

❑ Pressing out and in for vehicles with four-wheel drive ⇒ page 31

un

pt
an
d
itte

❑ Different versions ⇒ page 13

y li
rm

ab

❑ Allocation ⇒ Electronic parts catalogue „ETKA“

pe

ility
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wit
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26 - Shield
h re
hole

❑ For vehicles with front-wheel drive only

spec
es, in part or in w

27 - Bolt
t to the co

❑ 6 Nm
❑ Self-locking
rrectness of i

28 - Subframe
l purpos

❑ Various versions
❑ Removing and installing without steering box ⇒ page 21
nform
ercia

❑ Removing and installing with steering box ⇒ page 23

m

a
com

❑ Allocation ⇒ Electronic parts catalogue „ETKA“

ion in
r
te o

29 - Upper bonder rubber bush for pendulum support

thi
s
iva

do

❑ Pressing out and in for vehicles with front-wheel drive ⇒ page 28

r
rp

cum
fo

❑ Pressing out and in for vehicles with four-wheel drive ⇒ page 31

en
ng

t.
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❑ Different versions ⇒ page 13 t. Cop py
rig
gh
❑ Allocation ⇒ Electronic parts catalogue „ETKA“
ht
pyri by
Vo
co lksw
by
30 - Bolt
cted agen
Prote AG.

❑ M12 x 1.5 x 110

❑ 70 Nm + 180° further
❑ Always renew after removing.
❑ Tighten only in unladen state ⇒ page 6

12 Rep. gr.40 - Front suspension

 Golf Variant 2007 ➤ , Jetta 2005 ➤
Running gear, axles, steering - Edition 07.2010

31 - Nut
❑ 65 Nm
❑ When tightening, counterhold on hexagon socket of joint stub.
❑ Self-locking
❑ Always renew after removing.
32 - Anti-roll bar
❑ Various versions
❑ Allocation ⇒ Electronic parts catalogue „ETKA“
❑ Removing and installing ⇒ page 50 .

Distinguishing characteristics of bonded rubber bushes for pen‐

dulum support

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“ .
G. Volkswage
I - The corners of the inner
lksw
core
agen -1- point towards
A n AG d
oethe
s no opening for
pendulum support -arrow-
by Vo (T version) t gu
a d ran
ise
II - The corners
ut
hoof the inner core -2- point away from the opening
r tee
or
for pendulumss support -arrow- (V version)
a ac
ce
e
nl

pt
du

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itte

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erm

ab
ility
ot p

wit
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h re
hole

spec
es, in part or in w

t to the co
rrectness of i
l purpos

nform
mercia

at
om

ion
c

in t
or

his
ate

do
priv

cum
for

en
ng

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

3. Subframe, anti-roll bar, suspension links 13

 . Volkswagen AG
gen AG does
Golf Variant 2007 ➤ , Jetta 2005 ➤ olks
wa not
yV gu
Running gear, axles, steering - Edition 07.2010
ise
d b ara
nte
r
ho eo
ut ra
3.2 Assembly overview: front left vehicle level sender -G78-
a c
ss

ce
le
un

pt
an
d
itte

y li
rm
Note

ab
pe

ility
ot

wit
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♦ The front left vehicle level sender -G78/- is only available as a replacement part complete with coupling rod

h re
and upper and lower retaining plates.

hole

spec
♦ Replace with subframe installed.
es, in part or in w

t to the co
1 - Subframe

rrectness of i
2 - Bolt
l purpos

❑ M6 x 16
❑ 9 Nm

nform
mercia

3 - Front left vehicle level send‐

a
com

ti
er -G78- and front right vehicle

on in
level sender -G289-
r
te o

thi
s
iva

❑ Complete with attach‐

do
r
rp

c
ments

um
fo

en
g

❑ Lever -arrow- must face

n

t.
yi Co
op
outwards C py
t. rig
gh ht
❑ Removing and installing yri
p by
o Vo
by c
⇒ page 14 .
lksw
cted agen
Prote AG.
❑ Following renewal, ba‐
sic settings for headlight
must be performed.
Basic setting of headlights ⇒
"Guided fault-finding" function
of vehicle diagnostic, testing
and information system
VAS 5051

4 - Suspension link
5 - Nut
❑ 9 Nm
❑ Self-locking
❑ Always renew after re‐
moving.

3.3 Removing and installing front left vehicle

level sender -G78-
Special tools and workshop equipment required

14 Rep. gr.40 - Front suspension

 Golf Variant 2007 ➤ , Jetta 2005 ➤
Running gear, axles, steering - Edition 07.2010

♦ Torque wrench -V.A.G 1410-

Removing

Note
AG. Volkswagen AG d
agen oes
olksw not
To remove front d left
by V vehicle level sender -G78- , steering
gu
ara must be
turned to right lock to ensure clearance between suspension link
ise nte
or eo
h
and anti-roll
s aut bar. ra
c
s
ce
e
nl

– Separate connector. pt
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an
itte

y li
– Remove bolt and nut.
erm

ab
ility
ot p

– Take out vehicle level sender.

wit
, is n

h re

Installing
hole

spec
es, in part or in w

Install in reverse order. Note the following points:

t to the co

Note
rrectness of i

♦ Lever on vehicle level sender must face towards outside of

l purpos

vehicle.
♦ Thread of vehicle level sender must be screwed into front hole
nform
ercia

in suspension link. Lug of bracket for vehicle level sender must

m

at

engage in rear hole in order to guarantee correct installation

om

io

position.
n
c

in t
or

his
ate

do
riv

– Perform basic setting of headlights ⇒ "Guided fault-finding"

p

cum

function of vehicle diagnostic, testing and information system

for

en
g

VAS 5051
n

t.
yi Co
Cop py
ht. rig
ht
Specified torques
rig by
copy Vo
by lksw
cted agen
Component Prote
Specified torque
AG.

Bolt to subframe 9 Nm
Nut 9 Nm
♦ Use new nut

3.4 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 .

3. Subframe, anti-roll bar, suspension links 15

 Golf Variant 2007 ➤ , Jetta 2005 ➤
Running gear, axles, steering - Edition 07.2010
AG. Volkswagen AG d
agen oes
ksw
3.5 Fixing position of subframe and brack‐ d by
Vol not
gu
ara
ets ise nte
or eo
h
aut ra
s c
Special tools and workshop equipment required s

ce
e
nl

pt
du
♦ Locating pins -T10096-

an
itte

y li
erm

ab
ility
ot p

wit
, is n

h re
hole

spec
es, in part or in w

t to the co
rrectness of i
l purpos

nform
ercia

♦ Engine and gearbox jack -V.A.G 1383 A-

m

at
om

ion
c

in t
or

his
ate

do
priv

cum
for

en
ng

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

Installing locating pins -T10096-

To fix position of subframe with brackets, locating pins -T10096-
must be screwed one after the other into positions -1-, -8-, -9- and
-18-.

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 the bearing bracket securing bolts along both sides

one after the other with locating pins -T10096- and tighten
them to 20 Nm.

16 Rep. gr.40 - Front suspension

 Golf Variant 2007 ➤ , Jetta 2005 ➤
Running gear, axles, steering - Edition 07.2010

Fixing position of mounting bracket

– Replace the bracket securing bolts along both sides one after
the other with locating pins -T10096- and tighten them to 20
Nm.

Fixing position of bracket

n AG. Volkswagen AG do
The position of the front axle is now fixed. olkswage es n
ot g
V
by ua
Continue with removal of anti-roll barrise⇒
d page 51 . ran
tee
ho
ut or
Continue with removal and installation
ss
a of steering box, left-hand ac
drive vehicle (2nd generation) up to model year 2008

ce
e
nl

⇒ page 331 .

pt
du

an
itte

y li
Continue with removal and installation of steering box, right-hand
erm

ab
drive vehicle (2nd generation) up to model year 2008

ility
ot p

⇒ page 340 .

wit
, is n

h re
Continue with removal and installation of steering box, left-hand
hole

spec
drive vehicle (3rd generation) from model year 2009
es, in part or in w

⇒ page 349 .

t to the co
Continue with removal and installation of steering box, right-hand
drive vehicle (3rd generation) from model year 2009

rrectness of i
⇒ page 356 .
l purpos

Removing locating pins -T10096-

Remove in reverse order. Note that the locating pins -T10096- are

nform
ercia

replaced one after the other with new bolts.

m

at
om

io

Specified torques
n
c

in t
or

his
te

Component Specified torque

a

do
priv

cum

Subframe to body 70 Nm + 90°

for

en
g

♦ Use new bolts

n

t.
yi Co
Cop py
t. rig
gh
Bracket to body 70 Nm + 90°
ht
pyri by
♦ Use new bolts
co Vo
by lksw
cted agen
Prote AG.

Mounting bracket to body 70 Nm + 90°

♦ Use new bolts

3.6 Lowering subframe

Special tools and workshop equipment required

3. Subframe, anti-roll bar, suspension links 17

 Golf Variant 2007 ➤ , Jetta 2005 ➤
Running gear, axles, steering - Edition 07.2010
n AG. Volkswagen AG do
swage es n
♦ Locating pins -T10096- byV
olk ot g
ua
d ran
ir se tee
tho
u or
a ac
ss

ce
e
nl

pt
du

an
itte

y li
erm

ab
ility
ot p

wit
, is n

h re
hole

spec
es, in part or in w

t to the co
♦ Engine and gearbox jack -V.A.G 1383 A-

rrectness of i
l purpos

nform
mercia

at
om

ion
c

in t
or

his
ate

do
priv

cum
for

en
ng

t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co
Removing
by lksw
cted agen
Prote AG.
– Turn steering wheel to straight-ahead position and remove ig‐
nition key so that the steering lock engages.
– Remove nuts -arrows- and remove footwell trim -1-.

– Remove bolt -1- and pull universal joint -2- off steering box.
– Remove lower noise insulation ⇒ General body repairs, ex‐
terior; Rep. gr. 50 ; Assembly overview - noise insulation .

18 Rep. gr.40 - Front suspension

 Golf Variant 2007 ➤ , Jetta 2005 ➤
Running gear, axles, steering - Edition 07.2010

– Detach exhaust system bracket from subframe -arrows-.

– Disconnect pendulum support from gearbox by removing bolts

-14-.
– Disconnect coupling rods from anti-roll bar.
– Fix position of subframe ⇒ page 16 .

AG. Volkswagen AG d
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– Position engine and gearbox jack -V.A.G 1383 A- under sub‐
frame.
– Place, for example, a wooden block -1- between engine and

rrectness of i
gearbox jack -V.A.G 1383 A- and subframe.
l purpos

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Prote AG.

3. Subframe, anti-roll bar, suspension links 19

 Golf Variant 2007 ➤ , Jetta 2005 ➤
Running gear, axles, steering - Edition 07.2010

– Remove bolts -4- and -5- and lower subframe a maximum of

10 cm.

Note

Be sure to observe electrical wires to avoid overstretching them.

Installing
Install in reverse order.
– Install lower noise insulation ⇒ General body repairs, exterior;
Rep. gr. 50 ; Assembly overview - noise insulation .
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Ensure that bellows are not damaged or twisted. au ac
ss

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Specified torques

ab
ility
ot p

wit
Component Specified torque
is n

h re
ole,

Subframe to body 70 Nm + 90°

spec
urposes, in part or in wh

♦ Use new bolts

t to the co
Subframe to bracket 70 Nm + 90°
♦ Use new bolts

rrectne
Anti-roll bar to coupling rod 65 Nm
♦ Use new nut

ss o
cial p

f
♦ Counterhold on multi-point socket of joint pin

inform
mer

Universal joint to steering box 30 Nm

atio
m

♦ Use new bolt

o

n
c

i
or

n thi
te

Exhaust system bracket to subframe

sd
iva

o
r

⇒ Engine; Rep. gr. 26

p

cum
r
fo

en
ng

t.
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Cop py
t. rig
gh ht
Torque specifications for pendulum support to gearbox yri
p by
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Caution

From model year 08, HeliCoil inserts are installed in the pen‐
dulum support connection in the 02Q gearboxes. Identification
⇒ Rep. gr. 34 .
Use a bolt with hardness class 10.9 for this and all other gear‐
boxes.
If there is no HeliCoil insert in the 02Q gearbox, use bolts with
the strength class 8.8 and the corresponding torque setting.

Bolt Specified torque

M10 x 35 strength class 8.8 40 Nm + 90° further
♦ Use new bolt

M10 x 35 strength class 10.9 50 Nm + 90° further

♦ Use new bolt

20 Rep. gr.40 - Front suspension

 Golf Variant 2007 ➤ , Jetta 2005 ➤
Running gear, axles, steering - Edition 07.2010

Bolt Specified torque

M10 x 75 strength class 8.8 40 Nm + 90° further
♦ Use new bolt

M10 x 75 strength class 10.9 50 Nm + 90° further

♦ Use new bolt

3.7 Removing and installing subframe with‐

out steering box
Special tools and workshop equipment required
♦ Torque wrench -V.A.G 1331-

AG. Volkswagen AG d
agen oes
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V gu
d by ara
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♦ Torque
ss a wrench -V.A.G 1332- c
ce
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pt
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spec
es, in part or in w

t to the co
rrectness of i
l purpos

Removing
nform
ercia

– Remove lower noise insulation ⇒ General body repairs, ex‐

terior; Rep. gr. 50 ; Assembly overview - noise insulation .
m

at
om

io

– Detach exhaust system bracket from subframe.

n
c

in t
or

his
e

Vehicles with front-wheel drive

at

do
priv

– Remove bolts -arrows- from heat shield.

um
for

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– Remove heat shield from subframe.
Co
Cop py
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gh
Continuation for all vehicles
ht
pyri by
Vo
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cted agen
Prote AG.

3. Subframe, anti-roll bar, suspension links 21

 Golf Variant 2007 ➤ , Jetta 2005 ➤
Running gear, axles, steering - Edition 07.2010

– Disconnect pendulum support from gearbox by removing bolts

-14-.
– Fix position of subframe ⇒ page 16 .
– Now unscrew bolts for:
♦ steering box -3- and -6-
♦ anti-roll bar -11- and -16-
gen AG
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♦ and subframe d-4-,
by -5-, -12- and -15-.
Vo gu
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Installing utho eo
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ss
Install in reverse order.

ce
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nl

pt
du

– Install noise insulation and tighten, torque settings ⇒ General

an
itte

y li
body repairs, exterior; Rep. gr. 50 ; Assembly overview - noise
erm

ab
insulation.

ility
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wit
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hole

spec
es, in part or in w

t to the co
Specified torques
Component Specified torque

rrectness of i
Swivel joint to cast steel suspension link 60 Nm
l purpos

♦ Use new nuts nf

ercia

Swivel joint to sheet steel or forged aluminium suspension 100 Nm

orm

link
m

atio
m

♦ Use new nuts

o

n in
or c

thi
e

Subframe to body 70 Nm + 90°

t

sd
iva

♦ Use new bolts

o
r
rp

cu
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m
f

en
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t.
Mounting bracket to body 70 Nm + 90°
yi Co
op
♦ Use new bolts
C py
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Bracket to body 70 Nm + 90°
by lksw
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♦ Use new bolts
AG.

Anti-roll bar to subframe 20 Nm + 90°

♦ Use new bolts

Anti-roll bar to coupling rod 65 Nm

♦ Use new nut
♦ Counterhold on multi-point socket of joint pin

Shield to subframe 6 Nm
♦ Bolt M6 is self-locking

Steering box to subframe 50 Nm + 90°

♦ Use new bolts

Exhaust system bracket to subframe

⇒ Engine; Rep. gr. 26

22 Rep. gr.40 - Front suspension

 Golf Variant 2007 ➤ , Jetta 2005 ➤
Running gear, axles, steering - Edition 07.2010

Torque specifications for pendulum support to gearbox

Caution

From model year 08, HeliCoil inserts are installed in the pen‐
dulum support connection in the 02Q gearboxes. Identification
⇒ Rep. gr. 34 .
Use a bolt with hardness class 10.9 for this and all other gear‐
boxes.
If there is no HeliCoil insert in the 02Q gearbox, use bolts with
the strength class 8.8 and the corresponding torque setting.

Bolt Specified torque

M10 x 35 strength class 8.8 40 Nm + 90° further
n AG. Volkswagen AG do
♦ Use new bolt lkswage es n
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o
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db ran
M10 x 35 strength class 10.9 ir se 50 Nm + te90°
ho e o further
♦ Use new bolt aut ra
c
ss

ce
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nl

M10 x 75 strength class 8.8 40 Nm + 90° further

pt
du

an
♦ Use new bolt
itte

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erm

ab
ility
M10 x 75 strength class 10.9
ot p

50 Nm + 90° further

wit
♦ Use new bolt
, is n

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hole

spec
es, in part or in w

t to the co
3.8 Removing and installing subframe with
steering box

rrectness of i
Special tools and workshop equipment required
l purpos

♦ Ball joint puller -3287 A-

nform
mercia

at
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ion
c

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or

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ate

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for

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Cop py
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pyri by
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♦ Torque wrench -V.A.G 1332-

3. Subframe, anti-roll bar, suspension links 23

 Golf Variant 2007 ➤ , Jetta 2005 ➤
Running gear, axles, steering - Edition 07.2010

Removing
– Remove battery and battery tray ⇒ Electrical system; Rep. gr.
27 ; Battery; Removing and installing battery .
– Disconnect cable -1- from electrics box.

– Disconnect earth cable -2-.

– Separate connection -3-.

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– Thread wiring harness out of all retainers along longitudinal s

ce
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member so that it can be removed together with the steering

pt
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harness.
itte

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ility
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spec
es, in part or in w

t to the co
rrectness of i
l purpos

– Remove nuts -arrows- and remove footwell trim -1-.

nform
mercia

at
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ion
c

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or

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ate

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Prote AG.

24 Rep. gr.40 - Front suspension

 Golf Variant 2007 ➤ , Jetta 2005 ➤
Running gear, axles, steering - Edition 07.2010

– Remove bolt -1- and pull universal joint -2- off steering box.
– Remove front wheels.
– Remove lower noise insulation ⇒ General body repairs, ex‐
terior; Rep. gr. 50 ; Assembly overview - noise insulation .
– Pull connector off oil level and temperature sender -G266- and
pull wiring off subframe.

– Detach exhaust system bracket from subframe -arrows-.

– Detach coupling rods from anti-roll bar.

– Remove nuts -arrows-.

– Loosen nut on track rod ball joint but do not remove complete‐
ly.
Leave nut screwed on a few turns to protect thread on pin.

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agen oes
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– Press track rod ball joint off wheel bearing housing using ball
ce
le
un

joint splitter -3287A- and remove nut now.

pt
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ab
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is n

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spec
urposes, in part or in wh

t to the co
rrectness o
cial p

f inform
mer

atio
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n
c

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te

sd
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pr

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Cop py
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25
copy Vo
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cted agen 3. Subframe, anti-roll bar, suspension links
Prote AG.
 Golf Variant 2007 ➤ , Jetta 2005 ➤ n AG. Volkswagen AG do
wage es n
Running gear, axles, steering - Edition y07.2010
Volks ot g
b ua
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ris tee
– Disconnect pendulum support from gearbox
tho by removing bolts or
au
-14-. ss
ac

ce
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nl
– Fix position of subframe with brackets.

pt
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erm

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es, in part or in w

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nform
mercia

at
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ion
c

in t
or

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

a

do
riv

frame.
p

cum
for

en
ng

– Place a wooden block -1- or similar between V.A.G 1383 A

t.
yi Co
op
and subframe.
C py
t. rig
gh ht
pyri by
Vo
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by
cted agen
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– Remove bolts -4 and 5- and lower subframe with brackets

slightly, observing electrical wires.
– Lower engine and gearbox jack -V.A.G 1383 A- slowly while
guiding out wiring harness for steering box.

26 Rep. gr.40 - Front suspension

 Golf Variant 2007 ➤ , Jetta 2005 ➤
Running gear, axles, steering - Edition 07.2010

– Secure subframe to engine and gearbox jack -V.A.G 1383 A-

with the appropriate strap.
Installing
Install in reverse order.
– Install noise insulation and tighten, torque settings ⇒ General
body repairs, exterior; Rep. gr. 50 ; Assembly overview - noise
insulation.

Specified torques
Component n AG. Volkswagen AG do Specified torque
lkswage es n
Swivel joint to cast steel
by V suspension link
o ot g
ua 60 Nm
♦ Use new nutsorised ran
tee
th or
au ac
Swivel joint to sheet steel or forged aluminium suspension
ss 100 Nm

ce
le

link
un

pt
♦ Use new nuts

an
d
itte

y li
erm

ab
Subframe to body 70 Nm + 90°

ility
ot p

♦ Use new bolts

wit
is n

h re
ole,

spec
Mounting bracket to body 70 Nm + 90°
urposes, in part or in wh

♦ Use new bolts

t to the co
Bracket to body 70 Nm + 90°
♦ Use new bolts
rrectne

Anti-roll bar to coupling rod 65 Nm

s

♦ Use new nut

s o
cial p

f i

♦ Counterhold on multi-point socket of joint pin

nform
mer

atio

Track rod ball joint to wheel bearing housing 20 Nm + 90°

om

♦ Use new nut

c

i
or

n thi
te

sd
a

Universal joint to steering box 30 Nm

iv

o
pr

♦ Use new bolt

um
r
fo

en
ng

t.
yi Co
op
Exhaust system bracket to subframe C py
t. rig
⇒ Engine; Rep. gr. 26
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

Torque specifications for pendulum support to gearbox

Caution

From model year 08, HeliCoil inserts are installed in the pen‐
dulum support connection in the 02Q gearboxes. Identification
⇒ Rep. gr. 34 .
Use a bolt with hardness class 10.9 for this and all other gear‐
boxes.
If there is no HeliCoil insert in the 02Q gearbox, use bolts with
the strength class 8.8 and the corresponding torque setting.

3. Subframe, anti-roll bar, suspension links 27

 Golf Variant 2007 ➤ , Jetta 2005 ➤
Running gear, axles, steering - Edition 07.2010

Bolt Specified torque

M10 x 35 strength class 8.8 40 Nm + 90° further
♦ Use new bolt

M10 x 35 strength class 10.9 50 Nm + 90° further

♦ Use new bolt

M10 x 75 strength class 8.8 40 Nm + 90° further

♦ Use new bolt

M10 x 75 strength class 10.9 50 Nm + 90° further

♦ Use new bolt

3.9 Repairing subframe (front-wheel drive)

Special tools and workshop

equipment required
♦ Removal tool -3372- AG. Volkswagen AG d
agen oes
lksw not
♦ Assembly tool -T10214- byV
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♦ Assembly tool -T10244-uthor eo
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un

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ab
ility
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wit
is n

h re
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spec
urposes, in part or in wh

t to the co
rrectness o
cial p

f inform
mer

atio
om

n
c

i
or

n thi
te

sd
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pr

cum
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fo

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ng

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

Pressing out bonded rubber bush

– Remove subframe ⇒ page 21 .
– Attach assembly tool -T10244- to subframe.

28 Rep. gr.40 - Front suspension

 Golf Variant 2007 ➤ , Jetta 2005 ➤
Running gear, axles, steering - Edition 07.2010

– Press out both bonded rubber bushes at the same time as

illustrated.

Note

♦ Flattened side of thrust piece -3372/1- must face towards in‐

sert -A- of traverse -T10244- , as otherwise insert may be
damaged.
♦ Tube -T10244/3- has a larger and a smaller internal diameter.
The subframe must lie against the larger internal diameter of
the tube -T10244/3- .
AG. Volkswagen AG d
agen oes
lksw not
Pressing in bonded rubber d bybush
Vo gu
ara
ise nte
or eo
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pt
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itte

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rm

ab
pe

ility
– Bolt bonded rubber bushes together using original bolt, mak‐
ot

wit
, is n

ing sure that both notches -arrows- line up precisely.

h re
hole

spec
es, in part or in w

t to the co
rrectness of i
l purpos

nform
mercia

a
com

tion in

– Insert assembled bonded rubber bushes with bolt head down‐

r
te o

thi

wards into tube -T10214/2- .

s
iva

do
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rp

1- Thrust piece -T10214/3-

um
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t.
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2- Bonded rubber bush
Co
Cop py
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3- Tube -T10214/2-
rig ht
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4- Tube -T10214/1-
cted agen
Prote AG.

5- Thrust plate -VW 401-

6- Thrust plate -VW 402-

3. Subframe, anti-roll bar, suspension links 29

 Golf Variant 2007 ➤ , Jetta 2005 ➤
Running gear, axles, steering - Edition 07.2010

– Press in bonded rubber bushes -1- until dimension -a- is ob‐

tained.
Dimension -a- = 2 - 3 mm.

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)

n AG. Volkswagen AG do
lkswage es n
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T-type bonded rubber bush utho
or
a ac
ss
– Align tube -T10214/2- with pressed-in bonded rubber bushes
ce
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nl

on subframe.
pt
du

an
itte

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erm

ab
ility

Note
ot p

wit
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♦ The corners of the inner core of the bonded rubber bush

hole

spec

-arrows- must point towards the cross member -T10244- -1-.

es, in part or in w

t to the co

♦ The corners of the inner core of the bonded rubber bush

-arrows- must be parallel to the edge of the cross member -
T10244- -1-.
rrectness of i
l purpos

The distance -a- must be identical on the right and left to ensure
parallel installation.
nf
ercia

orm
m

atio
om

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or c

thi
te

sd
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cu
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f

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

30 Rep. gr.40 - Front suspension

 Golf Variant 2007 ➤ , Jetta 2005 ➤
Running gear, axles, steering - Edition 07.2010

V-type bonded rubber bush

– Align tube -T10214/2- with pressed-in bonded rubber bushes
on subframe.

Note

♦ The corners of the inner core of the bonded rubber bush

-arrows- must point away from the cross member -T10244-
-1-.
♦ The corners of the inner core of the bonded rubber bush
-arrows- must be parallel to the edge of the cross member -
T10244- -1-. . Volkswag
AG en AG
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The distance ed b -a- must be identical on the right and
y V gu
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Continuation
ss for both types: c

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pt
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– Position subframe against smaller internal diameter of tube -
itte

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T10244/3- .
erm

ab
ility
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– Press in bushes to stop and until a force of 20 kN is attained.

wit
, is n

h re
– Detach assembly tool -T10244- from subframe and check
hole

pressed-in bonded rubber bushes for proper seating. spec

es, in part or in w

t to the co
rrectness of i
l purpos

nform
mercia

at
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ion
c

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or

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• It is permissible for the outer diameter -1- of the two bonded
t. Cop py
rubber bushes to project up to 2 mm over the edge in the area
rig
gh ht
yri by
of the opening for the pendulum support.
op Vo
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• The recesses of the bonded rubber bushes must be positioned
AG.

in the centre of the subframe opening.

• A gap -arrow- between the bonded rubber bushes is accept‐
able.
– Install subframe ⇒ page 22 .

3.10 Repairing subframe (four-wheel drive)

Special tools and workshop equipment required

3. Subframe, anti-roll bar, suspension links 31

 Golf Variant 2007 ➤ , Jetta 2005 ➤
Running gear, axles, steering - Edition 07.2010

♦ Assembly tool -T10214-

♦ Assembly tool -T10244-

Pressing out bonded rubber bush

– Remove subframe ⇒ page 21 . agen
AG. Volkswagen AG d
oes
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V
– Press out both bonded rubber bushes at the same time d b as
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illustrated. rise nte
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Note
pt
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♦ Chamfer of thrust piece -T10214/3- must point up.
ility
ot p

wit
♦ Tube -T10244/3- has a larger and a smaller internal diameter.
is n

The subframe must lie against the larger internal diameter of h re

ole,

the tube -T10244/3-.

spec
urposes, in part or in wh

t to the co

Pressing in bonded rubber bush

rrectness o
cial p

f inform
mer

atio
om

n
c

i
or

n thi
te

sd
iva

o
pr

cum
r
fo

en
ng

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

32 Rep. gr.40 - Front suspension

 Golf Variant 2007 ➤ , Jetta 2005 ➤
Running gear, axles, steering - Edition 07.2010

– Bolt bonded rubber bushes together using original bolt, mak‐

ing sure that both notches -arrows- line up precisely.

AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c

ce
le
un

pt
an
d
itte

– Insert assembled bonded rubber bushes with bolt head down‐

y li
rm

ab
wards into tube -T10214/2- .
pe

ility
ot

wit
1- Thrust piece -T10214/3-
, is n

h re
hole

2- Bonded rubber bush

spec
es, in part or in w

3- Tube -T10214/2-

t to the co
4- Tube -T10214/1-

rrectness of i
5- Thrust plate -VW 401-
l purpos

6- Thrust plate -VW 402-

nform
mercia

a
com

tion in
r
te o

thi
s
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do
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rp

cum
fo

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ng

t.
yi Co
op py
– Press in bonded rubber bushes -1- until dimension -a- is ob‐
t. C rig
gh ht
tained. pyri by
Vo
o
by c lksw
cted agen
Dimension -a- = 2 - 3 mm.
Prote AG.

3. Subframe, anti-roll bar, suspension links 33

 Golf Variant 2007 ➤ , Jetta 2005 ➤
Running gear, axles, steering - Edition 07.2010

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)

T-type bonded rubber bush

– Align tube -T10214/2- with pressed-in bonded rubber bushes
on subframe.

n AG. Volkswagen AG do
wage
Note yV
olks es n
ot g
d b ua
ran
ir se tee
♦ The corners of the inner core of the bonded rubber bushutho
or
-arrows- must point towards the cross member -T10244-
ss
a
-1-. ac

ce
e
nl

♦ The corners of the inner core of the bonded rubber bush

pt
du

an
-arrows- must be parallel to the edge of the cross member -
itte

y li
erm

T10244- -1-.

ab
ility
ot p

wit
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The distance -a- must be identical on the right and left to ensure

h re
parallel installation.
hole

spec
es, in part or in w

t to the co
V-type bonded rubber bush
– Align tube -T10214/2- with pressed-in bonded rubber bushes
on subframe.

rrectness of i
l purpos

Note nf
ercia

♦ The corners of the inner core of the bonded rubber bush

rm
m

-arrows- must point away from the cross member -T10244-

atio
m

-1-.
o

n in
or c

thi
e

♦ The corners of the inner core of the bonded rubber bush

t

sd
iva

-arrows- must be parallel to the edge of the cross member -

o
r
rp

cu

T10244- -1-.
o

m
f

en
ng

t.
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op py
The distance -a- must be identical on the right and left to ensure
t. C rig
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yri
parallel installation. p by
co Vo
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cted agen
Continuation for both types: Prote AG.

34 Rep. gr.40 - Front suspension

 Golf Variant 2007 ➤ , Jetta 2005 ➤
Running gear, axles, steering - Edition 07.2010

– Position subframe against smaller internal diameter of tube

-T10244/3-.
– Press in bushes to stop and until a force of 20 kN is attained.
– Detach assembly tool -T10244- from subframe and check
pressed-in bonded rubber bushes for proper seating.

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wit
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spec
urposes, in part or in wh

t to the co
• The recesses of the bonded rubber bushes must be positioned
in the centre of the subframe opening.

rrectne
• A gap -arrow- between the bonded rubber bushes is accept‐
able.

ss
– Install subframe ⇒ page 22 .

o
cial p

f inform
mer

atio
om

n
c

i
or

n thi
te

sd
iva

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pr

cum
r
fo

en
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t.
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op
3.11 Checking swivel joint C py
ht. rig
rig ht
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Checking axial play
co Vo
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Prote AG.
– Firmly pull suspension link down in -direction of arrow- and
press up again.
Checking radial play

3. Subframe, anti-roll bar, suspension links 35

 Golf Variant 2007 ➤ , Jetta 2005 ➤
Running gear, axles, steering - Edition 07.2010

– Press lower part of wheel forcefully inwards and outwards in

-direction of arrow-.

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♦ There should be no palpableutor
ho visible „play“ during both tests. eo
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♦ Observe swivel joint while performing tests.
s

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pt
du

♦ Take into account possible existing wheel bearing play or

an
itte

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„play“ in upper suspension strut mounting.
erm

ab
ility
ot p

♦ Check rubber boot for damage and renew swivel joint if nec‐

wit
, is n

essary.

h re
hole

spec
es, in part or in w

3.12 Removing and installing swivel joint

t to the co
rrectness of i
Special tools and workshop
equipment required
l purpos

♦ Ball joint puller -3287A-

nform
ercia

♦ Torque wrench -V.A.G

1332-
m

at
om

io
♦ Engine and gearbox jack -

n
c

in t
r

V.A.G 1383 A-
o

his
ate

do
riv

♦ Angle wrench -V.A.G 1756-

p

cum
for

en
ng

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

Removing
– Loosen drive shaft bolt at wheel hub:
♦ Hexagon bolt ⇒ page 70
♦ Twelve-point bolt ⇒ page 71

36 Rep. gr.40 - Front suspension

 Golf Variant 2007 ➤ , Jetta 2005 ➤
Running gear, axles, steering - Edition 07.2010

Caution

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

ing on its wheels. gen AG
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d a oes
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The wheel bearing can be damaged by the weight
db
y V of the vehi‐
o gu
ara
cle if the bolt is loosened. or
ise nte
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ut ra
If a vehicle must be moved with thessdrive
a shaft removed, an c
outer joint must be fitted and tightened to 50 Nm.

ce
e
nl

pt
du

an
itte

y li
erm

ab
– Remove wheel.

ility
ot p

wit
, is n

– Remove nuts -arrows-.

h re
hole

– Pull drive shaft slightly out of wheel hub.

spec
es, in part or in w

t to the co
– Pull swivel bearing out of suspension link.
– Pull suspension link downwards as far as necessary.

rrectness of i
l purpos

nform
mercia

at
om

ion
c

in t
or

– Apply ball joint splitter -3287 A- as shown in figure and press

his
ate

out swivel joint.

do
priv

cum
for

en
ng

t.
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Note t. Cop py
rig
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♦ Place engine and gearbox jack -V.A.G 1383 A- or similar un‐
cop Vo
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derneath (danger of accident through falling parts when press‐
cted agen
Prote AG.
ing out the swivel joint).
♦ Leave nut screwed on a few turns to protect thread on swivel
joint.

Installing
– Fit swivel joint in wheel bearing housing.
– Fit drive shaft in wheel hub.
– Screw new self-locking nut onto swivel joint while counter‐
holding with Torx key -T40- .

3. Subframe, anti-roll bar, suspension links 37

 Golf Variant 2007 ➤ , Jetta 2005 ➤
Running gear, axles, steering - Edition 07.2010

– Tighten nuts -arrows-.

Note

Ensure that bellows are not damaged or twisted.

– Fit wheel and tighten, torque setting ⇒ page 241 .

– Tighten drive shaft bolt at wheel hub:
♦ Hexagon bolt ⇒ page 70
♦ Twelve-point bolt ⇒ page 71

Note

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

wheel bearing will be damaged.

Specified torques
Component Specified torque
Swivel joint to cast steel suspension link 60 Nm
♦ Use new nuts n AG. Volkswagen AG do
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Swivel joint to sheet steel or forged aluminium
o
ir se
d
suspension 100
ran
tee Nm
link auth or
ac
♦ Use new nuts ss

ce
le
un

pt
Swivel joint to wheel bearing housing 60 Nm
an
d
itte

y li
♦ Use new nut
erm

ab
ility
ot p

Drive shaft to wheel hub „hexagon bolt“ 200 Nm + 180° wit

is n

h re
♦ Use new bolt
ole,

spec
urposes, in part or in wh

Drive shaft to wheel hub „12-point bolt“ 70 Nm + 90°

t to the co

♦ Use new bolt

rrectne

3.13 Removing and installing suspension link

ss o

with mounting bracket

cial p

f inform
mer

Special tools and workshop equipment required

atio
om

♦ Torque wrench -V.A.G 1332-

n
c

i
or

n thi
te

sd
iva

o
pr

cum
r
fo

en
ng

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

38 Rep. gr.40 - Front suspension

 Golf Variant 2007 ➤ , Jetta 2005 ➤
Running gear, axles, steering - Edition 07.2010

♦ Locating pins -T10096-

Removing
– Remove wheel. agen
AG. Volkswagen AG d
oes
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– Remove lower noise sinsulation
d by
⇒ General body repairs, ex‐ ara
i e nte
terior; Rep. gr. 50th;oAssembly overview - noise insulation .
r eo
au ra
– Remove nuts -arrows-.
ss c

ce
le
un

pt
– Pull wheel bearing housing with swivel joint out of suspension

an
d
itte

link.

y li
rm

ab
pe

ility
– Fix position of mounting bracket ⇒ page 17 .
ot

wit
, is n

h re
hole

spec
es, in part or in w

t to the co
rrectness of i
l purpos

– Replace bolt -1- for left side and bolt -8- for right side with lo‐
cating pins -T10096- and tighten locating pins to 20 Nm.
nform
mercia

a
com

ti

Note
on in
r
te o

thi

The locating pins -T10096- may be tightened only to a maximum

s
iva

do
r

of 20 Nm; otherwise the threads of the locating pins may be dam‐

rp

cum
fo

aged.
en
ng

t.
yi Co
Cop py
t. rig
– Now remove bolt -10- for left side and bolt -17- for right side.opyri
gh by
Vo
ht
c by lksw
cted agen
Prote AG.

3. Subframe, anti-roll bar, suspension links 39

 Golf Variant 2007 ➤ , Jetta 2005 ➤
Running gear, axles, steering - Edition 07.2010

– Remove bolts -1-.

Installing
– Insert suspension link with mounting bracket into subframe.

– Position items -10- and -17- but do not yet tighten.

AG. Volkswagen AG d
agen oes
olksw not
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or eo
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nl

– Start bolt -1- and tighten.

pt
du

an
itte

y li

– Now replace locating pin -T10096- with a new bolt and tighten
erm

ab

to specified torque.
ility
ot p

wit
, is n

h re
hole

spec
es, in part or in w

t to the co
rrectness of i
l purpos

– Bolt suspension link to swivel joint and tighten -arrows-.

nform
mercia

at
om

ion
c

in t
or

his
ate

do
priv

cum
for

en
ng

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

40 Rep. gr.40 - Front suspension

 Golf Variant 2007 ➤ , Jetta 2005 ➤
Running gear, axles, steering - Edition 07.2010

– Bolt suspension link to bracket -10- and -17- in unladen state.

Continue installation in reverse order.

Note

Ensure that bellows are not damaged or twisted.

n AG. Volkswagen AG do
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– Install lower noisebyinsulation
Volk ⇒ General body repairs, ot g exterior;
u
Rep. gr. 50 ; rAssembly
ise
d overview - noise insulation . arant
o ee
h
– Install wheelaut and tighten bolts or nuts ⇒ page 241 . or
ac
ss

ce
le
un

pt
an
d
itte

y li
erm

ab
ility
ot p

wit
is n

h re
ole,

spec
urposes, in part or in wh

t to the co
Specified torques
Component Specified torque

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

ss o
cial p

f in
Mounting bracket to body 70 Nm + 90°
form
mer

♦ Use new bolts atio

om

Swivel joint to cast steel suspension link 60 Nm

c

i
or

n thi

♦ Use new nuts

te

sd
iva

o
pr

cum

Swivel joint to sheet steel or forged aluminium suspension 100 Nm

r
fo

en
ng

link
t.
yi Co
op
♦ Use new nuts C py
t. rig
gh ht
pyri by
Suspension link to bracket 70 Nm + 180°
co Vo
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cted agen
♦ Use new bolt Prote AG.

♦ Tighten bolt in unladen state

3.14 Removing and installing suspension link

with mounting bracket (left side for ve‐
hicles with DSG or automatic gearbox‐
es)
Special tools and workshop equipment required

3. Subframe, anti-roll bar, suspension links 41

 Golf Variant 2007 ➤ , Jetta 2005 ➤
Running gear, axles, steering - Edition 07.2010

♦ Locating pins -T10096-

♦ Engine and gearbox jack -V.A.G 1383 A-

Removing
– Remove front left wheel.
– Remove noise insulation (bottom). ⇒ General body repairs,
exterior; Rep. gr. 50 ; Overview - noise insulation .
– Detach exhaust system bracket from subframe.
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– Remove bolts -arrows- from heat shield.ised ara
nte
or eo
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– Remove heat shield from subframe.aut ra
ss c
ce

Continuation for all vehicles

le
un

pt
an
d
itte

y li
erm

ab
ility
ot p

wit
is n

h re
ole,

spec
urposes, in part or in wh

t to the co
rrectness o
cial p

f inform
mer

atio
om

n
c

i
or

n thi
te

sd
iva

o
pr

cum
r
fo

en
ng

t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote
42
AG.
Rep. gr.40 - Front suspension
 Golf Variant 2007 ➤ , Jetta 2005 ➤
Running gear, axles, steering - Edition 07.2010

– Disconnect pendulum support from gearbox by removing bolts

-14-.
– If present, detach coupling rod of front left vehicle level sender
-G78- from suspension link.
– Fix position of bracket and mounting bracket of suspension
link on left side of vehicle with locating device -T10096-
⇒ page 16 .

– Remove nuts -arrows-.

AG. Volkswagen AG d
agen oes
olksw not
byV gu
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ce
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un

pt
an
d
itte

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erm

– Loosen bolt -17-. ab

ility
ot p

wit
is n

– Now unscrew bolts for: h re

ole,

spec
♦ steering box -3- and -6-
urposes, in part or in wh

t to the co

♦ anti-roll bar -11- and -16-

♦ subframe on right side -5- and -12-.
rrectne

.
ss o
cial p

f inform
mer

atio
om

n
c

i
or

n thi
te

sd
iva

o
pr

cum
r
fo

en
ng

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

3. Subframe, anti-roll bar, suspension links 43

 Golf Variant 2007 ➤ , Jetta 2005 ➤
Running gear, axles, steering - Edition 07.2010

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

frame.
– Place, for example, a wooden block -1- between engine and
gearbox jack -V.A.G 1383 A- and subframe.

– Remove bolts -2-, -4-, -5- and -12- and lower subframe with
brackets as far as necessary.
– At the same time, lever dowel sleeves of steering box out of
left bracket.
– Remove bolt -17- and remove suspension link from bracket.
Installing
n AG. Volkswagen AG do
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Install in reverse order. yV
olks es n
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ran
ir se tee
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Note ss
a ac

ce
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un

pt
♦ Ensure proper seating of dowel sleeves for steering box in

an
d
itte

y li
suspension bracket.
rm

ab
pe

ility
♦ Ensure that bellows are not damaged or twisted.
ot

wit
, is n

h re
hole

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

spec
Rep. gr. 50 ; Overview - noise insulation .
es, in part or in w

– Install wheel and tighten bolts or nuts ⇒ page 241 . t to the co

Specified torques
rrectness of i
l purpos

Component Specified torque

Subframe to body 70 Nm + 90°
nform
ercia

♦ Use new bolts

m

a
com

Bracket to body 70 Nm + 90°

ion in

♦ Use new bolts

r
te o

thi
s
iva

do

Mounting bracket to body 70 Nm + 90°

r
rp

cum

♦ Use new bolts

fo

en
ng

t.
yi Co
op
Mounting bracket to bracket 50 Nm + 90°
C py
t. rig
gh
♦ Use new bolts
ht
pyri by
Vo
co lksw
by
cted agen
Swivel joint to cast steel suspension link 60 Nm
Prote AG.

♦ Use new nuts

Swivel joint to sheet steel or forged aluminium suspension 100 Nm

link
♦ Use new nuts

Anti-roll bar to subframe 20 Nm + 90°

♦ Use new bolts

Shield to subframe 6 Nm
♦ Bolt M6 is self-locking

44 Rep. gr.40 - Front suspension

 Golf Variant 2007 ➤ , Jetta 2005 ➤
Running gear, axles, steering - Edition 07.2010

Component Specified torque

Steering box to subframe 50 Nm + 90°
♦ Use new bolts

Exhaust system bracket to subframe

⇒ Engine; Rep. gr. 26

Torque specifications for pendulum support to gearbox

Caution

From model year 08, HeliCoil inserts are installed in the pen‐
dulum support connection in the 02Q gearboxes. Identification
⇒ Rep. gr. 34 .
Use a bolt with hardness class 10.9 for this and all other gear‐
boxes.
If there is no HeliCoil insert in the 02Q gearbox, use bolts with
the strength class 8.8 and the corresponding torque setting.

Bolt Specified torque

M10 x 35 strength class 8.8 AG. Volkswagen AG d 40 Nm + 90° further
♦ Use new bolt agen oes
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ara
ed
M10 x 35 strength class 10.9 horis 50 Nm n+te90° further
eo
♦ Use new bolt s aut ra
c
s

ce
le

M10 x 75 strength class 8.8 40 Nm + 90° further

un

pt
an
d

♦ Use new bolt

itte

y li
erm

ab
ility
ot p

M10 x 75 strength class 10.9 50 Nm + 90° further

wit
♦ Use new bolt
is n

h re
ole,

spec
urposes, in part or in wh

t to the co
rrectness o
cial p

f inform
mer

atio
om

n
c

i
or

n thi
te

sd
iva

o
pr

cum
r
fo

en
ng

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

3. Subframe, anti-roll bar, suspension links 45

 Golf Variant 2007 ➤ , Jetta 2005 ➤
Running gear, axles, steering - Edition 07.2010

3.15 Renewing bonded rubber bush for suspension link

Special tools and workshop

equipment required
♦ Tube -T10219/1-
♦ Drift -T10219/2-
♦ Thrust plate -VW 402-
♦ Press tool -VW 411-

AG. Volkswagen AG d
agen oes
olksw not
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d b ara
rise nte
tho eo
au ra
ss c
ce
e
nl

pt
du

an
itte

y li
erm

ab
ility
ot p

wit
, is n

h re
hole

spec
es, in part or in w

t to the co
rrectness of i

Pressing out bonded rubber bush

l purpos

– Press out bonded rubber bush as illustrated.

1- Press tool -VW 411-
nform
ercia

2- Tube -T10219/1-
m

at
om

io

3- Thrust plate -VW 402-

n
c

in t
or

his
e

Pressing in bonded rubber bush

at

do
priv

Start the bonded rubber bush at an angle to prevent damage

um
for

en

when pressing in. The bonded rubber bush will then straighten up
ng

t.
yi Co
as it is pressed in. t. Cop py
rig
gh ht
– Moisten outer surface of bonded rubber bush with assembly pyri by
Vo
co
oil -G 294 421 A1- .
by lksw
cted agen
Prote AG.

46 Rep. gr.40 - Front suspension

 Golf Variant 2007 ➤ , Jetta 2005 ➤
Running gear, axles, steering - Edition 07.2010

– Apply bonded rubber bush at an angle (towards suspension

link). Lip -arrow- must slide into hole as shown.
1- Drift -T10219/2-
2- Tube -T10219/1-
3- Thrust plate -VW 402-

AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
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or eo
h
aut ra
ss c

ce
le
un

pt
an
d
itte

y li
erm

ab
ility
ot p

wit
is n

h re
ole,

spec
– Press in bonded rubber bush until core of bush -1- and hole in
urposes, in part or in wh

suspension link -2- are flush.

t to the co
rrectness o
cial p

f inform
mer

atio
om

n
c

i
or

n thi
te

sd
iva

o
pr

– Press bush back slightly in the suspension link.

um
r
fo

en
ng

t.
yi
1- Tube -T10219/1-
Co
Cop py
t. rig
2- Thrust plate -VW 402-
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.

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

3. Subframe, anti-roll bar, suspension links 47

 Golf Variant 2007 ➤ , Jetta 2005 ➤
Running gear, axles, steering - Edition 07.2010

3.16 Renewing mounting bracket with suspension link bush

Special tools and workshop

equipment required
n AG. Volkswagen AG do
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♦ Guide -VW 439- olks es n
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byV ua
d ran
♦ Thrust plate -VW 401- ir se tee
tho
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a ac
♦ Thrust plate -VW 402- ss

ce
e
nl

pt
du

an
itte

y li
erm

ab
ility
ot p

wit
, is n

h re
hole

spec
es, in part or in w

t to the co
rrectness of i
l purpos

nform
mercia

at
om

ion
c

in t
or

his
ate

do
priv

cum
for

en
ng

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

♦ Tube -VW 418 A-

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.

48 Rep. gr.40 - Front suspension

 Golf Variant 2007 ➤ , Jetta 2005 ➤
Running gear, axles, steering - Edition 07.2010

Note

Hold suspension link when pressing off.

1- Thrust plate -VW 401-

2- Guide -VW 439-
3- Thrust plate -VW 402-
Pressing in mounting bracket with bush onto suspension link
– Moisten hexagon flats of suspension link with assembly lubri‐
cant -G 294 421 A1- diluted 1:20.

– Carefully press bush onto suspension link to stop.

1- Tube -VW 418 A-
n AG. Volkswagen A
2- Mounting bracket
olks
wage with bonded rubber
G do
esbush.
no
V t gu
by ara
3- Suspension
ris
ed link nte
tho eo
4- Thrust
ss
au plate -VW 401- ra
c ce
le
un

pt
an
d
itte

y li
rm

ab
pe

ility
ot

wit
, is n

h re
hole

spec
es, in part or in w

t to the co
rrectness of i
l purpos

nform
mercia

a
com

tion in
r
te o

thi
s
iva

do
r
rp

cum
fo

en
ng

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

3. Subframe, anti-roll bar, suspension links 49

 Golf Variant 2007 ➤ , Jetta 2005 ➤
Running gear, axles, steering - Edition 07.2010

3.17 Removing and installing anti-roll bar

Special tools and workshop

equipment required
♦ Locating pins -T10096-
♦ Torque wrench -V.A.G
1332-
♦ Engine and gearbox jack -
V.A.G 1383 A-
♦ Ball joint puller -3287 A-

n AG. Volkswagen AG do
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss
ce
e
nl

pt
du

an
itte

y li
erm

ab
ility
ot p

wit
, is n

h re
hole

spec
es, in part or in w

t to the co
rrectness of i
l purpos

Removing
nf
ercia

orm

– Remove front wheels.

m

atio
om

– Remove nuts -arrows- and remove footwell trim -1-.

n in
or c

thi
te

sd
iva

o
r
rp

cu
o

m
f

en
ng

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

50 Rep. gr.40 - Front suspension

 Golf Variant 2007 ➤ , Jetta 2005 ➤
Running gear, axles, steering - Edition 07.2010

– Remove bolt -1- and pull universal joint -2- off steering box.
– Remove lower noise insulation ⇒ General body repairs, ex‐
terior; Rep. gr. 50 ; Assembly overview - noise insulation .
– Detach coupling rods from anti-roll bar.

– Remove nuts -arrows-.

– Loosen nut on track rod ball joint on each side but do not re‐
move completely.
Leave nut screwed on a few turns to protect thread on pin.

– Press track rod ball joint off wheel bearing housing with ball
joint puller -3287 A- . agen
AG. Volkswagen AG d
oes
olksw not
– Fixing position of subframe with brackets ⇒ page 16e.d by V gu
ara
ris nte
ho eo
aut ra
ss c

ce
e
nl

pt
du

an
itte

y li
erm

ab
ility
ot p

wit
, is n

h re
hole

spec
es, in part or in w

t to the co
– Unbolt anti-roll bar from subframe -11- and -16-.
– Disconnect pendulum support from gearbox by removing bolts
-14-. rrectness of i
l purpos

nform
mercia

at
om

ion
c

in t
or

his
ate

do
priv

cum
for

en
ng

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

3. Subframe, anti-roll bar, suspension links 51

 Golf Variant 2007 ➤ , Jetta 2005 ➤
Running gear, axles, steering - Edition 07.2010

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

frame.
– Place, for example, a wooden block -1- between engine and
gearbox jack -V.A.G 1383 A- and subframe.

– Remove bolts -4- and -5- and lower subframe with brackets
slightly, observing electrical wires.

AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c

ce
le
un

pt
an
d
itte

y li
rm

ab
pe

ility
ot

wit
, is n

h re
– Now lift the anti-roll bar -1- forwards over the bracket -2- and
hole

down from the subframe.

spec
es, in part or in w

Installing

t to the co
Install in reverse order.

rrectness of i
Note
l purpos

♦ Coat seal on steering box with suitable lubricant, e.g. soft

nform
ercia

soap, before installing steering box.

m

♦ After fitting the steering box to the jointed shaft, ensure that
com

tion in

the seal is not kinked when lying against the assembly plate
r
te o

thi

and that the opening to the footwell is correctly sealed. Oth‐

s
iva

erwise, this can result in water leaks and/or noise.

do
r
rp

cum
fo

♦ Ensure sealing surfaces are clean.

en
ng

t.
yi Co
Cop py
t. rig
– Install lower noise insulation ⇒ General body repairs, exterior; gh ht
yri by
Rep. gr. 50 ; Assembly overview - noise insulation . cop Vo
by lksw
cted agen
Prote AG.
– Install front wheels and tighten ⇒ page 241 .

Specified torques
Component Specified torque
Subframe to body 70 Nm + 90°
♦ Use new bolts

52 Rep. gr.40 - Front suspension

 Golf Variant 2007 ➤ , Jetta 2005 ➤
Running gear, axles, steering - Edition 07.2010

Component Specified torque

Bracket to body 70 Nm + 90°
♦ Use new bolts

Mounting bracket to body 70 Nm + 90°

♦ Use new bolts

Subframe to bracket 70 Nm + 90°

♦ Use new bolts

Swivel joint to cast steel suspension link 60 Nm

♦ Use new nuts

Swivel joint to sheet steel or forged aluminium suspension 100 Nm

link
♦ Use new nuts

Anti-roll bar to coupling rod 65 Nm

♦ Use new nut
AG. Volkswagen AG d
agen oes
♦ Counterhold on multi-point socket of joint pin Volksw not
gu
d by ara
ise nte
Anti-roll bar to subframe ut
hor
20 Nm + 90° eo
♦ Use new bolts ss a ra
c

ce
le
un

pt
Suspension link to bracket 70 Nm + 180°

an
d
itte

♦ Use new bolt

y li
rm

ab
pe

ility
♦ Tighten bolt in unladen state
ot

wit
, is n

h re
Steering box to subframe 50 Nm + 90°
hole

spec
♦ Use new bolts
es, in part or in w

t to the co
Universal joint to steering box 30 Nm
♦ Use new bolt

rrectness of i
l purpos

Torque specifications for pendulum support to gearbox

nform
ercia

Caution
m

a
com

tion in
r

From model year 08, HeliCoil inserts are installed in the pen‐
te o

thi
dulum support connection in the 02Q gearboxes. Identification
s
iva

do

⇒ Rep. gr. 34 .
r
rp

cum
fo

en
g

Use a bolt with hardness class 10.9 for this and all other gear‐
n

t.
yi Co
op
boxes. C py
t. rig
gh ht
yri by
If there is no HeliCoil insert in the 02Q gearbox, use bolts with op Vo
by c lksw
the strength class 8.8 and the corresponding torque setting. cted agen
Prote AG.

Bolt Specified torque

M10 x 35 strength class 8.8 40 Nm + 90° further
♦ Use new bolt

M10 x 35 strength class 10.9 50 Nm + 90° further

♦ Use new bolt

M10 x 75 strength class 8.8 40 Nm + 90° further

♦ Use new bolt

3. Subframe, anti-roll bar, suspension links 53

 Golf Variant 2007 ➤ , Jetta 2005 ➤
Running gear, axles, steering - Edition 07.2010

Bolt Specified torque

M10 x 75 strength class 10.9 50 Nm + 90° further
♦ Use new bolt

– After installing, perform basic settings for steering angle send‐

er -G85- ⇒ Vehicle diagnostic, testing and information system
VAS 5051.

AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c
ce
le
un

pt
an
d
itte

y li
rm

ab
pe

ility
ot

wit
, is n

h re
hole

spec
es, in part or in w

t to the co
rrectness of i
l purpos

nform
mercia

a
com

tion in
r
te o

thi
s
iva

do
r
rp

cum
fo

en
ng

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

54 Rep. gr.40 - Front suspension

 Golf Variant 2007 ➤ , Jetta 2005 ➤
Running gear, axles, steering - Edition 07.2010
AG. Volkswagen AG d
agen oes
lksw not
4 Assembly overview: wheel bearing Vo gu
d by ara
ise nte
or eo
h
aut ra
s c
1 - Suspension strut s

ce
le
un

pt
2 - Track rod ball joint

an
d
itte

y li
rm

ab
3 - Multi-point socket head bolt

pe

ility
ot
❑ Tip of bolt must point in

wit
, is n
direction of travel

h re
hole

spec
4 - Hexagon socket head bolt

es, in part or in w

t to the co
❑ 8 Nm
5 - Front left speed sensor -
G47- / front right speed sensor

rrectness of i
-G45-
l purpos

❑ Before inserting speed

sensor, clean inner sur‐
face of fitting hole and

nform
ercia

coat with lubricating

m

paste -G 000 650- .

a
com

tion in
6 - Splash plate
r
te o

thi
s
iva

7 - Nut

do
r
rp

cum
❑ M12 x 1.5
fo

en
ng

t.
yi
❑ 20 Nm + 90° further
Co
Cop py
t. rig
❑ Self-locking
gh ht
pyri by
Vo
o
❑ Always renew after re‐
by c lksw
cted agen
moving.
Prote AG.

8 - Bolt
❑ 10 Nm
9 - Ventilated brake disc
10 - Bolt
❑ M16 x 1.5 x 80
❑ Hexagon bolt, 200 Nm
and turn +180° further
❑ 12-point bolt, 70 Nm +
90° further
❑ Always renew after removing.
When bolt is loosened or tightened, vehicle must not be standing on its wheels

11 - Bolt
❑ Torque settings ⇒ Brake systems; Rep. gr. 46 ; Repairing front brake
12 - Wheel hub with wheel bearing
❑ The ABS sensor ring is installed in the wheel hub
❑ Various versions
❑ Allocation ⇒ Electronic parts catalogue „ETKA“
13 - Wheel bearing housing
❑ Removing and installing ⇒ page 58 .
❑ With bolted-on brake carrier.
❑ If wheel bearing housing is renewed, wheels must be aligned ⇒ page 261 .
❑ Allocation ⇒ Electronic parts catalogue „ETKA“
14 - Wheel bearing housing
❑ Removing and installing ⇒ page 58 .

4. Assembly overview: wheel bearing 55

 Golf Variant 2007 ➤ , Jetta 2005 ➤
Running gear, axles, steering - Edition 07.2010
❑ With bolted-on brake carrier.
❑ If wheel bearing housing is renewed, wheels must be aligned ⇒ page 261 .
❑ Allocation ⇒ Electronic parts catalogue „ETKA“
15 - Multi-point socket head bolt
❑ M12 x 1.5 x 45
❑ 70 Nm + 90° further
❑ Always renew after removing.
16 - Drive shaft
❑ Removing and installing ⇒ page 72
17 - Nut
❑ M12 x 1.5
❑ 70 Nm + 90° further
❑ Self-locking
❑ Always renew after removing.

4.1 Removing and installing wheel bearing

unit
Special tools and workshop equipment required
♦ Torque wrench -V.A.G 1332-

AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
Removing s aut ra
c
s
– Loosen drive shaft bolt at wheel hub:
ce
le
un

pt
an
d
itte

♦ Hexagon bolt ⇒ page 70

y li
rm

ab
pe

ility

♦ Twelve-point bolt ⇒ page 71

ot

wit
, is n

h re
hole

spec

Note
es, in part or in w

t to the co

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

wheel bearing will be damaged.
rrectness of i

– Remove wheel.
l purpos

– Remove brake caliper and hang from body using wire ⇒ Brake
system; Rep. gr. 46 ; Repairing front brake .
nform
ercia

– Remove speed sensor ⇒ Brake systems;; Rep. gr. 46 ; Re‐

m

pairing front brake .

com

tion in
r

– Remove brake disc.

te o

thi
s
iva

do

Only vehicles with VL 100 drive shaft

r
rp

cum
fo

– Press drive shaft as far as possible out of wheel hub (towards

en
ng

t.
yi Co
gearbox). . Cop py
rig
ht ht
rig by
py

56
co Vo
by lksw
cted
Rep. gr.40 - Front suspension
agen
Prote AG.
 Golf Variant 2007 ➤ , Jetta 2005 ➤
Running gear, axles, steering - Edition 07.2010

– Remove bolts -arrows-.

– Take wheel bearing unit out of wheel bearing housing.
Continuation for all vehicles

– Remove nuts -arrows-.

– Pull swivel joint out of suspension link.
– Pull drive shaft out of wheel hub.

AG. Volkswagen AG d
agen oes
olksw not
– Remove bolts -arrows-. ed by
V gu
ara
ris nte
o
– Take wheel bearing
aut
h unit out of wheel bearing housing. eo
ra
ss c
Installing
ce
e
nl

pt
du

an

Install in reverse order.

itte

y li
erm

ab

– Install brake caliper ⇒ Brake systems;; Rep. gr. 46 ; Repairing

ility
ot p

front brake .
wit
, is n

h re

– Tighten drive shaft bolt at wheel hub:

hole

spec
es, in part or in w

♦ Hexagon bolt ⇒ page 70

t to the co

♦ Twelve-point bolt ⇒ page 71

rrectness of i

Note
l purpos

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

nform

wheel bearing will be damaged.

mercia

at
om

– Install speed sensor ⇒ Brake systems; Repair group 46; Re‐

ion
c

pairing front brake .

in t
or

his
ate

– Install wheel and tighten bolts or nuts ⇒ page 241 .

do
priv

cum
for

en
g

Specified torques
n

t.
yi Co
Cop py
t. rig
Component Specified torque
gh ht
pyri by
Vo
o
by c lksw
Drive shaft to wheel hub „hexagon bolt“ Prote
cted AG.
agen
200 Nm + 180°
♦ Use new bolt

Drive shaft to wheel hub „12-point bolt“ 70 Nm + 90°

♦ Use new bolt

Swivel joint to cast steel suspension link 60 Nm

♦ Use new nuts

4. Assembly overview: wheel bearing 57

 AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
Golf Variant 2007 ➤ , Jetta 2005 ➤ oris e nte
h eo
Running gear, axles, steering - Edition
aut 07.2010 ra
c
ss

ce
e
nl

pt
Component Specified torque

du

an
itte

y li
Swivel joint to sheet steel or forged aluminium suspension 100 Nm

erm

ab
link

ility
ot p
♦ Use new nuts

wit
, is n

h re
hole
Wheel hub with wheel bearing to wheel bearing housing 70 Nm + 90°

spec
es, in part or in w
♦ Use new bolts

t to the co
rrectness of i
4.2 Removing and installing wheel bearing housing
l purpos

Special tools and workshop

nf
ercia

o
equipment required

rm
m

atio
m

♦ Ball joint puller -3287A-

o

n in
or c

thi
♦ Torque wrench -V.A.G
te

sd
a

1332-
iv

o
r
rp

cu
o

m
f

♦ Engine and gearbox jack -

en
ng

t.
yi
V.A.G 1383 A-
Co
Cop py
t. rig
gh
♦ Angle wrench -V.A.G 1756-
ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.

58 Rep. gr.40 - Front suspension

 Golf Variant 2007 ➤ , Jetta 2005 ➤
Running gear, axles, steering - Edition 07.2010

♦ Spreader -3424-

Removing
– Loosen drive shaft bolt at wheel hub:
♦ Hexagon bolt ⇒ page 70
♦ Twelve-point bolt ⇒ page 71

Note

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

wheel bearing will be damaged.

– Remove wheel.
– Remove brake caliper and hang from body using wire ⇒ Brake
system; Rep. gr. 46 ; Repairing front brake .
– Remove speed sensor ⇒ Brake systems;; Rep. gr. 46 ; Re‐
pairing front brake . AG. Volkswagen AG d
agen oes
ksw not
– Remove brake disc. byV
ol
gu
ara
ed
is nte
– Now remove splash plate from wheel bearing housing. ut
hor eo
a ra
s c
– Loosen nut on track rod ball joint but do not remove
s complete‐

ce
e

ly.
nl

pt
du

an
itte

y li
Leave nut screwed on a few turns to protect thread on pin.
erm

ab
ility
ot p

– Press track rod ball joint off wheel bearing housing using ball
wit
, is n

joint puller -3287 A- and now remove nut.

h re
hole

– Press drive shaft as far as possible out of wheel hub (towards spec
es, in part or in w

gearbox).
t to the co
rrectness of i
l purpos

nf
ercia

orm
m

atio
om

n in
or c

thi
te

sd
iva

o
r
rp

cu
o

m
f

en
ng

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

4. Assembly overview: wheel bearing 59

 Golf Variant 2007 ➤ , Jetta 2005 ➤
Running gear, axles, steering - Edition 07.2010

– Remove threaded connection between wheel bearing housing

and suspension strut -arrow-.

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

– Turn ratchet handle through 90° and detach from spreader
-3424- .

– Remove nuts -arrows-.

– Now position engine and gearbox jack -V.A.G 1383 A- under
wheel bearing housing.
– First press swivel joint off suspension link in order to press
wheel bearing housing off suspension strut. n AG. Volkswagen AG do
lkswage es n
o ot g
byV ua
d ran
ir se
Note tho tee
or
au ac
ss
If wheel bearing housing is renewed, swivel joint must be trans‐

ce
le
un

pt
ferred. Always use new nuts.

an
d
itte

y li
erm

ab
Installing
ility
ot p

wit
is n

Carry out installation in the reverse sequence, noting the follow‐

h re
ole,

ing: spec
urposes, in part or in wh

– Tighten drive shaft bolt at wheel hub:

t to the co

♦ Hexagon bolt ⇒ page 70

♦ Twelve-point bolt ⇒ page 71
rrectness

Note
o
cial p

f inform

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

mer

wheel bearing will be damaged.

atio
om

n
c

i
or

n thi

If wheel bearing housing is renewed, wheels must be aligned

te

sd
a

⇒ page 261 .
iv

o
pr

cum
r
fo

– Install wheel and tighten bolts or nuts ⇒ page 241 .

en
ng

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

60 Rep. gr.40 - Front suspension

 Golf Variant 2007 ➤ , Jetta 2005 ➤
Running gear, axles, steering - Edition 07.2010

Specified torques agen

AG. Volkswagen AG d
oes
olksw not
yV gu
Component ised b
Specified
ara torque
nte
or e
h
Suspension strut to wheel bearing housing
s aut 70 Nm + o90°
ra
c
♦ Use new nut s

ce
e
nl

pt
du

an
Swivel joint to cast steel suspension link 60 Nm

itte

y li
erm
♦ Use new nut

ab
ility
ot p

wit
Swivel joint to sheet steel or forged aluminium suspension 100 Nm
, is n

h re
link
hole

spec
♦ Use new nut
es, in part or in w

t to the co
Track rod ball joint to wheel bearing housing 20 Nm + 90°
♦ Use new nut

rrectness of i
Drive shaft to wheel hub „hexagon bolt“ 200 Nm + 180°
l purpos

♦ Use new bolt

Drive shaft to wheel hub „12-point bolt“ 70 Nm + 90°

nf
ercia

♦ Use new bolt

orm
m

atio
om

n in
or c

thi
te

sd
iva

o
r
rp

cu
o

m
f

en
ng

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

4. Assembly overview: wheel bearing 61

 Golf Variant 2007 ➤ , Jetta 2005 ➤
Running gear, axles, steering - Edition 07.2010

5 Assembly overview: suspension strut

1 - Shock absorber
❑ Can be renewed sepa‐
rately
❑ Allocation ⇒ Electronic
parts catalogue „ETKA“
2 - Bump stop
3 - Protective sleeve
4 - Coil spring
❑ Removing and installing
⇒ page 69 . AG. Volkswagen AG d
agen oes
❑ Observe colour coding Volksw not
gu
by ara
❑ Allocation ⇒ Electronic
rised
nte
parts catalogue
au
t „ETKA“
h o eo
ra
ss c
Spring allocation via PR No.

ce
e
nl

pt
du

an
itte

These numbers are located on

y li
erm

ab
the vehicle data sticker.

ility
ot p

❑ Surface of coil must not

wit
, is n

h re
be damaged.
hole

spec
5 - Deep groove ball thrust
es, in part or in w

bearing
t to the co
6 - Suspension strut mounting
❑ Note correct installation
rrectness of i

position ⇒ page 65
l purpos

7 - Nut
❑ M14 x 1.5
nf
ercia

or

❑ 60 Nm
m
m

atio
m

❑ Self-locking
o

n in
or c

❑ Always renew after re‐

thi
te

moving.
sd
iva

o
r
rp

cu

8 - Suspension strut turret

o

m
f

en
ng

t.
yi Co
9 - Bolt t. Cop py
rig
gh
❑ 15 Nm + 90° further
ht
pyri by
Vo
o
by c lksw
❑ Always renew after removing. Prote
cted AG.
agen

10 - Protective cap

62 Rep. gr.40 - Front suspension

 Golf Variant 2007 ➤ , Jetta 2005 ➤
Running gear, axles, steering - Edition 07.2010
AG. Volkswagen AG d
agen oes
5.1 Removing and installing suspension strut d byV
olksw not
gu
ara
ise nte
or eo
h
aut ra
Special tools and workshop ss c
equipment required

ce
e
nl

pt
du

an
itte
♦ Torque wrench -V.A.G

y li
erm

ab
1332-

ility
ot p
♦ Spreader -3424-

wit
, is n

h re
hole
♦ Engine and gearbox jack -

spec
V.A.G 1383 A-

es, in part or in w

t to the co
♦ Support -T10149-

rrectness of i
l purpos

nform
mercia

at
om

ion
c

in t
or

his
ate

do
priv

cum
for

en
ng

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

Removing
– Loosen drive shaft bolt at wheel hub:
♦ Hexagon bolt ⇒ page 70
♦ Twelve-point bolt ⇒ page 71

Note

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

wheel bearing will be damaged.

– Remove wheel.

5. Assembly overview: suspension strut 63

 Golf Variant 2007 ➤ , Jetta 2005 ➤
Running gear, axles, steering - Edition 07.2010

– Unscrew hexagon nut for coupling rod -arrow- from suspen‐

sion strut.
– Unhook speed sensor wiring from suspension strut.

– Remove nuts -arrows-.

– Pull wheel bearing housing with swivel joint out of suspension
link.
– Pull outer joint of drive shaft out of wheel hub.
– Secure drive shaft to body with wire.

Caution

Do not allow the drive shaft to hang down under nits

AGown
. Volkweight,
swagen AG
for this would allow the inner joint to bendl wagefar and be dam‐ does n
kstoo
o ot g
aged. yV ua
edb ran
s ri tee
ho
aut or
ac
ss
– Bolt swivel joint to suspension link again. ce
le
un

pt
an
d
itte

y li
– Use wheel bolt to attach engine and gearbox jack -V.A.G 1383
rm

ab
A- with support -T10149- to wheel hub.
pe

ility
ot

wit
, is n

h re

WARNING
hole

spec
es, in part or in w

♦ Do not lift or lower vehicle while engine and gearbox jack

t to the co

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

the lifting platform.
rrectness of i

♦ Do not leave engine and gearbox jack -V.A.G 1383 A- un‐

der vehicle longer than necessary.
l purpos

nform
ercia

– Separate threaded connection between wheel bearing hous‐

m

a
com

ing and suspension strut -arrow-.

tion in
r
te o

thi
s
iva

do
r
rp

cum
fo

en
ng

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

64 Rep. gr.40 - Front suspension

 Golf Variant 2007 ➤ , Jetta 2005 ➤
Running gear, axles, steering - Edition 07.2010

– 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.
– Tie wheel bearing housing up to subframe bracket using a
piece of wire.
– Pull engine and gearbox jack -V.A.G 1383 A- out from under
wheel bearing housing.

WARNING

♦ Do not leave engine and gearbox jack -V.A.G 1383 A- un‐

der vehicle longer than necessary.

– Remove wiper arms ⇒ Electrical system; Rep. gr. 92 ; Wiper

system; Removing and installing wiper arms .
– Remove plenum chamber cover.

– Remove hexagon bolts -arrows- for upper shock absorber

mounting and remove suspension strut.
Installing
n AG. Volkswagen AG do
wage e
– Insert suspension
Vol
ks strut with one of the two
s nomarkings
t gu
-arrows- by
dpointing forwards. ara
ise n
r tee
ho
aut or
ac
ss
ce
le
un

pt
an
d
itte

y li
rm

ab
pe

ility
ot

wit
, is n

h re
hole

Installation position of spring plate

spec
es, in part or in w

t to the co
rrectness of i
l purpos

nform
mercia

a
com

tion in
r
te o

thi
s
iva

do
r
rp

cum
fo

en
ng

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

5. Assembly overview: suspension strut 65

 Golf Variant 2007 ➤ , Jetta 2005 ➤
Running gear, axles, steering - Edition 07.2010

Tighten hexagon bolts -arrows- for upper shock absorber mount‐

ing.
– Install plenum chamber cover.
– Install wiper arms ⇒ Electrical system; Rep. gr. 92 ; Wiper
system; Removing and installing wiper arms .

– 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.
♦ Do not leave engine and gearbox jack -V.A.G 1383 A- un‐
der vehicle longer than necessary.

– Position suspension strut on wheel bearing housing.

– Remove wire from wheel bearing housing.
– Using engine and gearbox jack -V.A.G 1383 A- , carefully raise
wheel bearing housing until bolt securing suspension strut to
wheel bearing housing can be inserted. AG. Volkswagen AG d
agen oes
lksw not
– Press brake disc towards suspension strut by hand while lift‐ by V o gu
ara
ing. rised
nte
ho eo
ut
Otherwise the shock absorber tube can cant in the bore ofss the
a ra
c
wheel bearing housing.

ce
le
un

pt
an
d

– Remove spreader -3424- .

itte

y li
rm

ab
pe

ility
– Tighten threaded connection between wheel bearing housing
ot

wit
, is n

and suspension strut -arrow-

h re
hole

spec
es, in part or in w

WARNING t to the co

♦ Do not leave engine and gearbox jack -V.A.G 1383 A- un‐

der vehicle longer than necessary.
rrectness of i
l purpos

nform
mercia

a
com

tion in
r
te o

thi
s
iva

do
r
rp

cum
fo

en
ng

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

66 Rep. gr.40 - Front suspension

 Golf Variant 2007 ➤ , Jetta 2005 ➤
Running gear, axles, steering - Edition 07.2010

– Remove nuts -arrows-.

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

Note

Ensure that bellows are not damaged or twisted.

– Tighten drive shaft bolt at wheel hub:

♦ Hexagon bolt ⇒ page 70
♦ Twelve-point bolt ⇒ page 71

Note

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

wheel bearing will be damaged.

Continue installation in reverse order.

– Install wheel and tighten bolts or nuts ⇒ page 241 .

Specified torques
Component Specified torque
Suspension strut to wheel bearing housing 70 Nm + 90°
♦ Use new nut
n AG. Volkswagen AG do
swage es n
Suspension strut to body (suspension turret) by Vo lk
15otNm
gu + 90°
♦ Use new bolts ir se
d ara
nte
tho eo
au ra
Swivel joint to cast steel suspension link
ss 60 Nm c
♦ Use new nuts
ce
e
nl

pt
du

an
itte

y li

Swivel joint to sheet steel or forged aluminium suspension 100 Nm

erm

ab

link
ility
ot p

♦ Use new nuts

wit
, is n

h re
hole

Coupling rod to suspension strut 65 Nm

spec

♦ Use new nut

es, in part or in w

t to the co

♦ Counterhold on multi-point socket of joint pin

rrectness of i

Drive shaft to wheel hub „hexagon bolt“ 200 Nm + 180°

♦ Use new bolt
l purpos

Drive shaft to wheel hub „12-point bolt“ 70 Nm + 90°

♦ Use new bolt
nf
ercia

orm
m

atio
om

n in
or c

thi
te

sd
iva

o
r
rp

cu
o

m
f

en
ng

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

5. Assembly overview: suspension strut 67

 Golf Variant 2007 ➤ , Jetta 2005 ➤
Running gear, axles, steering - Edition 07.2010

5.2 Repairing suspension strut

Special tools and workshop

equipment required
♦ Torque wrench -V.A.G
1332-
♦ Spring compressor -V.A.G AG. Volkswagen AG d
1752/1- agen oes
olksw not
y V gu
b ara
♦ Strut support clamp -V.A.G rise
d
nte
1752/20- utho eo
ra
s a c
s
♦ Spring retainer -V.A.G

ce
le
un

1752/5-

pt
an
d
itte

y li
♦ Shock absorber set -
erm

ab
T10001-

ility
ot p

wit
is n

♦ Commercially available

h re
ole,

ratchet handle

spec
urposes, in part or in wh

t to the co
rrectness o
cial p

f inform
mer

atio
om

n
c

i
or

n thi
te

sd
iva

o
pr

cum
r
fo

en
ng

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

– Remove coil spring strut ⇒ page 63 .

68 Rep. gr.40 - Front suspension

 Golf Variant 2007 ➤ , Jetta 2005 ➤
Running gear, axles, steering - Edition 07.2010

Removing coil spring

– Clamp suspension strut support clamp -V.A.G 1752/20- -4- in
a vice.
Volkswa
– Clamp suspension strut in suspensionagenstrut support clamp
AG. gen AG
does -
ksw
V.A.G 1752/20- -4-. by Vol not
gu
a d ran
se
– Pre-tension coil springthwith
or spring compressor -V.A.G 1752/1-
i tee
or
until deep groove ball
ss
au
thrust bearing is free at top. ac

ce
le

1- Torque wrench -V.A.G 1332-

un

pt
an
d
itte

y li
2- Tool insert -T10001/8-
erm

ab
ility
ot p

3- Spring compressor -V.A.G 1752/1-

wit
is n

h re
4- Strut support clamp -V.A.G 1752/20-
ole,

spec
urposes, in part or in wh

5- Spring retainer -V.A.G 1752/4-

t to the co
6- Tool insert -T10001/5-
7- Ratchet handle -T10001/11-

rrectne
WARNING

ss o
cial p

f
First compress spring far enough to ensure that upper spring

inform
plate is free.
mer

atio
om

n
c

i
or

n thi
e

– Ensure that coil spring is correctly seated in spring retainer -

t

sd
iva

o
V.A.G 1752/4- -arrow-.
pr

cum
r
fo

en
ng

– Unscrew hexagon nut from piston rod.

t.
yi Co
Cop py
– Remove individual components of suspension strut and coil
t. rig
gh ht
yri
spring with spring compressor -V.A.G 1752/1- .
p by
o Vo
by c lksw
cted agen
Install coil spring.
Prote AG.

– 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 re‐
move from coil spring.
– Install suspension strut ⇒ page 65 .

Specified torques
Component Specified torque
Suspension strut mounting to shock absorber 60 Nm
♦ Use new nut

5. Assembly overview: suspension strut 69

 Golf Variant 2007 ➤ , Jetta 2005 ➤
Running gear, axles, steering - Edition 07.2010

6 Removing and installing drive shafts

Removing and installing drive shaft with constant velocity joint
⇒ page 72 .
Removing and installing left drive shaft with (push-on) constant
velocity slip joint ⇒ page 74 .
Removing and installing right drive shaft with (push-on) constant
velocity slip joint ⇒ page 78 .
Removing and installing drive shafts with triple roller joint
AAR2600i ⇒ page 81 .
Removing and installing drive shafts with triple roller joint
AAR3300i ⇒ page 83 .
Removing and installing intermediate shaft ⇒ page 85 .

WARNING

When removing and installing drive shafts, do not allow them

to hang free and stop against joints due to over bending.
n AG. Volkswagen AG do
lkswage es n
o ot g
byV ua
6.1 Loosening and tightening drive shaft ho
ir se
d ran
tee
hexagon bolt ut or
a ac
ss

ce
e
nl

Special tools and workshop equipment required

pt
du

an
itte

y li
♦ Angle wrench -V.A.G 1756-
erm

ab
ility
ot p

wit
, is n

h re
hole

spec
es, in part or in w

t to the co
rrectness of i
l purpos

nform
mercia

at

Wheel bearings must not be subjected to load after bolt securing

om

io

drive shaft to wheel hub has been loosened.

n
c

in t
or

his
e

If wheel bearings are loaded with weight of vehicle, bearing will

at

do
riv

be damaged. This reduces the service life of the wheel bearing.

p

cum
or

It is therefore important to note the following:

f

en
ng

t.
yi Co
♦ Procedure for loosening hexagon bolt ⇒ page 70 . Cop py
t. rig
gh ht
yri
Do not attempt to move the vehicle without the drive shafts fitted p by
co Vo
as this would damage the wheel bearing. If the vehicle does have
by lksw
cted agen
Prote
to be moved, always note the following points:
AG.

– Fit an outer joint in place of drive shaft.

– Tighten outer joint to 120 Nm.
Loosening hexagon bolt
– With vehicle still standing on its wheels, loosen the hexagon
bolt a maximum of 90°, as the wheel bearing will otherwise be
damaged.
– Raise vehicle so that wheels are off the ground.
– Have second mechanic apply brakes.

70 Rep. gr.40 - Front suspension

 Golf Variant 2007 ➤ , Jetta 2005 ➤
Running gear, axles, steering - Edition 07.2010

– Remove hexagon bolt -arrow-.

Tightening hexagon bolt
– Renew hexagon bolt.

Note

The wheels must not be in contact swith wagethe ground when the
n AG. Volkswagen AG do drive
es n
shaft bolt is tightened; otherwise,y V the wheel bearing will be dam‐
olk ot g
ua
aged. ris
ed b ran
t ee
tho or
au ac
– Have second mechanic
ss apply brakes.

ce
e
nl

pt
– Tighten hexagon bolt to 200 Nm.
du

an
itte

y li
erm

– Lower vehicle onto its wheels.

ab
ility
ot p

– Turn hexagon bolt 180° further.

wit
, is n

h re
hole

spec
6.2 Loosening and tightening 12-point
es, in part or in w

t to the co
flange bolt securing drive shaft
Special tools and workshop equipment required

rrectness of i
♦ Socket, 24 mm -T10361-
l purpos

nform
mercia

at
om

ion
c

in t
or

his
ate

do
priv

cum
for

en
ng

t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote
♦ Angle wrench -V.A.G 1756-
AG.

Wheel bearings must not be subjected to load after bolt securing

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 therefore important to note the following:
♦ Procedure for loosening 12-point flange bolt.
Do not attempt to move the vehicle without the drive shafts fitted
as this would damage the wheel bearing. If the vehicle does have
to be moved, always note the following points:
– Fit an outer joint in place of drive shaft.

6. Removing and installing drive shafts 71

 Golf Variant 2007 ➤ , Jetta 2005 ➤
Running gear, axles, steering - Edition 07.2010

– Tighten outer joint to 120 Nm. AG. Volkswagen AG d

agen oes
olksw not
Loosening 12-point bolt d by
V gu
ara
ise nte
r
– To avoid damage to wheel bearing, do not loosen 12-point
ut
ho bolt eo
ra
using 24 mm socket -T10361- further than 90° with
ss a
vehicle still c
standing on its wheels.

ce
le
un

pt
an
d
– Raise vehicle so that wheels are off the ground.

itte

y li
erm

ab
– Have second mechanic apply brakes.

ility
ot p

wit
is n
– Remove 12-point bolt -arrow-.

h re
ole,

spec
Fitting 12-point bolt
urposes, in part or in wh

t to the co
– Renew 12-point bolt.

rrectne
Note

s
The wheels must not be in contact with the ground when the drive

s o
shaft bolt is tightened; otherwise, the wheel bearing will be dam‐
cial p

f in
aged.

form
mer

atio
m

– Have second mechanic apply brakes.

o

n
c

i
or

n thi
– Tighten 12-point bolt to 70 Nm.
te

sd
iva

o
r

– Lower vehicle onto its wheels.

p

cum
r
fo

en
ng

– Turn 12-point bolt 90° further.

t.
yi Co
Cop py
t. rig
gh ht
yri
6.3 Removing and installing drive shaft with
p by
o Vo
by c lksw
cted agen
constant velocity joint
Prote AG.

Special tools and workshop equipment required

♦ Torque wrench -V.A.G 1332-

♦ Angle wrench -V.A.G 1756-

72 Rep. gr.40 - Front suspension

 Golf Variant 2007 ➤ , Jetta 2005 ➤
Running gear, axles, steering - Edition 07.2010

Caution

When removing and installing drive shafts, do not allow them

to hang free and stop against joints due to over bending.

Removing
– Loosen drive shaft bolt at wheel hub:
♦ Hexagon bolt ⇒ page 70
♦ Twelve-point bolt ⇒ page 71

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.
If a vehicle must be moved with the drive shaft removed, an
outer joint must be fitted and tightened to 50 Nm.

– Remove lower noise insulation ⇒ General body repairs, ex‐

terior; Rep. gr. 50 ; Assembly overview - noise insulation .
– Unbolt drive shaft from gearbox flange shaft.
– Remove wheel.
– Push drive shaft outer joint out of wheel hub by hand.
– Remove nuts -arrows-.
– Pull wheel bearing housing with swivel joint out of suspension
link.
– Pull drive shaft out of wheel hub.
n AG. Volkswagen AG
wage does
Installing olks not
byV gu
ara
d
ise nte
Remove any paint tresidue
hor and/or corrosion on thread and splines eo
of outer joint. ss au ra
c
ce
le

– Insert drive shaft.

un

pt
an
d
itte

y li

– Guide outer joint into wheel hub splines as far as possible.

erm

ab
ility
ot p

wit
is n

h re
ole,

spec
urposes, in part or in wh

t to the co
rrectness o
cial p

f inform
mer

atio
om

n
c

i
or

n thi
te

sd
iva

o
pr

cum
r
fo

en
ng

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

73
cted agen
Prote AG.
6. Removing and installing drive shafts
 Golf Variant 2007 ➤ , Jetta 2005 ➤
Running gear, axles, steering - Edition 07.2010

– Bolt swivel joint to suspension link -arrows-.

Note

Ensure that bellows are not damaged or twisted.

– Place inner joint of drive shaft in position and tighten bolts di‐
agonally to 10 Nm.
– Tighten multi-point socket head bolts to prescribed torque, us‐
ing diagonal sequence.
– Install lower noise insulation ⇒ General body repairs, exterior;
Rep. gr. 50 ; Assembly overview - noise insulation .
– Tighten drive shaft bolt at wheel hub:
♦ Hexagon bolt ⇒ page 70
♦ Twelve-point bolt ⇒ page 71

Note

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

wheel bearing will be damaged.

– Install wheel and tighten bolts or nuts ⇒ page 241 .

. Volkswagen AG
gen AG does
swa
Specified torques yV
olk not
gu
d b ara
ise nte
Component hor eo Specified torque
aut ra
c
Swivel joint to suspension link
ss
60 Nm
ce
e

♦ Use new nut

nl

pt
du

an
itte

y li

Drive shaft to wheel hub „hexagon bolt“ 200 Nm + 180°

erm

ab
ility

♦ Use new bolt

ot p

wit
, is n

h re

Drive shaft to wheel hub „12-point bolt“ 70 Nm + 90°

hole

spec

♦ Use new bolt

es, in part or in w

t to the co

Drive shaft to flange shaft on gearbox „M8 multi-point sock‐ 40 Nm

et“ ♦ Initially tighten diagonally to 10 Nm
♦ Use new bolts
rrectness of i

Drive shaft to flange shaft on gearbox „M10 multi-point 70 Nm

l purpos

socket“ ♦ Initially tighten diagonally to 10 Nm

♦ Use new bolts
nf
ercia

orm
m

atio
om

n in
or c

6.4 Removing and installing left drive shaft

thi
te

sd
iva

with (push-on) constant velocity slip joint

o
r
rp

cu
o

m
f

en
ng

Special tools and workshop equipment required

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

74 Rep. gr.40 - Front suspension

 Golf Variant 2007 ➤ , Jetta 2005 ➤
Running gear, axles, steering - Edition 07.2010

♦ Multi-purpose tool -VW 771-

n AG. Volkswagen AG do
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss

ce
e
nl

pt
du

an
itte

y li
erm

ab
ility
ot p

♦ Drive shaft puller -T10382-

wit
, is n

h re
hole

spec
es, in part or in w

t to the co
rrectness of i
l purpos

nf
ercia

orm
m

atio
om

n in
or c

♦ Torque wrench -V.A.G 1332-

thi
te

sd
iva

o
r
rp

cu
o

m
f

en
ng

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

Removing
– Loosen drive shaft bolt at wheel hub ⇒ page 71 .

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.
If a vehicle must be moved with the drive shaft removed, an
outer joint must be fitted and tightened to 120 Nm.

– Remove lower noise insulation ⇒ Rep. gr. 50 ; Assembly

overview - noise insulation .
– Remove wheel.

6. Removing and installing drive shafts 75

 Golf Variant 2007 ➤ , Jetta 2005 ➤
Running gear, axles, steering - Edition 07.2010

– Remove nuts -arrows-.

– Pull wheel bearing housing with swivel joint out of suspension
link.
– Push drive shaft outer joint out of wheel hub by hand.
– Secure drive shaft to prevent it from falling.

– Position puller -T10382/1- behind constant velocity slip joint

-1-.
Cut-out -arrow- of puller -T10382/1- must face constant velocity
slip joint -1-.

n AG. Volkswagen AG do
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss
ce
le
un

pt
an
d
itte

y li
erm

ab
ility
ot p

wit
is n

h re
ole,

spec
urposes, in part or in wh

t to the co
rrectness o
cial p

f inform
mer

atio
om

n
c

i
or

n thi
te

sd
iva

o
pr

cum
r
fo

en
ng

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

76 Rep. gr.40 - Front suspension

 Golf Variant 2007 ➤ , Jetta 2005 ➤
Running gear, axles, steering - Edition 07.2010

– Install spindles -T10382/2- and traverse -T10382/3- on puller

plate -T10382/1- .
– Install multi-purpose tool -VW 771- on traverse -T10382/ 3- .
– Pull out drive shaft with a couple of strikes of multi-purpose
tool -VW 771- .
– Remove drive shaft from vehicle.
Installing
Remove any paint residue and/or corrosion on thread and splines
of outer joint.
– Insert new retaining ring in groove in stub shaft on gearbox.
– Lightly grease splines of stub shaft with universal grease -G
060 735 A2-
olkswagen AG
en AG. V
– Mesh outer oand ksw inner splines of gearbox
ag does and constant velocity
not
V l
slip joint.
ed
by gu
ara
ris nte
– Slide
au
tho drive shaft into constant velocity joint to stop
e o by hand.
ra
ss c
– Now push constant velocity joint onto stub shaft of gearbox ce
le
un

with a »sudden, hard push«. pt

an
d
itte

y li
erm

ab
ility
ot p

Note wit
is n

h re
ole,

Never use a hammer or other striking tool!

spec
urposes, in part or in wh

t to the co

– Check that constant velocity slip joint is seated securely by

pulling on constant velocity joint against resistance of retaining
ring.
rrectne

Caution
ss o
cial p

For this check, pull only on constant velocity slip joint, not on
inform

drive shaft.
mer

atio
om

n
c

i
or

– Detach tensioning strap -T10038- .

thi
te

sd
iva

– Guide outer joint into wheel hub splines as far as possible.

pr

cum
r
fo

en
ng

t.
yi Co
– Bolt swivel joint to suspension link -arrows-.
t. Cop py
rig
gh ht
pyri by
Vo
o
by c lksw
Note
cted agen
Prote AG.

Ensure that bellows are not damaged or twisted.

– Attach lower noise insulation ⇒ Rep. gr. 50 ; Assembly over‐

view - noise insulation .
– Tighten drive shaft bolt at wheel hub ⇒ page 71 .

Note

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

wheel bearing will be damaged.

– Install wheel and tighten bolts or nuts ⇒ page 241 .

6. Removing and installing drive shafts 77

 Golf Variant 2007 ➤ , Jetta 2005 ➤
Running gear, axles, steering - Edition 07.2010

Specified torques
Component Specified torque
Swivel joint to cast steel suspension link 60 Nm
♦ Use new nuts

Swivel joint to sheet steel or forged aluminium suspension 100 Nm

link
♦ Use new nuts

Drive shaft to wheel hub „12-point bolt“ 70 Nm + 90° further

♦ Use new bolt

6.5 Removing and installing right drive shaft with (push-on) constant velocity
slip joint

♦ Multi-purpose tool -VW

771-
♦ Tensioning strap -T10038-
♦ Drive shaft puller -T10382-
♦ Torque wrench -V.A.G
1332-
AG. Volkswagen AG d
agen oes
♦ Angle wrench -V.A.G 1756- olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
ss c

ce
e
nl

pt
du

an
itte

y li
erm

ab
ility
ot p

wit
, is n

h re
hole

spec
es, in part or in w

t to the co
rrectness of i
l purpos

nform
mercia

at
om

ion
c

in t
or

his
ate

do
priv

cum
for

en
ng

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

Removing
– Loosen drive shaft bolt at wheel hub ⇒ page 71 .

78 Rep. gr.40 - Front suspension

 Golf Variant 2007 ➤ , Jetta 2005 ➤
Running gear, axles, steering - Edition 07.2010

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.
If a vehicle must be moved with the drive shaft removed, an
outer joint must be fitted and tightened to 120 Nm.

– Remove lower noise insulation ⇒ Rep. gr. 50 ; Assembly

overview - noise insulation .
– Remove wheel.
– Remove nuts -arrows-.
– Pull wheel bearing housing with swivel joint out of suspension
link.
– Unbolt coupling rods from anti-roll bars on both sides.
– Push drive shaft outer joint out of wheel hub by hand.
– Secure drive shaft to prevent it from falling.

AG. Volkswagen AG d
agen oes
o lksw not
V gu
– Set up drive shaft puller -T10382- ed by . ara
nte
ris
o eo
For the constant velocity slipautjoint -1-, notch -arrow- in the puller
h
ra
plate -T10382/2- must faces the spindles -T10382/1- .
s c
ce
le
un

pt

– Assemble drive shaft puller -T10382- complete with multi-pur‐

an
d
itte

pose tool -VW 771- .

y li
erm

ab
ility
ot p

wit
is n

Note
h re
ole,

spec
urposes, in part or in wh

In order to pull the drive shaft out of the gearbox using the drive
t to the co

shaft puller -T10382- , the suspension strut with all attachments

must be pulled to the rear.
rrectness o
cial p

f inform
mer

atio
om

n
c

– Using tensioning strap -T10038- e.g. on lifting platform arm,

or

n thi
e

pull suspension strut with attachments back until the drive

t

sd
va

shaft puller -T10382- can be applied parallel to drive shaft.

i

o
pr

cum
r
fo

en
ng

t.
yi Co
Cop py
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cted agen
Prote AG.

6. Removing and installing drive shafts 79

 Golf Variant 2007 ➤ , Jetta 2005 ➤
Running gear, axles, steering - Edition 07.2010

– Set up drive shaft puller -T10382- and pull out drive shaft.
– Remove drive shaft from vehicle.
Installing
Remove any paint residue and/or corrosion on thread and splines
of outer joint.
– Insert new retaining ring in groove in stub shaft on gearbox.
– Lightly grease splines of stub shaft with universal grease -G
060 735 A2-
– Mesh outer and inner splines of gearbox and constant velocity
slip joint.
– Slide drive shaft into constant velocity joint to stop by hand.
– Now push constant velocity joint onto stub shaft of gearbox
with a »sudden, hard push«. en AG. V
olkswagen AG
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Never use a hammer or other striking tool!

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– Check that constant velocity slip joint is seated securely by
erm

ab
pulling on constant velocity joint against resistance of retaining

ility
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ring.

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Caution
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For this check, pull only on constant velocity slip joint, not on
drive shaft.

rrectness of i
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– Detach tensioning strap -T10038- .

– Guide outer joint into wheel hub splines as far as possible.
nform
mercia

– Bolt swivel joint to suspension link -arrows-.

at
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in t
or

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te

Note
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for

Ensure that bellows are not damaged or twisted.

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t.
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Cop py
t. rig
– Attach lower noise insulation ⇒ Rep. gr. 50 ; Assembly over‐
gh ht
pyri by
view - noise insulation .
co Vo
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cted agen
Prote AG.
– Tighten drive shaft bolt at wheel hub ⇒ page 71 .

Note

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

wheel bearing will be damaged.

– Install wheel and tighten bolts or nuts ⇒ page 241 .

Specified torques
Component Specified torque
Swivel joint to cast steel suspension link 60 Nm
♦ Use new nuts

80 Rep. gr.40 - Front suspension

 Golf Variant 2007 ➤ , Jetta 2005 ➤
Running gear, axles, steering - Edition 07.2010

Component Specified torque

Swivel joint to sheet steel or forged aluminium suspension 100 Nm
link
♦ Use new nuts

Drive shaft to wheel hub „12-point bolt“ 70 Nm + 90° further

♦ Use new bolt

6.6 Removing and installing drive shafts

with triple roller joint AAR2600i
n AG. Volkswagen AG do
Special tools and workshop equipment required olkswage es n
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♦ Torque wrench -V.A.G 1332- ir se
d ran
tee
tho
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es, in part or in w

t to the co
rrectness of i
♦ Wedge -T10161-
l purpos

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or

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Removing
– Loosen drive shaft bolt at wheel hub:
♦ Hexagon bolt ⇒ page 70
♦ Twelve-point bolt ⇒ page 71

Note

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

wheel bearing will be damaged.

– Remove wheel.
– Remove lower noise insulation ⇒ General body repairs, ex‐
terior; Rep. gr. 50 ; Assembly overview - noise insulation .

6. Removing and installing drive shafts 81

 Golf Variant 2007 ➤ , Jetta 2005 ➤
AG. Volkswagen AG d
Running gear, axles, steering - Edition 07.2010 olkswagen oes
not
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– Remove nuts -arrows-. horis tee
ut or
ac
– Pull wheel bearing housing with swivel s a of suspension
joint sout
link.

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an
itte
– Pull drive shaft out of wheel hub and tie up to body.

y li
erm

ab
ility
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wit
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hole

spec
es, in part or in w

t to the co
rrectness of i
– Insert wedge -T10161- between gearbox housing and triple
l purpos

roller joint.
– Press inner joint out of gearbox by striking wedge -T10161-

nf
ercia

with a hammer.

orm
m

atio
– Remove drive shaft.
om

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Installing

thi
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– Fit new retaining ring into groove of joint pin.

o
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– Mesh outer and inner splines of joint body and gearbox.

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– Slide drive shaft into joint body to stop by hand. t. C rig
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– Now »suddenly« push joint body into gearbox.
co Vo
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Prote AG.
The joint travel can be used for the »sudden push«. Do not, how‐
ever, pull the drive shaft too far out of the joint body.

Note

Never use a hammer or other striking tool!

– Check that drive shaft is seated securely in gearbox by pulling

on joint body against resistance of retaining ring.
For this check, pull only on joint body and not on drive shaft.
– Guide outer joint into wheel hub splines as far as possible.
– Install lower noise insulation ⇒ General body repairs, exterior;
Rep. gr. 50 ; Assembly overview - noise insulation .

82 Rep. gr.40 - Front suspension

 Golf Variant 2007 ➤ , Jetta 2005 ➤
Running gear, axles, steering - Edition 07.2010
. Volkswagen AG
gen AG does
– Bolt swivel joint to suspension link -arrows-. Volkswa not
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Ensure that bellows are not damaged or twisted.

du

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ab
– Tighten drive shaft bolt at wheel hub:

ility
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wit
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♦ Hexagon bolt ⇒ page 70

h re
hole

spec
♦ Twelve-point bolt ⇒ page 71
es, in part or in w

t to the co
Note

rrectness of i
During this step, vehicle must not be standing on its wheels or
l purpos

wheel bearing will be damaged.

– Install wheel and tighten bolts or nuts ⇒ page 241 .

nform
mercia

at
om

Specified torques

ion
c

in t
or

Component Specified torque

his
ate

do
riv

Swivel joint to cast steel suspension link 60 Nm

p

cum
or

♦ Use new nuts

f

en
ng

t.
yi Co
op py
Swivel joint to sheet steel or forged aluminium suspension 100 Nm
t. C rig
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link p by
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♦ Use new nuts
by lksw
cted agen
Prote AG.

Drive shaft to wheel hub „hexagon bolt“ 200 Nm + 180°

♦ Use new bolt

Drive shaft to wheel hub „12-point bolt“ 70 Nm + 90°

♦ Use new bolt

6.7 Removing and installing drive shafts

with triple roller joint AAR3300i
Special tools and workshop equipment required
♦ Torque wrench -V.A.G 1332-

Removing
– Loosen drive shaft bolt at wheel hub:
♦ Hexagon bolt ⇒ page 70
♦ Twelve-point bolt ⇒ page 71

6. Removing and installing drive shafts 83

 Golf Variant 2007 ➤ , Jetta 2005 ➤
Running gear, axles, steering - Edition 07.2010

– Remove wheel.
– Remove lower noise insulation ⇒ General body repairs, ex‐
terior; Rep. gr. 50 ; Assembly overview - noise insulation .
– Unbolt drive shaft from gearbox flange shaft.
– Remove nuts -arrows-. n AG. Volkswagen AG do
lkswage es n
– Pull wheel bearing housing with swiveld bjoint
y V out of suspension
o ot g
ua
link. o
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tee
th or
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– Pull drive shaft out of wheel hub.
ss
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ce
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Installing

pt
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an
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Remove any paint residue and/or corrosion on thread and splines
erm

ab
of outer joint.

ility
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wit
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– Insert drive shaft.

h re
hole

spec
– Guide outer joint into wheel hub splines as far as possible.
es, in part or in w

t to the co
– Bolt swivel joint to suspension link -arrows-.

rrectness of i
Note
l purpos

Ensure that bellows are not damaged or twisted.

nform
ercia

– Place inner joint of drive shaft in position and tighten bolts di‐
m

at
om

agonally to 10 Nm.

ion
c

in t
or

– Tighten multi-point socket head bolts to prescribed torque, us‐

his
ate

ing diagonal sequence.

do
priv

cum
or

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

f

en
ng

t.
yi
Rep. gr. 50 ; Overview - noise insulation .
Co
Cop py
t. rig
– Tighten drive shaft bolt at wheel hub:
gh ht
pyri by
Vo
co lksw
by
♦ Hexagon bolt ⇒ page 70 cted agen
Prote AG.

♦ Twelve-point bolt ⇒ page 71

Note

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

wheel bearing will be damaged.

– Install wheel and tighten bolts or nuts ⇒ page 241 .

Specified torques
Component Specified torque
Swivel joint to cast steel suspension link 60 Nm
♦ Use new nuts

Swivel joint to sheet steel or forged aluminium suspension 100 Nm

link
♦ Use new nuts

Drive shaft to wheel hub „hexagon bolt“ 200 Nm + 180°

♦ Use new bolt

Drive shaft to wheel hub „12-point bolt“ 70 Nm + 90°

♦ Use new bolt

84 Rep. gr.40 - Front suspension

 Golf Variant 2007 ➤ , Jetta 2005 ➤
Running gear, axles, steering - Edition 07.2010

Component Specified torque

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

6.8 Removing and installing intermediate

shaft
Special tools and workshop equipment required
♦ Torque wrench -V.A.G 1332-

Removing
– Remove drive shaft on right-hand side ⇒ page 72 .
– Loosen all bolts on bearing bracket -arrows-.
G. Volkswagen nA AG do
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– Pull intermediate shaft
y V off gearbox.
olks ot g
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ed ran
Repairing intermediate
tho
ris shaft ⇒ page 107 . tee
or
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Installing ss
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erm

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ility
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wit
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es, in part or in w

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– First renew seal -1- on gearbox.

rrectness of i
l purpos

nform
mercia

at
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ion
c

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or

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ate

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for

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t.
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Cop py
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rig ht
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by lksw
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Prote AG.

6. Removing and installing drive shafts 85

 Golf Variant 2007 ➤ , Jetta 2005 ➤
Running gear, axles, steering - Edition 07.2010

– Now push intermediate shaft onto stub shaft of gearbox until

bearing -2- contacts bearing bracket -1- without »gap«
-arrow-.

– Tighten bolts -arrows- to specified torque.

– Install drive shaft ⇒ page 73 .

Specified torques
Component Specified torque
Intermediate shaft bearing to bearing bracket 20 Nm

AG. Volkswagen AG d
agen oes
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tion in
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86
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Rep. gr.40 - Front suspension Prote
cted AG.
agen
 Golf Variant 2007 ➤ , Jetta 2005 ➤
Running gear, axles, steering - Edition 07.2010

7 Repairing drive shaft - overview of drive shafts

I - Assembly overview: drive

shaft with VL90 or VL100 con‐
stant velocity joint
⇒ page 90
II - Assembly overview: drive
shaft with VL107 constant ve‐
locity joint (bolt-on)
⇒ page 100
n AG. Volkswagen AG do
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III - Assembly overview: drive yV
olks ot g
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shaft with VL107 constant ve‐ ise d b ran
locity slip joint (push-on) uthor tee
or
⇒ page 109 ss
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urposes, in part or in wh

t to the co
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cial p

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atio
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n
c

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t.
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Prote AG.

7. Repairing drive shaft - overview of drive shafts 87

 Golf Variant 2007 ➤ , Jetta 2005 ➤
Running gear, axles, steering - Edition 07.2010

IV - Assembly overview: drive

shaft with triple roller joint
AAR2600i ⇒ page 114
V - Assembly overview: drive
shaft with triple roller joint
AAR3300i ⇒ page 120

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

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nf

Distinguishing between drive shafts when installed

ercia

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atio

VL90 VL100 VL107 (bolt- VL 107 (push- AAR2600i AAR3300i

om

on) on)
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Diameter of 90 100 107 - - -

t

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inner joint in
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mm
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Cover be‐ - - X - - -
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joint and drive p by
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flange Prote
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agen

With bearing - - X - - X
bracket on
right side
Inner joint fit‐ - - - - X -
ted in gearbox
Inner joint - - - x - -
pushed onto
stub shaft

88 Rep. gr.40 - Front suspension

 Golf Variant 2007 ➤ , Jetta 2005 ➤
Running gear, axles, steering - Edition 07.2010

7.1 Heat shields for drive shafts

Front-wheel drive:
Component agen
AG.Specified
Volkswagentorque
AG do
lksw es n
o ot g
Hexagon bolt -1- d by V 25 Nm ua
ran
e
oris tee
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au ac
ss

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d
itte

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ab
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Four-wheel drive:
ole,

spec
urposes, in part or in wh

Component Specified torque

t to the co
Nuts -1- 20 Nm
♦ Initially tighten all nuts to
10 Nm

rrectness o
cial p

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mer

atio
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n
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Four-wheel drive:
t

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Component Specified torque

en
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Nuts -1- 20 Nm
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♦ Initially tighten all nuts to
by
ht
10 Nm
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Prote AG.

7. Repairing drive shaft - overview of drive shafts 89

 Golf Variant 2007 ➤ , Jetta 2005 ➤
Running gear, axles, steering - Edition 07.2010

8 Assembly overview: drive shaft with VL90 or VL100 constant velocity

joint

1 - Outer constant velocity joint

❑ Renew only as com‐
plete unit
❑ Removing ⇒ page 94 .
❑ Installing: drive onto
shaft to stop using a
plastic mallet
❑ Checking ⇒ page 96
2 - Bolt
❑ M16 x 1.5 x 80 AG. Volkswagen AG d
agen oes
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❑ Hexagon bolt, 200 Nm d by V gu
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and turn +180° further rise nte
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❑ 12-point bolt, 70 Nm + ss a ra
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90° further

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❑ Always renew after re‐

an
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itte

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moving.
erm

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ility
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When bolt is loosened or tight‐

wit
is n

ened, vehicle must not be

h re
standing on its wheels
ole,

spec
urposes, in part or in wh

3 - Right drive shaft

t to the co
4 - Clamp
❑ Always renew after re‐

rrectne
moving.
❑ Tightening ⇒ page 96
ss o
cial p

5 - Boot
f inform

❑ Check for splits and

mer

chafing
atio
om

❑ Material: Hytrel (poly‐

c

i
or

ester elastomer)
thi
te

sd
iva

o
r

6 - Clamp
p

cum
r
fo

en
ng

❑ Always renew after re‐ yi

t.
Co
moving. t. Cop py
rig
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❑ Tightening ⇒ page 96
ht
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7 - Dished spring
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❑ Installation position ⇒ page 94 .
8 - Thrust washer
❑ Installation position ⇒ page 94 .
9 - Retaining ring
❑ Always renew after removing.
❑ Insert in groove in shaft
10 - Boot for constant velocity joint
❑ Material: Hytrel (polyester elastomer)
❑ Without breather hole
❑ Check for splits and chafing
❑ Drive off constant velocity joint with a drift
❑ Coat sealing surface of constant velocity joint with -D 454 300 A2- before installing.

90 Rep. gr.40 - Front suspension

 Golf Variant 2007 ➤ , Jetta 2005 ➤
Running gear, axles, steering - Edition 07.2010

11 - Clamp
❑ Always renew after removing.
❑ Tightening ⇒ page 96
12 - Left drive shaft
13 - Locking plate
❑ Always renew after removing.
AG. Volkswagen
14 - Multi-point socket head bolt lksw
agen AG do
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❑ Initially tighten diagonally to 10 Nm and then tighten ediagonally to specified torque ua
db ran
ris tee
M8 bolt: 40 Nm utho or
a ac
ss

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le
M10 bolt: 70 Nm

un

pt
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itte
❑ Always renew bolts after removing

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erm

ab
ility
15 - Retaining ring ot p

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is n

❑ Remove and install with circlip pliers -VW 161 A-

h re
ole,

spec
16 - Seal
urposes, in part or in wh

❑ Adhesive surface on constant velocity joint must be free of oil and grease!

t to the co
17 - Inner constant velocity joint
❑ Renew only as complete unit

rrectne
❑ Pressing off ⇒ page 95

s
❑ Pressing on ⇒ page 95

s o
cial p

f
❑ Checking ⇒ page 97

inform
mer

18 - Dished spring

atio
m

❑ Installation position ⇒ page 95 .

o

n
c

i
or

n thi
te

sd
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fo

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ng

t.
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Cop py
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Vo
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cted agen
Prote AG.

8. Assembly overview: drive shaft with VL90 or VL100 constant velocity joint 91
 Golf Variant 2007 ➤ , Jetta 2005 ➤
Running gear, axles, steering - Edition 07.2010

8.1 Dismantling and assembling drive shaft with VL90 or VL100 constant ve‐
locity joint

Special tools and workshop

equipment required
♦ Thrust plate -VW 401-
♦ Thrust plate -VW 402-
♦ Press tool -VW 408 A-
♦ Press tool -VW 411-
♦ Tube -VW 416 B-
♦ Thrust washer -VW 447 H-

AG. Volkswagen AG d
agen oes
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erm

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ility
ot p

wit
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es, in part or in w

t to the co
rrectness of i
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orm
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om

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or c

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te

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ng

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Cop py
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Prote AG.

92 Rep. gr.40 - Front suspension

 n AG. Volkswagen AG do
lkswage es n
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ir se
d Golf Variant a2007
ran
tee ➤ , Jetta 2005 ➤
o
auth Running gear, axles, steering o-r Edition 07.2010
ac
ss

ce
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nl

pt
du
♦ Circlip pliers -VW 161 A-

an
itte

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erm

ab
♦ Torque wrench -V.A.G

ility
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1331-

wit
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h re
♦ Torque wrench -V.A.G

hole
1332-

spec
♦ Special pliers -V.A.G 1682- es, in part or in w

t to the co
♦ Assembly tool -T10065-

rrectness of i
l purpos

nform
mercia

at
om

ion
c

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or

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ate

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for

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ng

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Cop py
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♦ Multi-purpose tool -VW 771-

8. Assembly overview: drive shaft with VL90 or VL100 constant velocity joint 93
 Golf Variant 2007 ➤ , Jetta 2005 ➤
Running gear, axles, steering - Edition 07.2010

♦ 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 joint

AG. Volkswagen AG d
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Installation position of dished spring and thrust washer on outer

, is n

h re

joint
hole

spec

1- Dished spring
es, in part or in w

t to the co

2- Thrust washer
– Install new retaining ring.
rrectness of i

– If necessary, push new joint boot onto drive shaft.

l purpos

– Drive onto shaft with plastic head hammer until retaining ring
engages.
nf
ercia

orm
m

atio
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te

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94
cted agen
Prote AG.
Rep. gr.40 - Front suspension
 Golf Variant 2007 ➤ , Jetta 2005 ➤
AG. Volkswagen ARunning
agen es n gear, axles, steering - Edition 07.2010
G do
olksw ot g
y V ua
db
Pressing off inner constant rise velocity joint ran
tee
ho
ut or
Assembling ss
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es, in part or in w

t to the co
rrectness of i
l purpos

nform
mercia

at
om

ion
c

in t
r

Installation position of dished spring at inner joint

o

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ate

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1- Dished spring
p

cum
for

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ng

t.
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Cop py
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Pressing on inner constant velocity joint

Note

Chamfer on internal circumference of ball hub (splines) must face

contact shoulder on drive shaft.

8. Assembly overview: drive shaft with VL90 or VL100 constant velocity joint 95
 AG. Volkswagen AG d
agen oes
olksw not
V
Golf Variant 2007 d b ➤ , Jetta 2005 ➤
y gu
ara
ise nte
Running gear,
thor axles, steering - Edition 07.2010 eo
au ra
ss c
Tighten clamp on outer joint

ce
le
un

pt
an
d
– Position clamp tensioner -V.A.G 1682- as shown in diagram.
itte

y li
Ensure jaws of tensioner lie in corners -arrows B- of ears on
rm

ab
pe

ility
O-type clip.
ot

wit
, is n

– Tighten clamp by turning spindle with a torque wrench (do not

h re
hole

cant pliers).

spec
es, in part or in w

t to the co
Note

rrectness of i
♦ Because a stainless steel boot clamp is required due to the
hard material of the joint boot (compared to rubber), it is pos‐
l purpos

sible to tighten the clamp only with clamp tensioner -V.A.G

1682- .

nform
ercia

♦ Torque setting: 25 Nm.

m

a
com

t
♦ Use torque wrench -C- with adjustment range 5 … 50 Nm, (e.g.

ion in
torque wrench -V.A.G 1331- ).
r
te o

thi
s
iva

♦ Make sure thread of spindle -A- on pliers moves freely. Lubri‐

do
r

cate with MoS2 grease if necessary.

rp

cum
fo

en
ng

t.
♦ If the thread is tight (e.g. due to dirt), the required clamping
yi Co
op
force for the boot clamp will not be attained although the cor‐
C py
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gh
rect torque is applied.
ht
pyri by
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Prote AG.

Tightening clamp on small diameter

8.2 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.

96 Rep. gr.40 - Front suspension

 Golf Variant 2007 ➤ , Jetta 2005 ➤
Running gear, axles, steering - Edition 07.2010

– Turn cage until the two rectangular windows -arrow- align with
joint body.
– Take out cage with hub.
AG. Volkswagen AG d
agen oes
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d by ara
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or eo
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aut ra
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un

pt
an
d
itte

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erm

ab
ility
ot p

wit
is n

h re
ole,

– Swing segment of hub into square cage window.

spec
urposes, in part or in wh

– Tip hub out of cage.

t to the co
The six balls for each joint belong to a tolerance group. Check
stub axle, hub, cage and balls for small indentations (pitting) and

rrectne
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

ss
are no reason to change the joint.

o
cial p

f inform
Installing
mer

atio
m

– Pack half of total grease quantity (40 g) into joint body.

o

n
c

i
or

n
– Fit cage with hub into joint body.

thi
te

sd
iva

– Press in opposing balls one after the other; the original position

o
pr

cum
r
fo

of the hub relative to the cage and joint body must be restored.

en
ng

t.
yi Co
– Fit new retaining ring into hub. Cop py
t. rig
gh ht
yri
– Distribute remaining grease in boot.
p by
o Vo
by c lksw
cted agen
Prote AG.

8.3 Checking inner constant velocity joint

Removing
The joint is to be dismantled to renew the grease if it is heavily
soiled, and to check the running surfaces and the balls for wear
and damage.
– Swing ball hub and ball cage.
– 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.

8. Assembly overview: drive shaft with VL90 or VL100 constant velocity joint 97
 Golf Variant 2007 ➤ , Jetta 2005 ➤
Running gear, axles, steering - Edition 07.2010

– 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 with cage and balls at a right angle to joint body.

When inserting, ensure that the wide spacing -a- on the joint body
is aligned with the narrow spacing -b- on the hub after it is swung
in.
Chamfer on inner diameter of ball hub (splines) must face larger
diameter of joint.
– Also make sure that chamfer on inner circumference of ball
hub is visible after swinging it into place.

AG. Volkswagen AG d
agen oes
olksw not
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– Swivel hub into joint body; at the same time, hub must be s
ce
le

swivelled out of cage -arrows- far enough to allow balls to fit

un

pt
an
d

into ball races.

itte

y li
erm

ab
ility
ot p

wit
is n

h re
ole,

spec
urposes, in part or in wh

t to the co
rrectness o
cial p

f inform
mer

atio
om

n
c

i
or

n thi
te

sd
iva

o
pr

cum
r
fo

en
ng

t.
yi Co
Cop py
ht. rig
rig ht
py by

98
co Vo
by lksw
cted
Rep. gr.40 - Front suspension
agen
Prote AG.
 Golf Variant 2007 ➤ , Jetta 2005 ➤
Running gear, axles, steering - Edition 07.2010

– 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.

n AG. Volkswagen AG do
lkswage es n
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ility
ot

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h re
hole

spec
es, in part or in w

t to the co
rrectness of i
l purpos

nform
mercia

a
com

tion in
r
te o

thi
s
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do
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rp

cum
fo

en
ng

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

8. Assembly overview: drive shaft with VL90 or VL100 constant velocity joint 99
 Golf Variant 2007 ➤ , Jetta 2005 ➤
Running gear, axles, steering - Edition 07.2010

9 Assembly overview: drive shaft with VL107 constant velocity joint

(bolt-on)

1 - Outer constant velocity joint

❑ Renew only as com‐
plete unit
❑ Removing ⇒ page 94 .
❑ Installing: drive onto
shaft to stop using a
plastic mallet
❑ Checking ⇒ page 96
2 - Bolt
❑ M16 x 1.5 x 80
❑ Hexagon bolt, 200 Nm
and turn +180° further
❑ 12-point bolt, 70 Nm +
90° further
❑ Always renew after re‐ n AG. Volkswagen AG do
moving. lkswage es n
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When bolt is loosened or tight‐
o
ir se
ran
tee
ened, vehicle must not abe
uth or
ac
standing on its wheelsss
ce
e
nl

pt
du

3 - Clamp
an
itte

y li

❑ Always renew after re‐

erm

ab
ility

moving.
ot p

wit
, is n

❑ Tightening ⇒ page 106

h re
hole

spec

4 - Boot
es, in part or in w

❑ Check for splits and

t to the co

chafing
❑ Material: Hytrel (poly‐
rrectness of i

ester elastomer)
l purpos

5 - Clamp
❑ Always renew after re‐
moving.
nform
ercia

❑ Tightening ⇒ page 106

m

at
om

io

6 - Dished spring
n
c

in t
or

❑ Installation position ⇒ page 104 .

his
ate

do
priv

7 - Thrust washer
um
for

en
g

❑ Installation position ⇒ page 104 .

n

t.
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Cop py
8 - Retaining ring
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❑ Always renew after removing.
co Vo
by lksw
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Prote
❑ Insert in groove in shaft
AG.

9 - Boot for constant velocity joint

❑ Material: Hytrel (polyester elastomer)
❑ Without breather hole
❑ Check for splits and chafing
❑ Drive off constant velocity joint with a drift
❑ Coat sealing surface with D 454 300 A2 before installing constant velocity joint
10 - Dished spring
❑ Installation position ⇒ page 104 .

100 Rep. gr.40 - Front suspension

 AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
e nte
horis
eo Golf Variant 2007 ➤ , Jetta 2005 ➤
ut
ss a Runningra
c gear, axles, steering - Edition 07.2010

ce
le
un

pt
11 - Clamp

an
d
itte

y li
❑ Always renew after removing.
rm

ab
pe

ility
❑ Tightening ⇒ page 106
ot

wit
, is n

h re
12 - Drive shaft
hole

spec
13 - Intermediate shaft
es, in part or in w

t to the co
❑ Right side of vehicle:
❑ Removing and installing ⇒ page 85 .

rrectness of i
❑ Repairing ⇒ page 107
l purpos

14 - Cover
❑ Always renew after removing.

nform
ercia

❑ Always renew
❑ Pressing off ⇒ page 104
m

a
com

tion in
15 - Retaining ring
r
te o

thi
❑ Remove and install with circlip pliers -VW 161 A-

s
iva

do
r
rp

c
16 - Seal

um
fo

en
ng

t.
❑ Adhesive surface on constant velocity joint must be free of oil and grease!
yi Co
Cop py
t. rig
17 - Inner constant velocity joint
gh ht
pyri by
Vo
o
❑ Renew only as complete unit
by c lksw
cted agen
Prote AG.
❑ Pressing off ⇒ page 104
❑ Pressing on ⇒ page 105
❑ Checking ⇒ page 97
18 - Cap
❑ Drive off carefully with drift
❑ Coat sealing surface with D 454 300 A2 before installing constant velocity joint
❑ Adhesive surface must be free of oil and grease!
19 - Locking plate
❑ Always renew after removing.
20 - Multi-point socket head bolt
❑ 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
21 - Clamp
❑ Always renew after removing.
❑ Tightening ⇒ page 106
22 - Bolt
❑ 20 Nm
23 - Countersunk head bolt
❑ Initially tighten to 5 Nm and then to 35 Nm
❑ Qty. 3
24 - Mounting bracket
25 - Mounting
❑ Pressing off on ⇒ page 107

9. Assembly overview: drive shaft with VL107 constant velocity joint (bolt-on) 101
 Golf Variant 2007 ➤ , Jetta 2005 ➤
Running gear, axles, steering - Edition 07.2010

9.1 Dismantling and assembling drive shaft with VL107 constant velocity joint

Special tools and workshop

equipment required
♦ Thrust plate -VW 401-
♦ Thrust plate -VW 402-
AG. Volkswagen AG d
agen oes
♦ Press tool -VW 408 A- Volksw not
gu
d by ara
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♦ Support sleeve -VW 522- horis nte
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aut ra
♦ Tensioner -40 - 204 A- ss c

ce
e
nl
♦ Special pliers -V.A.G 1682-

pt
du

an
itte

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erm

ab
ility
ot p

wit
, is n

h re
hole

spec
es, in part or in w

t to the co
rrectness of i
l purpos

nf
ercia

orm
m

atio
om

n in
or c

thi
te

sd
iva

o
r
rp

cu
o

m
f

en
ng

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

♦ Torque wrench -V.A.G 1331-

102 Rep. gr.40 - Front suspension

 Golf Variant 2007 ➤ , Jetta 2005 ➤
Running gear, axles, steering - Edition 07.2010

♦ 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- .
G. Volkswagen
– Assemble puller -T10382- complete with multi-purpose
wagen A toolAG- does n
VW 771- . Volks ot g
by ua d ran
ise tee
– Pull constant velocity joint from
ut
ho drive shaft with puller -T10382-
r
or
and multi-purpose tool -VW ss 771- .
a ac
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e

1- Puller plate -T10382/1-

nl

pt
du

an
itte

y li

2- Spindles -T10382/2-
erm

ab
ility
ot p

– Drive constant velocity joint off drive shaft using drift -A-.
wit
, is n

h re

The drift should be positioned exactly on the cross of the constant

hole

velocity joint.
spec
es, in part or in w

t to the co

Driving on outer joint

rrectness of i
l purpos

nform
mercia

at
om

ion
c

in t
or

his
ate

do
priv

cum
for

en
ng

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

103
Prote AG.
9. Assembly overview: drive shaft with VL107 constant velocity joint (bolt-on)
 Golf Variant 2007 ➤ , Jetta 2005 ➤
Running gear, axles, steering - Edition 07.2010

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.
– Drive onto shaft with plastic head hammer until retaining ringagen AG. Volkswagen AG do
engages. Vol
ksw es n
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by ua
ed ran
oris tee
th or
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ss
Driving off cover for inner joint

ce
e
nl

pt
du

an
– Remove retaining ring.
itte

y li
erm

ab
– Remove both clamps and slide boot towards outer joint.

ility
ot p

wit
, is n

– Use drift to drive off boot.

h re
hole

spec
es, in part or in w

t to the co
rrectness of i
l purpos

Pressing off inner constant velocity joint

nf
ercia

orm
m

atio
om

n in
or c

thi
te

sd
iva

o
r
rp

cu
o

m
f

en
ng

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

Installation position of dished spring at inner joint

1- Dished spring

104 Rep. gr.40 - Front suspension

 Golf Variant 2007 ➤ , Jetta 2005 ➤
Running gear, axles, steering - Edition 07.2010

Pressing on inner constant velocity joint

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

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

– Apply an unbroken bead of sealant 2 ... 0.3 mm Ø onto clean
surface of cover in area of inner holes -arrow-.

Volkswa
gen AG
– Using bolts -arrows-, align snew
wagecover in relation to
n AG. doebolt
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The alignment must be isevery
db accurate, because no further align‐
ara
nte
ment is possible once hor the part has been hammered on. eo
aut ra
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– Drive on cover using a plastic hammer.
s
ce
e
nl

pt
du

– Wipe off surplus sealant.

an
itte

y li
erm

ab
ility
ot p

wit
, is n

h re
hole

spec
es, in part or in w

t to the co
rrectness of i
l purpos

nf
ercia

orm
m

atio
om

n in
or c

thi
te

sd
iva

o
r
rp

cu
o

m
f

en
ng

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

9. Assembly overview: drive shaft with VL107 constant velocity joint (bolt-on) 105
 Golf Variant 2007 ➤ , Jetta 2005 ➤
Running gear, axles, steering - Edition 07.2010

Tighten clamp on outer joint

– Apply special pliers -V.A.G 1682- as shown in diagram. En‐
sure jaws of tool contact corners -arrows B- of clamp.
– 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- .
♦ Torque setting: 25 Nm.
♦ Use torque wrench -C- with adjustment range 5 … 50 Nm, (e.g.
torque wrench -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 boot clamp will not be attained although the cor‐
rect torque is applied.

Tightening clamp on small diameter AG. Volkswagen AG d

agen oes
ksw
Checking outer constant velocity joint ⇒ page 96 by
Vol not
gu
ara
ed
is nte
Checking inner constant velocity joint ⇒ page 97 hor eo
aut ra
s c
Checking function of constant velocity joint ⇒ page 99 s

ce
le
un

pt
an
d
itte

y li
rm

ab
pe

ility
ot

wit
, is n

h re
hole

spec
es, in part or in w

t to the co
rrectness of i
l purpos

nform
mercia

a
com

tion in
r
te o

thi
s
iva

do
r
rp

cum
fo

en
ng

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

106 Rep. gr.40 - Front suspension

 Golf Variant 2007 ➤ , Jetta 2005 ➤
Running gear, axles, steering - Edition 07.2010

9.2 Repairing intermediate shaft

Special tools and workshop

equipment required
♦ Thrust plate -VW 401-
♦ Thrust plate -VW 402-
♦ Thrust piece -T10032-
♦ Thrust piece -3118-
♦ Separating device Kukko
-15-2-

n AG. Volkswagen AG do
lkswage es n
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d ran
ir se tee
tho
u or
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ss
ce
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nl

pt
du

an
itte

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erm

ab
ility
ot p

wit
, is n

h re
hole

spec
es, in part or in w

t to the co
rrectness of i
l purpos

nform
mercia

at
om

ion
c

in t

Pressing off bearing

or

his
ate

– Press bearing off intermediate shaft as shown in figure.

do
priv

cum
for

The jaws of the Kukko splitter -15-2- must be facing shaft.

en
ng

t.
yi Co
op
1- Intermediate shaft with bearing
C py
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gh ht
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2- Thrust plate -VW 402- cop Vo
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cted agen
Prote AG.
3- Thrust plate -VW 401-
4- Separating device Kukko -15-2-

Note

Hold shaft when pressing out.

9. Assembly overview: drive shaft with VL107 constant velocity joint (bolt-on) 107
 Golf Variant 2007 ➤ , Jetta 2005 ➤
Running gear, axles, steering - Edition 07.2010

Pressing on bearing
– Press bearing to stop on intermediate shaft as shown in figure.
1- Thrust piece -T10032-
2- Intermediate shaft
3- Mounting
4- Thrust piece -3118-
5- Thrust plate -VW 401-
6- Separating device Kukko -15-2-
7- Thrust plate -VW 402-
Shoulder -arrow- of press tool -3118- must be facing bearing.

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

ce
e
nl

pt
du

an
itte

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erm

ab
ility
ot p

wit
, is n

h re
hole

spec
es, in part or in w

t to the co
rrectness of i
l purpos

nform
mercia

at
om

ion
c

in t
or

his
ate

do
priv

cum
for

en
ng

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

108 Rep. gr.40 - Front suspension

 Golf Variant 2007 ➤ , Jetta 2005 ➤
Running gear, axles, steering - Edition 07.2010

10 Assembly overview: drive shaft with VL107 constant velocity slip joint
(push-on)

1 - Outer constant velocity joint

❑ Renew only as com‐
plete unit
❑ Removing ⇒ page 110 .
❑ Installing: drive onto
shaft to stop using a
plastic mallet
❑ Checking ⇒ page 112
2 - Bolt
❑ 70 Nm + 90° further
❑ Always renew after re‐
moving.
When bolt is loosened or tight‐
ened, vehicle must not be
standing on its wheels

3 - Retaining ring
❑ Always renew after re‐
moving.
❑ Insert in groove in shaft
4 - Thrust washer
❑ Installation position
⇒ page 111 .
n AG. Volkswagen AG do
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5 - Dished spring Vol
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❑ Installation positionorise ran
tee
⇒ page 111 . auth or
ac
ss
6 - Clamp
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e
nl

pt
du

❑ Always renew after re‐

an
itte

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moving.
erm

ab
ility

❑ Tightening ⇒ page 112

ot p

wit
, is n

7 - Boot
h re
hole

spec

❑ Check for splits and

es, in part or in w

chafing
t to the co

❑ Material: Hytrel (polyester elastomer)

8 - Clamp
rrectness of i

❑ Always renew after removing.

l purpos

❑ Tightening ⇒ page 112

9 - Drive shaft
nform
ercia

10 - Clamp
m

at
om

io

❑ Always renew after removing.

n
c

in t
or

❑ Tightening ⇒ page 112

his
ate

do
riv

11 - Boot for constant velocity slip joint

p

cum
for

en
g

❑ Material: Hytrel (polyester elastomer)

n

t.
yi Co
op
❑ Without breather hole
C py
t. rig
gh ht
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❑ Check for splits and chafing p by
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by c lksw
cted agen
12 - Retaining ring Prote AG.

❑ Always renew after removing.

10. Assembly overview: drive shaft with VL107 constant velocity slip joint (push-on) 109
 Golf Variant 2007 ➤ , Jetta 2005 ➤
Running gear, axles, steering - Edition 07.2010
❑ Insert in groove in shaft
13 - Clamp
❑ Always renew after removing.
❑ Tightening ⇒ page 112
14 - Constant velocity slip joint
❑ Renew only as complete unit
❑ Removing ⇒ page 111 .
❑ Installing: drive onto shaft to stop using a plastic mallet

10.1 Dismantling and assembling drive shaft

with VL107 (push-on) constant velocity
slip joint
Special tools and workshop equipment required
♦ Multi-purpose tool -VW 771-

AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c
ce
le
un

pt
an
d
itte

y li

♦ Puller -T10382-
erm

ab
ility
ot p

wit
is n

h re
ole,

spec
urposes, in part or in wh

t to the co
rrectness o
cial p

f inform
mer

atio
m

Removing outer constant velocity joint

o

n
c

i
or

– Clamp drive shaft in vice using protective jaw covers.

thi
te

sd
iva

– Fold back boot.

o
pr

cum
r
fo

en
ng

– Set puller -T10382- up so that smooth side of puller plate -

t.
yi Co
T10382/1- points to spindles -T10382/2- . Cop py
t. rig
gh ht
yri
– Assemble puller -T10382- complete with multi-purpose tool -
p by
o Vo
by c lksw
VW 771- . Prote
cted AG.
agen

110 Rep. gr.40 - Front suspension

 Golf Variant 2007 ➤ , Jetta 2005 ➤
Running gear, axles, steering - Edition 07.2010

– 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.
Removing inner constant velocity slip joint
AG. Volkswagen AG d
agen
– Clamp drive shaft in vice using protective jaw covers.
Vol
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ed
– Fold back boot. oris nte
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th
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– Set puller -T10382- up so that smooth side
ss of puller plate - c
T10382/1- points to spindles -T10382/2- . ce
e
nl

pt
du

an
– Assemble puller -T10382- complete with multi-purpose tool -
itte

y li
erm

VW 771- .
ab
ility
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wit
, is n

– Pull constant velocity joint from drive shaft with puller -T10382-
h re

and multi-purpose tool -VW 771- .

hole

spec
es, in part or in w

1- Puller plate -T10382/1-

t to the co

2- Spindles -T10382/2-
Driving on inner constant velocity slip joint
rrectness of i

– Install new retaining ring.

l purpos

– If necessary, push new joint boot onto drive shaft.

nf
ercia

– Knock onto shaft with plastic hammer until circlip engages.

orm
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or c

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Prote AG.

10. Assembly overview: drive shaft with VL107 constant velocity slip joint (push-on) 111
 Golf Variant 2007 ➤ , Jetta 2005 ➤
Running gear, axles, steering - Edition 07.2010

Tighten clamp on outer joint

AG. Volkswagen AG d
– Apply special pliers -V.A.G 1682- as shown in diagram. En‐ ksw
agen oes
not
sure jaws of tool contact corners -arrows B- of clamp.y Vol gu
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– Tighten clamp by turning spindle with a torque uwrench
tho (do not eo
ra
cant pliers). ss a c

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Note

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♦ Because a stainless steel boot clamp is required due to the

wit
hard material of the joint boot (compared to rubber), it is pos‐ is n

h re
ole,
sible to tighten the clamp only with clamp tensioner -V.A.G

spec
urposes, in part or in wh

1682- .

t to the co
♦ Torque setting: 25 Nm.
♦ Use torque wrench -C- with adjustment range 5 … 50 Nm, (e.g.

rrectne
torque wrench -V.A.G 1331- ).
♦ Make sure thread of spindle -A- on pliers moves freely. Lubri‐

ss
cate with MoS2 grease if necessary.

o
cial p

f in
♦ If the thread is tight (e.g. due to dirt), the required clamping

form
mer

force for the boot clamp will not be attained although the cor‐

atio
m

rect torque is applied.

o

n
c

i
or

n thi
te

sd
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Tightening clamp on small diameter

i

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en
ng

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Cop py
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Prote AG.

10.2 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.

112 Rep. gr.40 - Front suspension

 Golf Variant 2007 ➤ , Jetta 2005 ➤
Running gear, axles, steering - Edition 07.2010

– Turn cage until the two rectangular windows -arrow- align with
joint body.
– Take out cage with hub.

– Swing segment of hub into square cage window.

– Tip hub out of cage.
. Volkswagen AG
The six balls for each joint belong to a tolerance group. Check wage
n AG does
stub axle, hub, cage and balls for small indentations (pitting)
Volks and not
gu
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traces of seizing. Too much circumferential backlash ris in the joint
ed nte
becomes noticeable during load change jolts; in thsuch cases, the
o eo
au ra
joint must be renewed. Smoothing and tracesss of wear of the balls c
are no reason to change the joint.

ce
le
un

pt
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d

Installing
itte

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erm

ab
– Pack half of total grease quantity (40 g) into joint body.

ility
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wit
is n

– Fit cage with hub into joint body.

h re
ole,

spec
– Press in opposing balls one after the other; the original position
urposes, in part or in wh

of the hub relative to the cage and joint body must be restored.

t to the co
– Fit new retaining ring into hub.
– Distribute remaining grease in boot.

rrectness o
cial p

f inform
mer

atio
om

n
c

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or

n thi
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sd
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Cop py
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co lksw
by
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Prote AG.

10. Assembly overview: drive shaft with VL107 constant velocity slip joint (push-on) 113
 Golf Variant 2007 ➤ , Jetta 2005 ➤
Running gear, axles, steering - Edition 07.2010

11 Assembly overview: drive shaft with triple roller joint AAR2600i

1 - Outer constant velocity joint

❑ Renew only as com‐
plete unit
❑ Removing ⇒ page 103 .
❑ Installing: drive onto
shaft with plastic mallet
until compressed retain‐
ing ring seats.
❑ Checking ⇒ page 96
2 - Bolt
❑ M16 x 1.5 x 80
❑ Hexagon bolt, 200 Nm
and turn +180° further
❑ 12-point bolt, 70 Nm +
90° further
❑ Always renew after re‐
moving.
When bolt is loosened or tight‐
ened, vehicle must not be
standing on its wheels

3 - Right drive shaft

4 - Left drive shaft
5 - Clamp
❑ Always renew after re‐
moving.
6 - Boot for constant velocity AG. Volkswagen AG d
agen
joint olksw
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❑ Check for splits and rised
nte
chafing ut
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❑ Material: Hytrel (poly‐ ss
ce
e

ester elastomer)
nl

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du

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itte

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7 - Clamp
erm

ab

❑ Always renew after removing.

ility
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❑ Tightening ⇒ page 106

h re
hole

8 - Dished spring
spec
es, in part or in w

❑ Installation position ⇒ page 117 .

t to the co

9 - Thrust washer
❑ Installation position ⇒ page 117 .
rrectness of i

10 - Retaining ring
l purpos

❑ Always renew after removing.

❑ Insert in groove in shaft
nform
ercia

11 - Clamp
m

at
om

io

❑ Always renew after removing.

n
c

in t
or

❑ Tighten clamp with hose clip pliers -V.A.G 1275-

his
ate

do
priv

12 - Boot for triple roller joint

um
for

en
g

❑ Check for splits and chafing

n

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rig ht
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Prote AG.

114 Rep. gr.40 - Front suspension

 Golf Variant 2007 ➤ , Jetta 2005 ➤
Running gear, axles, steering - Edition 07.2010

13 - Clamp
❑ Always renew after removing.
❑ Tighten clamp with hose clip pliers -V.A.Gn 1275-
AG. Volkswagen A ge G do
swa es n
14 - Retaining ring by
Vol
k ot g
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❑ Always renew after removing.
ho
ris tee
t or
au ac
15 - Joint body ss

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16 - Retaining ring

pt
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❑ Always renew after removing.
rm

ab
pe

ility
❑ Insert in groove in shaft using circlip pliers -VW 161 A- .
ot

wit
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17 - Triple roller star with rollers

h re
hole

spec
The chamfer -arrow- points towards drive shaft splines.
es, in part or in w

t to the co
11.1 Dismantling and assembling drive shaft with triple roller joint AAR2600i

rrectness of i
l purpos

Special tools and workshop

equipment required

nform
ercia

♦ Thrust plate -VW 401-

m

a
♦ Thrust plate -VW 402-
com

tion in
♦ Press tool -VW 408 A-
r
te o

thi
s
iva

do
♦ Press tool -VW 411-
r
rp

cum
fo

♦ Tube -VW 416 B-

en
ng

t.
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op
♦ Thrust washer -VW 447 H-
C py
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gh ht
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Vo
co lksw
by
cted agen
Prote AG.

11. Assembly overview: drive shaft with triple roller joint AAR2600i 115
 Golf Variant 2007 ➤ , Jetta 2005 ➤
Running gear, axles, steering - Edition 07.2010

♦ Hose clip pliers -V.A.G

1275-
♦ Torque wrench -V.A.G
1331-
♦ Torque wrench -V.A.G
1332-
♦ Special pliers -V.A.G 1682-
♦ Assembly tool -T10065-
AG. Volkswagen AG d
agen oes
olksw not
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d by ara
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or eo
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aut ra
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ce
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d
itte

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ab
ility
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wit
is n

h re
ole,

spec
urposes, in part or in wh

t to the co
rrectness o
cial p

f inform
mer

atio
om

n
c

i
or

n thi
te

sd
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o
pr

cum
r
fo

en
ng

t.
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Cop py
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Vo
o
by c lksw
♦ Multi-purpose tool -VW 771- Prote
cted AG.
agen

116 Rep. gr.40 - Front suspension

 Golf Variant 2007 ➤ , Jetta 2005 ➤
Running gear, axles, steering - Edition 07.2010

♦ Puller -T10382-

AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
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ce
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nl

pt
Removing outer constant velocity joint
du

an
itte

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– Clamp drive shaft in vice using protective jaw covers.
erm

ab
ility
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– Fold back boot.

wit
, is n

h re
– Set puller -T10382- up so that smooth side of puller plate -
hole

spec
T10382/1- points to spindles -T10382/2- .
es, in part or in w

t to the co
– Assemble puller -T10382- complete with multi-purpose tool -
VW 771- .

rrectness of i
– Pull constant velocity joint from drive shaft with puller -T10382-
and multi-purpose tool -VW 771- .
l purpos

1- Puller plate -T10382/1-

nf
ercia

2- Spindles -T10382/2-

orm
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Driving on outer constant velocity joint

atio
om

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or c

thi
te

sd
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o

m
f

en
ng

t.
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Cop py
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gh ht
pyri by
Vo
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by c lksw
cted agen
Prote AG.

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.
Dismantling
– Unfasten both clamps on inner joint and push back boot.
– Pull joint body off drive shaft.

11. Assembly overview: drive shaft with triple roller joint AAR2600i 117
 Golf Variant 2007 ➤ , Jetta 2005 ➤
Running gear, axles, steering - Edition 07.2010

– Remove retaining ring.

1 - Pliers (commercial type) or -VW 161 A-
– Set drive shaft into press.

AG. Volkswagen AG d
agen oes
lksw not
– Press triple roller star off drive shaft. d byV
o gu
ara
ise nte
r
– Pull boot off shaft. ut
ho eo
ra
s a c
– Clean shaft, joint body and groove
s for seal.

ce
e
nl

pt
du

Assembling

an
itte

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erm

ab
– Push small hose clip for boot onto shaft.

ility
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wit
– Push joint boot onto drive shaft.
, is n

h re
hole

– Push joint body onto drive shaft.

spec
es, in part or in w

Fitting triple roller star

t to the co
Drive shaft (tapered version) -arrow-

rrectness of i
Chamfer on triple roller star faces towards shaft and serves as an
assembly aid.
l purpos

nf
ercia

orm
m

atio
om

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

n in
or c

thi
e

– Ensure that pressure does not exceed 3.0 t.

t

sd
iva

o
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rp

cu

– If necessary, coat splines of drive shafts and triple roller star

o

m
f

en
ng

with lubricating paste -G 052 142 A2- .

t.
yi Co
Cop py
– Insert retaining ring, ensuring that it is seated correctly. ht. rig
rig ht
py by
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– Press 70 grammes of drive shaft grease from repair set into by c lksw
cted agen
triple roller joint.
Prote AG.

– 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.
Fitting triple roller star
Drive shaft (cylindrical version) -arrow-

118 Rep. gr.40 - Front suspension

 Golf Variant 2007 ➤ , Jetta 2005 ➤
Running gear, axles, steering - Edition 07.2010

– 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. wage
n AG. Volkswagen AG do
es n
lks ot g
Vo
– Tighten both clamps with hose d by clip pliers -V.A.G 1275- . ua
ran
ir se tee
tho
u or
a ac
ss

ce
e
nl

pt
du

an
itte

y li
erm

ab
ility
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wit
, is n

h re
hole

spec
es, in part or in w

t to the co
rrectness of i
l purpos

nf
ercia

orm
m

atio
om

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or c

thi
te

sd
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f

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

11. Assembly overview: drive shaft with triple roller joint AAR2600i 119
 Golf Variant 2007 ➤ , Jetta 2005 ➤
Running gear, axles, steering - Edition 07.2010
AG. Volkswagen AG d
agen oes
lksw not
12 Assembly overview: drive shaft with triple roller joint AAR3300i Vo gu
by ara
d
rise nte
tho eo
au ra
ss c
1 - Outer constant velocity joint

ce
e
nl

pt
du
❑ Renew only as com‐

an
itte

y li
plete unit
erm

ab
❑ Removing ⇒ page 94 .

ility
ot p

wit
, is n

❑ Installing: drive onto

h re
shaft with plastic mallet
hole

spec
until compressed retain‐
es, in part or in w

ing ring seats.

t to the co
❑ Checking ⇒ page 96
2 - Bolt

rrectness of i
❑ M16 x 1.5 x 80
l purpos

❑ Hexagon bolt, 200 Nm

and turn +180° further

nf
ercia

❑ 12-point bolt, 70 Nm +

orm
90° further
m

atio
m

❑ Always renew after re‐

o

n in
or c

moving.

thi
te

sd
iva

When bolt is loosened or tight‐

o
r
rp

cu
ened, vehicle must not be
o

m
f

en
ng

standing on its wheels

t.
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Cop py
t. rig
3 - Clamp
gh ht
pyri by
Vo
co
❑ Always renew after re‐
by lksw
cted agen
Prote
moving.
AG.

❑ Tightening ⇒ page 126

4 - Boot for constant velocity
joint
❑ Check for splits and
chafing
❑ Material: Hytrel (poly‐
ester elastomer)
5 - Clamp
❑ Always renew after re‐
moving.
❑ Tightening ⇒ page 106
6 - Dished spring
❑ Installation position ⇒ page 124 .
7 - Thrust washer
❑ Installation position ⇒ page 124 .
8 - Retaining ring
❑ Always renew after removing.
❑ Insert in groove in shaft
9 - Retaining ring
❑ Always renew after removing.
❑ Insert in groove in shaft
10 - Triple roller star with rollers
The chamfer -arrow- points towards drive shaft splines.

11 - Clamp
❑ Always renew after removing.

120 Rep. gr.40 - Front suspension

 AG. Volkswagen AG d
agen oes
ksw n t
by Vol
Golf Variant 2007 ➤ ,oJetta
gu 2005 ➤
ar
d
riseRunning gear, axles, steering - Editiona07.2010 nte
tho eo
au ra
❑ Tighten clamp with hose clip pliers -V.A.G
s 1275-
s c

ce
e
nl

pt
12 - Boot for triple roller joint

du

an
itte

y li
❑ Check for splits and chafing

erm

ab
ility
ot p
13 - Clamp

wit
, is n
❑ Always renew after removing.

h re
hole

spec
❑ Tighten clamp with hose clip pliers -V.A.G 1275-

es, in part or in w

t to the co
14 - Drive shaft
15 - Bolt

rrectness of i
❑ 20 Nm
16 - Mounting bracket l purpos

17 - Mounting

nform
ercia

18 - Joint body with intermediate shaft

m

at
om

❑ For right side of vehicle

ion
c

in t
or

19 - Countersunk head bolt

his
ate

do
riv

❑ Initially tighten to 5 Nm and then to 35 Nm

p

cum
for

20 - Joint body

en
ng

t.
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op
❑ For left side of vehicle C py
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gh ht
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21 - Multi-point socket head bolt cop Vo
by lksw
cted agen
❑ Initially tighten diagonally to 10 Nm and then tighten diagonally to specified torque Prote AG.

M8 bolt: 40 Nm

M10 bolt: 70 Nm
❑ Always renew bolts after removing

12. Assembly overview: drive shaft with triple roller joint AAR3300i 121
 Golf Variant 2007 ➤ , Jetta 2005 ➤
Running gear, axles, steering - Edition 07.2010

12.1 Dismantling and assembling drive shaft with triple roller joint AAR3300i

Special tools and workshop

equipment required
♦ Thrust plate -VW 401-
♦ Thrust plate -VW 402-
AG. Volkswagen AG d
agen
♦ Press tool -VW 408 A- olksw
oes
not
byV gu
ara
d
♦ Press tool -VW 411- orise nte
eo
h
ut ra
♦ Tube -VW 416 B- ss a c

ce
le
un
♦ Thrust washer -VW 447 H-

pt
an
d
itte

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rm

ab
pe

ility
ot

wit
, is n

h re
hole

spec
es, in part or in w

t to the co
rrectness of i
l purpos

nform
mercia

a
com

tion in
r
te o

thi
s
iva

do
r
rp

cum
fo

en
ng

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

122 Rep. gr.40 - Front suspension

 Golf Variant 2007 ➤ , Jetta 2005 ➤
Running gear, axles, steering - Edition 07.2010

♦ Hose clip pliers -V.A.G

1275-
♦ Torque wrench -V.A.G
1331-
♦ Torque wrench -V.A.G
1332-
♦ Special pliers -V.A.G 1682-
♦ Assembly tool -T10065-

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

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le
un

pt
an
d
itte

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erm

ab
ility
ot p

wit
is n

h re
ole,

spec
urposes, in part or in wh

t to the co
rrectness o
cial p

f inform
mer

atio
om

n
c

♦ Multi-purpose tool -VW 771-

i
or

n thi
te

sd
iva

o
pr

cum
r
fo

en
ng

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

12. Assembly overview: drive shaft with triple roller joint AAR3300i 123
 Golf Variant 2007 ➤ , Jetta 2005 ➤
Running gear, axles, steering - Edition 07.2010

♦ 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

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

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rm

ab
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ility
ot

wit
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Installation position of dished spring and thrust washer on outer

h re
hole

joint
spec
es, in part or in w

1- Dished spring
t to the co

2- Thrust washer
– Install new retaining ring.
rrectness of i

– If necessary, push new joint boot onto drive shaft.

l purpos

– Knock onto shaft with plastic hammer until circlip engages.

nform
ercia

Dismantling
m

a
com

– Unfasten both clamps on inner joint and push back boot.

ion in
r
te o

– Pull joint body off drive shaft.

thi
s
iva

do
r
rp

cum
fo

en
ng

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

124
Prote AG.
Rep. gr.40 - Front suspension
 Golf Variant 2007 ➤ , Jetta 2005 ➤
Running gear, axles, steering - Edition 07.2010

– Remove retaining ring.

1 - Pliers (commercial type) or -VW 161 A-
– Set drive shaft into press.

– Press triple roller star off drive shaft.

– Pull boot off drive shaft.
– Clean drive shaft, joint body and groove for seal.
Assembling
– Push small hose clip for boot onto shaft.
n AG. Volkswagen AG do
– Push joint boot onto drive shaft. olkswage es n
ot g
byV ua
– Push joint body onto drive shaft. ir se
d ran
tee
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Fitting triple roller star ss
au ac

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le

Drive shaft (tapered version) -arrow-

un

pt
an
d
itte

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Chamfer on triple roller star faces towards shaft and serves as an
rm

ab
assembly aid.
pe

ility
ot

wit
, is n

h re
hole

spec
es, in part or in w

t to the co
– Fit triple roller star onto shaft and press on to stop.
– Ensure that pressure does not exceed 3.0 t.

rrectness of i
– If necessary, coat splines of drive shafts and triple roller star
l purpos

with lubricating paste -G 052 142 A2- .

– Insert retaining ring, ensuring that it is seated correctly.

nform
ercia

– Press 70 grammes of drive shaft grease from repair set into

m

a
com

t
triple roller joint.
ion in
r
te o

– Slide joint body over rollers and hold.

thi
s
iva

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– Press 60 grammes of drive shaft grease from repair kit into

rp

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rear of triple roller joint.

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Drive shaft (cylindrical version) -arrow-
AG.

12. Assembly overview: drive shaft with triple roller joint AAR3300i 125
 Golf Variant 2007 ➤ , Jetta 2005 ➤
Running gear, axles, steering - Edition 07.2010

– 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
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Note

To make it easier to insert the multi-point socket-head bolts when t to the co

installing the drive shaft, position ear -arrow A- of hose clip be‐ rrectne
tween mounting flanges -arrows B- of joint body.
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– Tighten hose clip using hose clip pliers -V.A.G 1275- .

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– Tighten small clamp using hose clip pliers -V.A.G 1275- .

126 Rep. gr.40 - Front suspension

 Golf Variant 2007 ➤ , Jetta 2005 ➤
Running gear, axles, steering - Edition 07.2010

42 – Rear suspension
1 Appraisal of accident vehicles
A checklist for evaluating running gear of accident vehicles can
be found under ⇒ page 1 .

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1. Appraisal of accident vehicles 127

 Golf Variant 2007 ➤ , Jetta 2005 ➤
Running gear, axles, steering - Edition 07.2010

2 Repairing rear suspension (front-

wheel drive)

2.1 Overview - rear axle

I - Assembly overview: sub‐

frame, transverse link, track
rod (front-wheel drive)
⇒ page 132
II - Assembly overview: wheel
bearing housing, trailing arm
(front-wheel drive)
⇒ page 147
III - Assembly overview: shock
absorber, coil spring
⇒ page 164
IV - Assembly overview: anti-
roll bar ⇒ page 170

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♦ It is not permitted to carry out welding and straightening oper‐

l purpos

ations on load-bearing or wheel-guiding suspension compo‐

nents.
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♦ Always renew self-locking nuts.

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bonded rubber bushes only when the wheel bearing housing

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is raised to unladen position ⇒ page 129 .

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128 Rep. gr.42 - Rear suspension

 Golf Variant 2007 ➤ , Jetta 2005 ➤
Running gear, axles, steering - Edition 07.2010

2.2 Rear axle in unladen position

Special tools and workshop

equipment required
♦ Engine and gearbox jack -
V.A.G 1383 A-
♦ Tensioning strap -T10038-
♦ Support -T10149-

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Note
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All bolts on running gear components with bonded rubber bushes

t to the co

may be tightened only when the component is in the unladen po‐

sition (normal position).
rrectne

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

ss

Axle components with bonded rubber bushes must therefore be

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brought to a position equivalent to the unladen (normal) position

inform

before being tightened.

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Otherwise, the bonded rubber bush would be subject to torsion

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loading, shortening its service life.

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To simulate this position on the lifting platform, raise the axle on

iva

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

cum
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support -T10149- .
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2. Repairing rear suspension (front-wheel drive) 129

 Golf Variant 2007 ➤ , Jetta 2005 ➤
Running gear, axles, steering - Edition 07.2010

Before the axle on one side is raised, the vehicle must be strapped
to the lifting platform arms using tensioning strap -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- with a wheel bolt.

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130 Rep. gr.42 - Rear suspension

 Golf Variant 2007 ➤ , Jetta 2005 ➤
Running gear, axles, steering - Edition 07.2010
n AG. Volkswagen A
Respective nuts and bolts may
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Sports running gear except 18" 365 ± 10 mm

t to the co
wheels (2UC)
Sports running gear with 18" 365 ± 10 mm
wheels (G02/G05/G07/2UC)

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Golf Variant BlueMotion 365 ± 10 mm

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Standard running gear (2UD) 390 ± 10 mm
Sports running gear GLI (G10) 380 ± 10 mm

Running gear: Jetta from 2006 Ride height -a- in mm

(India) 1)
Standard running gear 395 ± 10 mm
(G56/2UE)
1)The type of running gear fitted to the vehicle is recorded on the
vehicle data sticker. The running gear is identified by the PR
number. Which PR. No. refers to which running gear can be found
here ⇒ page 275 .
– Raise wheel bearing housing using engine and gearbox jack
until dimension -a- is attained.

WARNING

♦ Do not lift or lower vehicle while engine and gearbox jack

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

– Tighten respective nuts and bolts.

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

2. Repairing rear suspension (front-wheel drive) 131

 Golf Variant 2007 ➤ , Jetta 2005 ➤
Running gear, axles, steering - Edition 07.2010

3 Assembly overview: subframe, transverse link, track rod (front-wheel

drive)

1 - Eccentric bolt
❑ For camber adjustment
❑ Check wheel alignment
whenever this compo‐
nent is loosened
⇒ page 261 .
2 - Nut
❑ M12 x 1.5
❑ 95 Nm
❑ Self-locking
❑ Always renew after re‐
moving.
❑ Always tighten threaded
connections in unladen
position ⇒ page 129
3 - Eccentric washer
❑ Inner hole with lug
4 - Eccentric bolt
❑ For track adjustment
❑ Check wheel alignment
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es, in part or in w

t to the co

moving.
❑ Always tighten threaded connections in unladen position ⇒ page 129
rrectness of i

6 - Eccentric washer
❑ Inner hole with lug
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7 - Subframe
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8 - Bolt
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❑ M12 x 1.5 x 90
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❑ 90 Nm + 90° further
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❑ Always renew after removing.

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11 - Nut
❑ M12 x 1.5 x 75
❑ 90 Nm + 90° further

132 Rep. gr.42 - Rear suspension

 Golf Variant 2007 ➤ , Jetta 2005 ➤
Running gear, axles, steering - Edition 07.2010
❑ Self-locking
❑ Always renew after removing.
❑ Always tighten threaded connections in unladen position ⇒ page 129
12 - Bolt agen
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❑ Always renew after removing.

t to the co
❑ Always tighten threaded connections in unladen position ⇒ page 129
15 - Washer

rrectness of i
16 - Nut
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❑ M14 x 1.5
❑ 130 Nm + 90° further

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❑ Self-locking
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❑ Always tighten threaded connections in unladen position ⇒ page 129

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❑ Always tighten threaded connections in unladen position ⇒ page 129

20 - Track rod
❑ Various versions
♦ Forwards closed (left and right track rods differ)
♦ Downwards open (left and right track rods identical)
❑ It is permitted to install mixed types.
❑ Allocation ⇒ Electronic parts catalogue „ETKA“
❑ Removing and installing ⇒ page 143 .
21 - Bolt
❑ Always renew after removing.
22 - Nut
❑ M12 x 1.5
❑ 90 Nm + 90° further
❑ Self-locking
❑ Always renew after removing.
❑ Always tighten threaded connections in unladen position ⇒ page 129

3. Assembly overview: subframe, transverse link, track rod (front-wheel drive) 133
 Golf Variant 2007 ➤ , Jetta 2005 ➤
Running gear, axles, steering - Edition 07.2010

3.1 Removing and installing rear axle AG. Volkswagen AG d

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Special tools and workshop orise nte
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♦ Locating pins -T10096-
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Removing subframe with attachments

– Remove wheels.
– Remove coil springs ⇒ page 164 .
– Remove front and rear silencers of exhaust system ⇒ Engine
⇒ Rep. gr. 26 .
– On vehicles with automatic headlight range control, separate
wiring connection -1-.
– Remove ABS speed sensor out of wheel bearing housing.

134 Rep. gr.42 - Rear suspension

 Golf Variant 2007 ➤ , Jetta 2005 ➤
Running gear, axles, steering - Edition 07.2010

– Remove bolt -arrow-.

– Lever off spring clip -1- for handbrake cable.

– Push lever -2- in -direction of arrow- and unhook brake cable
-3-.

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– Unscrew
s au hexagon bolt -1- and detach handbrake cable r a -2-
c
from brake cable bracket.
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– Remove retainer -1- by pushing out inner pin of rivet -arrow-.

Continuation for all vehicles
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3. Assembly overview: subframe, transverse link, track rod (front-wheel drive) 135
 Golf Variant 2007 ➤ , Jetta 2005 ➤
Running gear, axles, steering - Edition 07.2010

– Unclip speed sensor wire from retainer -1- -arrows-.

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– Pull out hose retainer -1- on both sides of vehicle.

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– Mark installation position of bearing bracket on body.
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– Remove bolts -arrows-.

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– Now secure vehicle to hoist using tensioning straps -T10038

-.

WARNING

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

vehicle will slip off the lifting platform/hoist.

136 Rep. gr.42 - Rear suspension

 Golf Variant 2007 ➤ , Jetta 2005 ➤
Running gear, axles, steering - Edition 07.2010

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

frame using universal gearbox mounting -V.A.G 1359/2- and
secure with tensioning strap.

– Unscrew bolt -1- or -2- on both sides.

Note

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

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– Fix position of subframe usingtho2 locating pins -T10096- and
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The locating pins -T10096- may be tightened only to a maximum

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of 20 Nm; otherwise the threads of the locating pins may be dam‐ h re

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t to the co

– Unscrew remaining 2 bolts from subframe.

– Carefully lower subframe with attachments a maximum of 30
mm.
rrectness

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When lowering, ensure there is sufficient clearance to the brake

mer

lines and electrical cables.

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– Unclip brake line -1- from clips -arrows-.

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♦ The clips will be destroyed and must be renewed.
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♦ For reasons of clarity, the illustration shows the subframe from
AG.

above in removed state.

– Lower subframe with attachments.

Installing subframe with attachments
Install in reverse order. Note the following points:

3. Assembly overview: subframe, transverse link, track rod (front-wheel drive) 137
 Golf Variant 2007 ➤ , Jetta 2005 ➤
Running gear, axles, steering - Edition 07.2010

Specified torques
Component Specified torque
Subframe to body 90 Nm + 90°
♦ Use new bolts

Shock absorber to wheel bearing housing 180 Nm

Mounting bracket to body 50 Nm + 45°
♦ Use new bolts
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138 Rep. gr.42 - Rear suspension

 Golf Variant 2007 ➤ , Jetta 2005 ➤
Running gear, axles, steering - Edition 07.2010

3.2 Vehicle level sender for vehicles

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lower retaining plates.

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♦ Renewing without removing subframe ⇒ page 139 .

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1 - Subframe
2 - Lower transverse link

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3 - Bolt
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❑ 5 Nm
4 - Rear left vehicle level send‐

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er -G76-
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sic settings for headlight
must be performed.
Perform basic settings of
headlights using ⇒ Vehicle di‐
agnostic, testing and informa‐
tion system VAS 5051.

3.3 Renew vehicle level sender in vehicle

Special tools and workshop equipment required

3. Assembly overview: subframe, transverse link, track rod (front-wheel drive) 139
 Golf Variant 2007 ➤ , Jetta 2005 ➤
Running gear, axles, steering - Edition 07.2010

♦ Torque wrench -V.A.G 1410-

Removing
– Separate connection -1-.
– Remove bolts -2- from lower transverse link.
– Remove bolts -arrows- from subframe.
– Remove rear left vehicle level sender -G76- .
Installing
Install in reverse order. Note the following points:
The lever of rear left vehicle level sender -G76- must face outside
of vehicle.
– Following renewal, carry out basic setting of headlights ⇒
"Guided fault-finding" function of vehicle diagnostic, testing
and information system VAS 5051 .

Specified torques
Component Specified torque
Rear left vehicle level sender -G76- to lower transverse link 5 Nm
and subframe wage
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3.4 Removing and installing upper trans‐ au ra
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♦ Torque wrench -V.A.G 1332-

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Removing
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– Remove wheel.
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– Remove coil spring ⇒ page 164 .

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140
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Rep. gr.42 - Rear suspension
 Golf Variant 2007 ➤ , Jetta 2005 ➤
Running gear, axles, steering - Edition 07.2010

– Unhook speed sensor line -arrow A- from upper transverse

link.
– Remove bolt -1-.

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– Mark position of eccentric boltVo-arrow- relative to subframe
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– Remove bolt -arrow-. aut or
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– Remove upper transverse link.

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an
itte

Installing

y li
erm

ab
– Install upper transverse link on vehicle and tighten bolts hand

ility
ot p

tight.

wit
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h re
hole

– Bring rear axle into unladen position ⇒ page 129 .

spec
es, in part or in w

The transverse link may be bolted only when dimension „a“ has

t to the co
been attained ⇒ page 179 .

– Bolt upper transverse link to subframe and tighten new nut to

rrectness of i
specified torque.
l purpos

– Observe mark made for position of eccentric bolt -arrow- rel‐

ative to subframe.
nform
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c

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or

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ate

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– Tighten bolt -1- for upper transverse link. cop Vo
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Note

Washer -2- must be installed so that there is a gap -arrow B- be‐

tween washer and splash plate -3-.

– Attach speed sensor line -arrow A- from upper transverse link.

– Install coil spring ⇒ page 164 .
– Install wheel and tighten bolts or nuts ⇒ page 241 .
– Perform wheel alignment ⇒ page 261 .

3. Assembly overview: subframe, transverse link, track rod (front-wheel drive) 141
 AG. Volkswagen AG d
agen oes
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Golf Variant
thor 2007 ➤ , Jetta 2005 ➤ eo
u ra
Running
ss agear, axles, steering - Edition 07.2010 c

ce
e
nl

pt
du
Specified torques

an
itte

y li
erm

ab
Component Specified torque

ility
ot p

wit
Upper transverse link to wheel bearing housing 130 Nm + 90°
, is n

h re
♦ Use new nuts and bolts
hole

spec
♦ Tighten threaded connections only when vehicle is in
es, in part or in w

t to the co
the normal running position

Upper transverse link to subframe 95 Nm

rrectness of i
♦ Use new nut ♦ To tighten nuts, set torque wrench -V.A.G
1332- to 80 Nm.
l purpos

♦ Tighten threaded connections only when vehicle is in

the normal running position ♦ Applies only in conjunction with insert tool,
18 mm -T10179-

nform
mercia

at
om

ion
c

in t
or

3.5 Removing and installing lower trans‐

his
ate

do
riv

verse link
p

cum
for

en
ng

t.
Special tools and workshop equipment required
yi Co
Cop py
t. rig
♦ Torque wrench -V.A.G 1332-
gh ht
pyri by
Vo
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Removing
– Remove wheel.
– Remove coil spring. ⇒ page 164 .
– Remove bolt -arrow- for lower transverse link -1-.
Vehicles with dynamic headlight range control

142 Rep. gr.42 - Rear suspension

 Golf Variant 2007 ➤ , Jetta 2005 ➤
Running gear, axles, steering - Edition 07.2010

– Remove bolts -1- from lower transverse link.

Continuation for all vehicles
– Mark position of eccentric bolt -arrow- relative to subframe us‐
ing e.g. a felt tip pen.
– Disconnect and lower rear part of exhaust system.
– Remove bolt -arrow-.
– Remove lower transverse link.
Installing
– Install lower transverse link on vehicle and tighten bolts hand
tight.
The transverse link may be bolted only when dimension „a“ has
been attained ⇒ page 131 .

– Bolt upper transverse link to subframe and tighten new nut

-arrow- only to specified torque.
– Observe mark made for position of eccentric bolt -arrow- rel‐
ative to subframe.
– Reinstall rear section of exhaust system.
Vehicles with dynamic headlight range control
– Install bolts -1- in lower transverse link.
Continuation for all vehicles
n AG. Volkswagen AG do
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ho
– Tighten bolt -arrow- for lower transverse link -1-. aut or
ac
ss
– Install coil spring ⇒ page 164 .

ce
le
un

pt
an
d
itte

– Install wheel and tighten bolts or nuts ⇒ page 241 .

y li
rm

ab
pe

– Perform wheel alignment ⇒ page 261 .

ility
ot

wit
, is n

h re
hole

spec
es, in part or in w

t to the co
rrectness of i
l purpos

Specified torques
Component Specified torque
nform
ercia

Lower transverse link to wheel bearing housing 90 Nm + 90°

m

♦ Use new nuts and bolts

com

tion in
r

♦ Tighten threaded connections only when vehicle is in

te o

thi

the normal running position

s
iva

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rp

cum
fo

Lower transverse link to subframe 95 Nm

en
ng

t.
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♦ Tighten threaded connections only when vehicle is in
ht
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the normal running position
co lksw
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3.6 Removing and installing track rod

Special tools and workshop equipment required

3. Assembly overview: subframe, transverse link, track rod (front-wheel drive) 143
 Golf Variant 2007 ➤ , Jetta 2005 ➤
Running gear, axles, steering - Edition 07.2010

♦ Torque wrench -V.A.G 1331-

♦ Torque wrench -V.A.G 1332-

AG. Volkswagen AG d
agen oes
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pt
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Removing
erm

ab
ility
ot p

– Remove wheel.

wit
is n

h re
– Remove coil spring ⇒ page 165 .
ole,

spec
urposes, in part or in wh

– Remove nut -1- and pull coupling rod -2- out of anti-roll bar. t to the co
– Remove bolt -arrow- for track rod -3-.
rrectness o
cial p

f inform
mer

atio
om

n
c

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or

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sd
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– Remove bolts -arrows- for anti-roll bar clamp.

fo

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t.
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cted agen
Prote AG.

144 Rep. gr.42 - Rear suspension

 Golf Variant 2007 ➤ , Jetta 2005 ➤
Running gear, axles, steering - Edition 07.2010

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

– Remove track rod.
Installing
– Install track rod on vehicle and tighten bolts hand tight.

Note

Note different versions of track rods: downwards open or forwards

n AG. Volkswagen AG do
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– Bring rear axle into unladen position ⇒ pagetho129 .
r eo
au ra
c
The transverse link may be bolted only whenss dimension „a“ has

ce
been attained ⇒ page 179 . e
nl

pt
du

an
itte

y li
erm

ab
– Bolt track rod to subframe and tighten new nut to specified

ility
ot p

torque.

wit
, is n

h re
hole

spec
es, in part or in w

t to the co
rrectness of i
l purpos

nf
ercia

orm
m

atio
– Tighten bolts -arrows- for anti-roll bar clamp.
om

n in
or c

thi
te

sd
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f

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Cop py
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– Tighten bolt -arrow- for track rod -3-.

– Connect coupling rod -2- to anti-roll bar and tighten nut -1-.
– Install coil spring ⇒ page 165 .
– Install wheel and tighten bolts or nuts ⇒ page 241 .
– Perform wheel alignment ⇒ page 261 .

3. Assembly overview: subframe, transverse link, track rod (front-wheel drive) 145
 Golf Variant 2007 ➤ , Jetta 2005 ➤
Running gear, axles, steering - Edition 07.2010

Specified torques
Component Specified torque
Track rod to wheel bearing housing 130 Nm + 90°
♦ Use new nuts and bolts
♦ Tighten threaded connections only when vehicle is in
the normal running position

Track rod to subframe 90 Nm + 90°

♦ Use new nuts and bolts

Anti-roll bar to subframe 25 Nm + 45°

♦ Use new bolts
♦ Tighten threaded connections only when vehicle is in
the normal running position

Anti-roll bar to coupling rod 45 Nm

♦ Use new nut

AG. Volkswagen AG d
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pe

ility
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spec
es, in part or in w

t to the co
rrectness of i
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tion in
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te o

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s
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Prote AG.

146 Rep. gr.42 - Rear suspension

 Golf Variant 2007 ➤ , Jetta 2005 ➤
Running gear, axles, steering - Edition 07.2010

4 Assembly overview: wheel bearing housing, trailing arm (front-wheel

drive)

1 - Bolt
❑ 50 Nm + 45° further
❑ Always renew after re‐
moving.
2 - Mounting bracket
3 - Bolt
❑ M12 x 1.5 x 80
❑ 90 Nm + 90° further
❑ Always renew after re‐ AG. Volkswagen AG d
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4 - Coupling rod ris
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❑ Connects anti-roll
au bar to ra
c
ss
trailing arm and wheel

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nl

bearing housing

pt
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5 - Bolt
erm

ab
ility
❑ Observe tightening se‐
ot p

wit
quence ⇒ page 159 .
, is n

h re
❑ 90 Nm + 90° further
hole

spec
❑ Always renew after re‐
es, in part or in w

t to the co
moving.
6 - Trailing arm rrectness of i
❑ Removing and installing
⇒ page 157 .
l purpos

❑ Repairing ⇒ page 161

7 - Bolt
nf
ercia

orm

❑ 8 Nm
m

atio
om

8 - Rear right speed sensor -

n in
or c

G44- / rear left speed sensor -

thi
te

sd
a

G46-
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❑ Can be tested in guided

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f

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fault finding using ⇒ Ve‐

t.
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hicle diagnostic, testing and information system VAS 5051 C py
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❑ Before inserting sensor, clean inner surface of hole and coat with lubricating paste -G 000 650- .
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9 - Wheel bearing housing
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Prote AG.

❑ Removing and installing ⇒ page 148 .

10 - Bonded rubber bush
❑ Renewing ⇒ page 152 .
11 - Nut
❑ 45 Nm
❑ Always renew after removing.
12 - Bolt
❑ 4 Nm
13 - Brake disc
14 - Dust cap
❑ Always renew after removing.
❑ Pressing off and driving in ⇒ page 155

4. Assembly overview: wheel bearing housing, trailing arm (front-wheel drive) 147
 Golf Variant 2007 ➤ , Jetta 2005 ➤
Running gear, axles, steering
agen
AG.-VEdition
olkswage07.2010
n AG d
o w es n
olks ot g
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A proper seal can be rachieved
ise
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only by installing a new grease rancap.
tee
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15 - Bolt au ac
ss

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❑ M16 x 1.5 x 70
nl

pt
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an
❑ 180 Nm + 180° further
itte

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❑ Loosen and tighten with bit XZN 18 -T10162-

ility
ot p

❑ Always renew after removing.

wit
, is n

h re
hole

16 - Wheel hub with wheel bearing

spec
es, in part or in w

❑ The ABS sensor ring is installed in the wheel hub

t to the co
❑ Removing and installing ⇒ page 155 .
The wheel bearing and wheel hub are assembled in one housing.

rrectness of i
This wheel bearing/wheel hub unit is maintenance-free and has zero play. Adjustments and repairs are not
l purpos

possible!

17 - Bolt

nf
ercia

orm
❑ 12 Nm
m

atio
om

18 - Splash plate

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thi
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4.1 Removing and installing wheel bearing
f

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ng

t.
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housing Cop py
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rig ht
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Special tools and workshop equipment required co Vo
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Prote
♦ Torque wrench -V.A.G 1332-
AG.

Removing
– Remove wheel.
– Remove coil spring ⇒ page 164 .
– Remove wheel bearing/wheel hub unit ⇒ page 155 .
– Remove cover plate.
– Remove speed sensor out of wheel bearing housing.

148 Rep. gr.42 - Rear suspension

 Golf Variant 2007 ➤ , Jetta 2005 ➤
Running gear, axles, steering - Edition 07.2010

– Remove bolt -arrow-.

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

– Hold wheel bearing housing and remove bolts -arrows-.

– Remove coupling rod -1- from trailing arm.
Installing

AG. Volkswagen AG d
agen oes
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byV gu
ara
ed
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aut ra
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ce
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pt
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d
itte

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ab
– Install track rod bolt -1-, upper transverse link -2- and lower
pe

transverse link -3-. ility

ot

wit
, is n

– Attach coupling rod -arrow- to wheel bearing housing hand h re

hole

spec
tight.
es, in part or in w

t to the co
rrectness of i
l purpos

nform
mercia

a
com

tion in
r
te o

thi
s
iva

do
r
rp

cum
fo

en
ng

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

4. Assembly overview: wheel bearing housing, trailing arm (front-wheel drive) 149
 Golf Variant 2007 ➤ , Jetta 2005 ➤
Running gear, axles, steering - Edition 07.2010

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 important to keep to the specified sequence for the following
operations.

– Position trailing arm and mounting bracket on wheel bearing

housing using bolts -2- but do not tighten yet.

– Install bolts -arrows- and tighten to prescribed torque.

– Install splash plate.
– Install wheel bearing/wheel hub unit.
– Bring rear axle into unladen position ⇒ page 129 .
The transverse link may be bolted only when dimension
n AG. V „a“ has
olkswagen AG
been attained ⇒ page 179 . wage does
olks not
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db ara
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tho eo
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c
ss
ce
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nl

pt
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an
itte

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– Tighten bolt for track rod -1-.

erm

ab
ility
ot p

– Tighten bolt for lower transverse link -3-.

wit
, is n

h re
hole

spec
es, in part or in w

t to the co
rrectness of i
l purpos

nform
mercia

at
om

ion
c

in t
or

his
ate

do
priv

cum
for

en
ng

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

150 Rep. gr.42 - Rear suspension

 Golf Variant 2007 ➤ , Jetta 2005 ➤
Running gear, axles, steering - Edition 07.2010

– Tighten bolt -1- for upper transverse link.

Note

Washer -2- must be installed so that there is a gap -arrow B- be‐

tween washer and splash plate -3-.

– Tighten bolt -arrow-.

– Install coil spring ⇒ page 165 .
– Install speed sensor in wheel bearing housing.
– Install brake disc.
– Attach brake carrier with brake caliper ⇒ Brake systems; Rep.
gr. 46 .
– Install wheel and tighten bolts or nuts ⇒ page 241 .

Specified torques
Component Specified torque
Upper transverse link to wheel bearing housing 130 Nm + 90°
♦ Use new nuts and bolts n AG. Volkswagen AG ge does
swa
♦ Tighten threaded connectionsbyonly k
Vol when vehicle is in
not
gu
ara
the normal running position
ris
ed
nte
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Wheel bearing housing to
ss lower suspension link c 90 Nm + 90°
ce

♦ Use new nuts and bolts

e
nl

pt
du

an
itte

♦ Tighten threaded connections only when vehicle is in

y li
erm

ab

the normal running position

ility
ot p

wit
, is n

Wheel bearing housing to track rod 130 Nm + 90°

h re

♦ Use new nuts and bolts

hole

spec
es, in part or in w

♦ Tighten threaded connections only when vehicle is in

t to the co

the normal running position

Trailing arm to wheel bearing housing 90 Nm + 45°

rrectness of i

♦ Use new bolts

l purpos

Coupling rod to wheel bearing housing. 45 Nm

♦ Use new nut
nf
ercia

orm

Splash plate to wheel bearing housing 12 Nm

m

atio
om

ABS speed sensor to wheel bearing housing 8 Nm

n in
or c

thi
e

Shock absorber to wheel bearing housing 180 Nm

t

sd
iva

o
r

Brake disc to wheel bearing housing. 4 Nm

rp

cu
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m
f

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ng

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

4. Assembly overview: wheel bearing housing, trailing arm (front-wheel drive) 151
 Golf Variant 2007 ➤ , Jetta 2005 ➤
Running gear, axles, steering - Edition 07.2010

4.2 Renewing bonded rubber bush for wheel bearing housing

Special tools and workshop AG. Volkswagen AG d

equipment required agen oes
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♦ Press tool -30 - 506 B- orise nte
th eo
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♦ Drift sleeve -41-501-
ss a c

ce
le

♦ Sleeve -3160-
un

pt
an
d
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♦ Assembly tool -3301-
erm

ab
ility
ot p

♦ Assembly tool -3346-

wit
is n

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♦ Assembly tool -3350-
ole,

spec
urposes, in part or in wh

t to the co
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cial p

f inform
mer

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c

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te

sd
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pr

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fo

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Cop py
t. rig
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pyri by
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co lksw
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♦ Torque wrench -V.A.G 1332-

Removing
– Remove wheel.
– Remove coil spring ⇒ page 164 .
– Remove wheel bearing/wheel hub unit ⇒ page 155 .

152 Rep. gr.42 - Rear suspension

 Golf Variant 2007 ➤ , Jetta 2005 ➤
Running gear, axles, steering - Edition 07.2010

– Remove cover plate.

– Remove bolt -arrow- for lower transverse link -1-.
Pressing out bonded rubber bush

AG. Volkswagen AG d
agen oes
olksw not
y V gu
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rise nte
tho eo
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– Apply special tools as shown in illustration. ss c

ce
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pt
1- Nut -3346/3-
du

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itte

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erm

2- Thrust piece -3301-

ab
ility
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3- Tube -3301/3-

wit
, is n

h re
4- Drift sleeve -41 - 501-
hole

spec
es, in part or in w

5- Thrust piece -3350/1-

t to the co
6- Spindle -3346/2-
– Pull out bonded rubber bush by tightening spindle.

rrectness of i
Pulling in bonded rubber bush
l purpos

– Apply special tools as shown in illustration.

nf
ercia

or
1- Nut -3346/3-
m
m

atio
om

2- Thrust piece -3301-

n in
or c

thi
e

3- Press tool -30 - 506 B-

t

sd
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cu

4- Bonded rubber bush

o

m
f

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ng

t.
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5- Sleeve -3160-
Co
Cop py
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6- Thrust piece -3350/1-
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7- Spindle -3346/2-
agen
Prote AG.

– Pull in bonded rubber bush by turning spindle.

Note

♦ Do not use lubricant.

♦ Install bonded rubber bush carefully so that it does not cant.

Installing
– Install backplate.
– Install wheel bearing/wheel hub unit.
– Bring rear axle into unladen position ⇒ page 129 .
The transverse link may be bolted only when dimension „a“ has
been attained ⇒ page 179 .

4. Assembly overview: wheel bearing housing, trailing arm (front-wheel drive) 153
 Golf Variant 2007 ➤ , Jetta 2005 ➤
Running gear, axles, steering - Edition 07.2010

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

– Install coil spring ⇒ page 164 .
– Install brake disc.
– Attach brake carrier with brake caliper ⇒ Brake systems; Rep.
gr. 46 .
– Install wheel and tighten bolts or nuts ⇒ page 241 .

Specified torques
Component Specified torque
Wheel bearing housing to lower suspension link 90 Nm + 90°
♦ Use new nuts and bolts
♦ Tighten threaded connections only when vehicle is in
the normal running position

Splash plate to wheel bearing housing 12 Nm

Brake disc to wheel bearing housing. 4 Nm

AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c
ce
e
nl

pt
du

an
itte

y li
erm

ab
ility
ot p

wit
, is n

h re
hole

spec
es, in part or in w

t to the co
rrectness of i
l purpos

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mercia

at
om

ion
c

in t
or

his
ate

do
priv

cum
for

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ng

t.
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Cop py
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cted agen
Prote AG.

154 Rep. gr.42 - Rear suspension

 Golf Variant 2007 ➤ , Jetta 2005 ➤
Running gear, axles, steering - Edition 07.2010

4.3 Removing and installing wheel bearing/wheel hub unit

n AG. Volkswagen AG do
Special tools and workshop lkswage es n
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equipment required d byV ua
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♦ Hub grease cap puller
au -VW
tho
or
ac
637/2- ss

ce
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nl

♦ Fitting sleeve -3241-

pt
du

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itte

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♦ Torque wrench -V.A.G
erm

ab
1332-

ility
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wit
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♦ Torque wrench -V.A.G

h re
hole

1410-

spec
es, in part or in w

♦ Tool insert -T10162-

t to the co
rrectness of i
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mercia

at
om

ion
c

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or

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ate

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priv

cum
for

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ng

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Cop py
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pyri by
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Removing
– Raise vehicle.
– Remove wheel.

4. Assembly overview: wheel bearing housing, trailing arm (front-wheel drive) 155
 Golf Variant 2007 ➤ , Jetta 2005 ➤
Running gear, axles, steering - Edition 07.2010

Loosen grease cap from seat by tapping lightly on the claw of the
hub grease cap puller -VW 637/2- .

n AG. Volkswagen AG do
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a ac
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pt
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erm

ab
ility
ot p

wit
is n

h re
ole,

spec
urposes, in part or in wh

t to the co
rrectne
– Lever off grease cap.

ss o
– Remove brake carrier with brake caliper and tie to body with
cial p

f in
wire ⇒ Brake systems; Rep. gr. 46 .

form
mer

atio
om

n
c

Note
i
or

n thi
te

sd
va

Hang brake caliper from body.

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fo

en
ng

t.
yi
– Remove cross-head screw for brake disc and remove brake
Co
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– Remove multi-point socket head bolt using socket insert -
c by lksw
cted agen
T10162- . Prote AG.

– Pull wheel hub/wheel bearing unit off stub axle.

Installing
– Carefully slide wheel hub/wheel bearing unit onto stub axle.
Ensure that the wheel bearing/wheel hub unit does not cant!
– Use a new multi-point socket head bolt and tighten it.

Note

♦ Always tighten bolt to specified torque using a torque wrench!

♦ Use a rigid spanner to turn bolt further for specified additional
turn.

156 Rep. gr.42 - Rear suspension

 Golf Variant 2007 ➤ , Jetta 2005 ➤
Running gear, axles, steering - Edition 07.2010

– Drive dust cap on with fitting sleeve -3241/4- .

Note

♦ Always renew removed grease caps.

♦ Damaged grease caps may allow moisture to enter the bear‐
ing. Therefore, always use the tool shown in the illustration.

Continue installation in reverse order.

– Install wheel and tighten bolts or nuts ⇒ page 241 .

Specified torques
Component Specified torque
Wheel hub with wheel bearing to wheel bearing housing 180 Nm + 180°
♦ Use new bolt

Brake disc to wheel bearing housing. 4 Nm

4.4 Removing and installing trailing arm with

mounting bracket
Special tools and workshop equipment required
♦ Torque wrench -V.A.G 1332-

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– Remove wheel.
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– Remove coil spring ⇒ page 164 .

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4. Assembly overview: wheel bearing housing, trailing arm (front-wheel drive) 157
 Golf Variant 2007 ➤ , Jetta 2005 ➤
Running gear, axles, steering - Edition 07.2010
n AG. Volkswagen AG do
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– Remove bolt -arrow- securing handbrake cable -1- to trailing y Volks ot g
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– Remove retainer -1- by pushing out inner pin of rivet -arrow-.

rrectness of i
Continuation for all vehicles
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– Unbolt coupling rod -1- from trailing arm. p by
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– Remove bolts -arrows-. Prote AG.

– Mark installation position of mounting bracket on body.

– Remove bolts -arrows-.

– Remove trailing arm with mounting bracket.
If the trailing arm is to be renewed, the mounting bracket must be
removed from the trailing arm.
The position of the mounting bracket relative to the trailing arm
must then be adjusted ⇒ page 158 .
Determining position of mounting bracket in relation to trailing arm

158 Rep. gr.42 - Rear suspension

 Golf Variant 2007 ➤ , Jetta 2005 ➤
Running gear, axles, steering - Edition 07.2010

Dimension -a- is 34 ± 1 mm.

1- Mounting bracket
2- Trailing arm
– Tighten bolt when dimension -a- is set.
Installing
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Threaded connectionyfor V trailing arm and wheel bearing
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may be tightened ionlyed after all other components (particularly
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or
been installed.
ss To tighten, wheel suspension must be in extendedc
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position. Only then do trailing arm and wheel bearing housing

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move to the necessary position -arrows-.

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Position: threaded connection between trailing arm and wheel
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It is important to keep to the specified sequence for the following
hole

spec
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a
com

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– Position trailing arm and mounting bracket on wheel bearing
ion in

housing using bolts -2- but do not tighten yet.

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– Attach coupling rod -3- to trailing arm but do not tighten nut
do
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yet.
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– Raise wheel suspension using engine and gearbox jack -
yi Co
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V.A.G 1383 A- and support -T10149- until mounting bracket . C rig
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– Tighten bolts -arrows- on position of old imprint.

– Lower wheel suspension again using engine and gearbox jack
-V.A.G 1383 A- and remove support -T10149- from wheel hub.

4. Assembly overview: wheel bearing housing, trailing arm (front-wheel drive) 159
 Golf Variant 2007 ➤ , Jetta 2005 ➤
Running gear, axles, steering - Edition 07.2010

– Tighten bolts -2- for trailing arm to specified torque setting,

observing required positions of parts ⇒ page 159 .

– Bolt coupling rod -1- to wheel bearing housing and anti-roll bar.

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– Bolt handbrake cable -1- to
s a trailing arm -2- -arrow-.
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– Attach retainer -1- by pushing in new inner pin of rivet

-arrow-.
nform
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Continuation for all vehicles

m

– Install coil spring ⇒ page 164 .

com

tion in
r

– Install wheel and tighten bolts or nuts ⇒ page 241 .

te o

thi
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– Perform wheel alignment ⇒ page 261 .

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Specified torques
Component Specified torque
Trailing arm to wheel bearing housing 90 Nm + 45°
♦ Use new bolts

Trailing arm to mounting bracket 90 Nm + 90°

♦ Use new bolt

160 Rep. gr.42 - Rear suspension

 Golf Variant 2007 ➤ , Jetta 2005 ➤
Running gear, axles, steering - Edition 07.2010

Component Specified torque

Mounting bracket to body 50 Nm + 45°
♦ Use new bolts

Coupling rod to trailing arm. 45 Nm

♦ Use new nut

Handbrake cable to trailing arm

⇒ Brake systems; Rep. gr. 46

4.5 Repairing trailing arm

Special tools and workshop agen

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♦ Assembly tool -T10230-

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♦ Removal tool -3372-
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Pressing out bonded rubber bush

– Remove trailing arm ⇒ page 157 .

4. Assembly overview: wheel bearing housing, trailing arm (front-wheel drive) 161
 Golf Variant 2007 ➤ , Jetta 2005 ➤
Running gear, axles, steering - Edition 07.2010

– Set up tools as shown in figure.

1- Tube -T10230/3-
2- Thrust piece -T10230/10-
3- Removal tool -3372-
4- Thrust plate -VW 401-
5- Thrust plate -VW 402-
– Press out bonded rubber bush. AG. Volkswagen AG d
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Pressing in bonded rubberdbush by Vo gu
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– Place trailing arm on a flat surface.
es, in part or in w

t to the co
– Position trailing arm on a level surface so that dimension -A-
= 114 mm is attained.

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– Mark a vertical line on bush of trailing arm -arrows-.
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Installation position

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There are two different types of bonded rubber bushes. On both

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– Position bonded rubber bush. pyri by
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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.

162 Rep. gr.42 - Rear suspension

 Golf Variant 2007 ➤ , Jetta 2005 ➤
Running gear, axles, steering - Edition 07.2010

– Set up special tools as shown in figure.

1- Tube -T10230/5-
2- Thrust plate -T10230/12- (chamfer must face bonded rubber
bush)
3- Bonded rubber bush
4- Removal tool -3372- agen
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– Press bonded rubber bush in flush. autho eo
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– Attach mounting bracket to trailing arm ⇒ page 158 .

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– Install trailing arm ⇒ page 159
itte

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es, in part or in w

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4. Assembly overview: wheel bearing housing, trailing arm (front-wheel drive) 163
 Golf Variant 2007 ➤ , Jetta 2005 ➤
Running gear, axles, steering - Edition 07.2010

5 Assembly overview: shock absorber, coil spring

1 - Upper spring seat

2 - Coil spring agen
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⇒ page 275 aut
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❑ Removing and installing

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⇒ page 164 .

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3 - Lower spring seat

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❑ End of coil spring turned

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4 - Bolt

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es, in part or in w

❑ M14 x 1.5 x 70

t to the co
❑ 180 Nm
5 - Bolt

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❑ 50 Nm + 45° further
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❑ Always renew after re‐

moving.

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6 - Shock absorber

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❑ Removing and installing
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⇒ page 166 .
or c

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❑ Note different running

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⇒ page 275 , vehicle
o

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data sticker.
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7 - Lower transverse link
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❑ Removing and installing
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⇒ page 142 . Prote AG.

8 - Wheel bearing housing

❑ Removing and installing
⇒ page 148 .

5.1 Removing and installing coil spring

Special tools and workshop equipment required
♦ Suspension strut clamp -V.A.G 1752-

164 Rep. gr.42 - Rear suspension

 Golf Variant 2007 ➤ , Jetta 2005 ➤
Running gear, axles, steering - Edition 07.2010

♦ Spring retainer -V.A.G 1752/3A-

♦ Adapter -V.A.G 1752/9- , not illustrated

Removing
– Remove wheel.
– Insert spring compressor -3-.

WARNING

Ensure that coil spring is correctly seated in spring retainers -

V.A.G 1752/3A- -2- (accident risk).

– Use a spanner or a reversible ratchet handle to compress

spring compressor.
– Compress coil spring until it can be removed. n AG. Volkswagen AG do
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– Remove spring. byV
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1- Spring retainer -V.A.G 1752/3A- tho tee
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2- Adapter -V.A.G 1752/9- ss

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3- Spring compressor -V.A.G 1752/1-

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Installing

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Note correct installation position.

wit
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hole

End of spring -arrow- must lie against stop on bottom spring seat. spec
es, in part or in w

t to the co
– Install spring together with spring seat.
– The bottom spring seat has a pin.
rrectness of i
l purpos

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at
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c

in t
or

his
ate

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5. Assembly overview: shock absorber, coil spring 165

 Golf Variant 2007 ➤ , Jetta 2005 ➤
Running gear, axles, steering - Edition 07.2010

– Insert this pin in holes in lower transverse link -arrow-.

– Then insert top spring seat into upper end of spring.
– Release tension on spring while locating upper spring seat on
lug on body.
– Remove spring compressor.
– Install wheel and tighten bolts or nuts ⇒ page 241 .

5.2 Removing and installing shock absorb‐

ers
Special tools and workshop equipment required
♦ Torque wrench -V.A.G 1332-

Removing agen
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– Remove wheel. ed by
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– Remove wheel housing liner ⇒auGeneral
th body repairs, exterior; eo
ra
Rep. gr. 66 ; wheel housing sliner .
s c
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nl

pt

– Remove coil spring ⇒ page 164 .

du

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itte

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– Remove bolts -arrows-.

erm

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hole

spec
es, in part or in w

t to the co
rrectness of i
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or c

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166 Rep. gr.42 - Rear suspension

 Golf Variant 2007 ➤ , Jetta 2005 ➤
Running gear, axles, steering - Edition 07.2010

– Remove bolt -arrow-.

– Remove shock absorber.
Installing
Install in reverse order. Note the following points:
– Bring rear axle into unladen position ⇒ page 129 .
The transverse link may be bolted only when dimension „a“ has
been attained ⇒ page 179 .

– Install shock absorber and tighten bolts -arrows-.

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– Tighten bolt -arrow-.

h re
hole

spec
– Install coil spring ⇒ page 164 .
es, in part or in w

t to the co
– Install wheel housing liner ⇒ General body repairs, exterior;
Rep. gr. 66 ; wheel housing liner . rrectness of i
– Install wheel and tighten bolts or nuts ⇒ page 241 .
l purpos

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Specified torques
t

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Component Specified torque

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ng

t.
yi
Shock absorber to body 50 Nm + 45°
Co
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♦ Use new bolts
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Shock absorber to wheel bearing housing cted 180 Nm
agen
Prote AG.

5. Assembly overview: shock absorber, coil spring 167

 Golf Variant 2007 ➤ , Jetta 2005 ➤
Running gear, axles, steering - Edition 07.2010

5.3 Repairing shock absorber

1 - Shock absorber
❑ Removing and installing
⇒ page 166 .
❑ Note different running
gear versions
⇒ page 275 , vehicle
data sticker.
2 - Protective cap
3 - Protective tube
4 - Support ring
❑ Allocation ⇒ Electronic
parts catalogue „ETKA“
5 - Bump stop
❑ For shock absorbers
with support ring
⇒ Item 4 (page 168)
❑ Allocation ⇒ Electronic
parts catalogue „ETKA“
6 - Shock absorber mounting
❑ For shock absorbers
with support ring
⇒ Item 4 (page 168)
❑ Allocation ⇒ Electronic
parts catalogue „ETKA“
7 - Nut AG. Volkswagen AG d
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❑ M10 x 1.0 ed by
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❑ 25 Nm ut
hor eo
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❑ Always renew after re‐ ss c
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❑ Loosening and tighten‐

itte

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ing ⇒ page 169

erm

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ility
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8 - Cover
wit
is n

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ole,

9 - Shock absorber mounting

spec
urposes, in part or in wh

❑ For shock absorbers without support ring ⇒ Item 4 (page 168)

t to the co

❑ Allocation ⇒ Electronic parts catalogue „ETKA“

10 - Bump stop
rrectne

❑ For shock absorbers without support ring ⇒ Item 4 (page 168)

❑ Allocation ⇒ Electronic parts catalogue „ETKA“
ss o
cial p

f inform
mer

Special tools and workshop equipment required

atio
om

n
c

i
or

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te

sd
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168 Rep. gr.42 - Rear suspension

 Golf Variant 2007 ➤ , Jetta 2005 ➤
Running gear, axles, steering - Edition 07.2010
n AG. Volkswagen AG do
lkswage es n
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♦ Torque wrench -V.A.G 1332- d byV ua
ran
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rrectness of i
♦ Shock absorber set -T10001-
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at
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c

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or

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do
priv

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for

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Dismantling and assembling
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Loosening and tightening threaded connection for shock absorb‐

er mounting
1- Commercially available ratchet handle
2- Socket -T10001/9-
3- Ratchet handle -T10001/11-
4- Socket -T10001/1-

Specified torque
Component Specified torque
Shock absorber mounting to shock absorber 25 Nm
♦ Use new nut

5. Assembly overview: shock absorber, coil spring 169

 Golf Variant 2007 ➤ , Jetta 2005 ➤
Running gear, axles, steering - Edition 07.2010

6 Assembly overview: anti-roll bar

The -arrow- points forwards.
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1 - Anti-roll bar ed byV gu
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⇒ page 275

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❑ Removing and installing

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⇒ page 170 .
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2 - Mounting
ot

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❑ Always renew mount‐

h re
hole

ings/bushes on both

spec
sides of vehicle
es, in part or in w

t to the co
3 - Clamp
4 - Bolt

rrectness of i
❑ 25 Nm + 45° further
l purpos

❑ Tighten evenly.
❑ Always renew after re‐

nform
ercia

moving.
❑ Always tighten threaded
m

a
com

ti
connections in unladen

on in
position ⇒ page 129
r
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thi
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5 - Wheel bearing housing

do
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6 - Nut

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7 - Multi-point socket head bolt
❑ Self-locking
❑ Always renew after re‐
moving.
8 - Coupling rod
❑ Connects anti-roll bar to
trailing arm and wheel bearing housing
9 - Subframe

6.1 Removing and installing anti-roll bar

Special tools and workshop equipment required

170 Rep. gr.42 - Rear suspension

 Golf Variant 2007 ➤ , Jetta 2005 ➤
Running gear, axles, steering - Edition 07.2010

♦ Torque wrench -V.A.G 1331-

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The following procedure is for the left side of the vehicle. The
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procedure for the right side of the vehicle is identical.
ot p

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– Remove nut -1- and pull coupling rod -2- out of anti-roll bar.

spec
urposes, in part or in wh

t to the co
Note

Do not loosen bolt -arrow- for track rod -3-.

rrectness o
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atio
om

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– Remove bolts -arrows- for anti-roll bar clamp.

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– Remove anti-roll bar.

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– Install anti-roll bar in vehicle. op Vo
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– Evenly tighten bolts -arrows- for anti-roll bar clamp.

6. Assembly overview: anti-roll bar 171

 AG. Volkswagen AG d
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V gu
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Golf Variant 2007 ➤ , Jetta 2005 ➤ orise nte
h eo
Running gear, axles, steering - Edition 07.2010 aut ra
c
ss

ce
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– Connect coupling rod -2- to anti-roll bar and tighten nut -1-.

un

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Specified torques l purpos

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Component Specified torque

a
com

tion in
Anti-roll bar to subframe 25 Nm + 45°
r
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♦ Use new bolts

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♦ Tighten threaded connections only when vehicle is in

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the normal running position

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172 Rep. gr.42 - Rear suspension

 Golf Variant 2007 ➤ , Jetta 2005 ➤
Running gear, axles, steering - Edition 07.2010

7 Assembly overview: attachments parts for subframe Jetta BlueMotion,

Golf Variant BlueMotion (front-wheel drive)

1 - Subframe
2 - Bolt
3 - Bracket
❑ With pop rivet bolt
4 - Nut
❑ 20 Nm
5 - Right shield
❑ Tighten nuts to 2 Nm
❑ Removing and installing
⇒ page 174
❑ During installation,
shield must be hooked
on the subframe from
below
⇒ Item 1 (page 173)
-arrow A- and engaged
above -arrow B-
6 - Bracket
❑ With pop rivet bolt

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7. Assembly overview: attachments parts for subframe Jetta BlueMotion, Golf Variant BlueMotion (front-wheel drive) 173
 Golf Variant 2007 ➤ , Jetta 2005 ➤
Running gear, axles, steering - Edition 07.2010

7.1 Removing and installing shield

Removing
– Remove nuts -1-.
– Pull shield -2- downwards off the subframe and detach above
at the same time -arrow-.
Installing

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– Hook shield into bottom part of subframe -arrow- and swivel in

h re
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-direction of arrow- so that it engages into upper part of sub‐

spec
urposes, in part or in wh

frame.

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174 Rep. gr.42 - Rear suspension

 Golf Variant 2007 ➤ , Jetta 2005 ➤
Running gear, axles, steering - Edition 07.2010

– Tighten nuts -1-.

Note

After installing shield check again whether the shield lug has en‐
gaged properly in subframe -arrow-.

Specified torques
Component Nm
Shield to subframe 2 Nm

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7. Assembly overview: attachments parts for subframe Jetta BlueMotion, Golf Variant BlueMotion (front-wheel drive) 175
 Golf Variant 2007 ➤ , Jetta 2005 ➤
Running gear, axles, steering - Edition 07.2010

8 Repairing rear suspension (four-

wheel drive)

8.1 Overview - rear axle

Note

♦ It is not permitted to weld or straighten load-bearing or wheel-guiding components of the suspension.

♦ Always renew self-locking nuts.
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♦ Always renew corroded nuts
Vol and bolts.
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♦ Bonded rubber bushesoris can be twisted only to a limited extent.anTherefore,
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⇒ page 178 . ss c

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I - Assembly overview: sub‐
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frame, final drive (four-wheel
ole,

drive) ⇒ page 180

spec
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t to the co
II - Assembly overview: trans‐
verse link, track rod (four-
wheel drive) ⇒ page 193
rrectness o
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176 Rep. gr.42 - Rear suspension

 Golf Variant 2007 ➤ , Jetta 2005 ➤
Running gear, axles, steering - Edition 07.2010

III - Assembly overview: wheel

bearing housing, trailing arm
(four-wheel drive)
⇒ page 204
IV - Assembly overview: shock
absorber, coil spring (four-
wheel drive) ⇒ page 218 AG. Volkswagen AG d
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8. Repairing rear suspension (four-wheel drive) 177

 n AG. Volkswagen AG do
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Running gear, axles, steering - Edition 07.2010 rised ran
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♦ Engine and gearbox jack -

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V.A.G 1383 A-

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♦ Tensioning strap -T10038-

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♦ Support -T10149-

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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).

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) position
before being tightened.
Otherwise, the bonded rubber bush would be subject to torsion
loading, shortening its service life.
To simulate this position on the lifting platform, raise the axle on
one side using the engine and gearbox jack -V.A.G 1383 A- and
support -T10149- .

178 Rep. gr.42 - Rear suspension

 Golf Variant 2007 ➤ , Jetta 2005 ➤
Running gear, axles, steering - Edition 07.2010

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

WARNING

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

vehicle will slip off the lifting platform!

– Turn wheel hub until one of the wheel bolt holes is at the top.
– 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-

The dimension -a- depends on the ride height of the installed run‐
ning gear:
Running gear for Golf Variant Ride height -a- in mm
from 2008 1)
olkswagen AG
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hole

spec

here ⇒ page 275 .

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– Raise wheel bearing housing using engine and gearbox jack

until dimension -a- is attained.
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WARNING
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gearbox jack is positioned beneath the vehicle.
nform
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♦ Do not leave the engine and gearbox jack under the ve‐
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– Remove support -T10149- .
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8. Repairing rear suspension (four-wheel drive) 179

 Golf Variant 2007 ➤ , Jetta 2005 ➤
Running gear, axles, steering - Edition 07.2010

9 Assembly overview: subframe, final drive wa(four-wheel drive)

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t to the co
❑ Removing and installing
⇒ Rep. gr. 39 ; Remov‐
ing and installing rear fi‐

rrectness of i
nal drive
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5 - Bolt
❑ M12 x 105

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❑ 60 Nm + 90° further
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bonded rubber bush.
8 - Bolt
❑ M12 x 105
❑ 60 Nm + 90° further
❑ Always renew after re‐
moving.

9.1 Removing and installing rear axle

Special tools and workshop equipment required
♦ Torque wrench -V.A.G 1332-

180 Rep. gr.42 - Rear suspension

 Golf Variant 2007 ➤ , Jetta 2005 ➤
Running gear, axles, steering - Edition 07.2010

♦ Engine and gearbox jack -V.A.G 1383 A-

Removing subframe with attachments

Note

Note that subsequent assembly work in which the twelve-point

bolt of the drive shaft has to be loosened has to be carried out
with the vehicle standing on its wheels. Loosen twelve-point bolt
for drive shaft ⇒ page 229 .

– Remove wheels.
– Remove coil springs ⇒ page
agen
A218
G. Vo.lkswagen AG d
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– Remove rear silencerby
V
of exhaust system ⇒ Rep. gr.
t gu
a26
ran ; Ex‐
ed
haust system;
hor Removing and installing parts of the exhaust
is tee
system . aut or
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– Disconnect electrical connections between rear axle and
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body.
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– Remove bolt -arrow-.

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9. Assembly overview: subframe, final drive (four-wheel drive) 181

 Golf Variant 2007 ➤ , Jetta 2005 ➤
Running gear, axles, steering - Edition 07.2010

– Remove retainer -1- by pushing out inner pin of rivet -arrow-.

– Mark installation position of mounting bracket on body.

– Remove bolts -arrows-.
– Disconnect connector for rear left vehicle level sender -G76- .

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

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– Unbolt rear propshaft tube with flexible coupling and vibration

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damper from rear final drive -arrows-.

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182
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Rep. gr.42 - Rear suspension Prote AG.
 Golf Variant 2007 ➤ , Jetta 2005 ➤
Running gear, axles, steering - Edition 07.2010

– Unscrew centre bearing bolts -arrows- two turns.

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es, in part or in w
– Support propshaft -A- on tunnel support -1- using a wooden

t to the co
block.
– Push rear propshaft tube towards gearbox as far as possible.

rrectness of i
– Disconnect Haldex coupling connector above final drive.
l purpos

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n

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

the vehicle will slip off the lifting platform!

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

frame using universal gearbox mounting -V.A.G 1359/2- and
secure with tensioning strap.

9. Assembly overview: subframe, final drive (four-wheel drive) 183

 Golf Variant 2007 ➤ , Jetta 2005 ➤
Running gear, axles, steering - Edition 07.2010

To fix position of subframe, locating pins -T10096- must be

screwed in successively at positions -1- and -2- on both sides of
vehicle.
– Unscrew one hexagon bolt -1- or -2- on both sides.

Note

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

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

tighten to 20 Nm.

Note
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The locating pins -T10096- may be
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en AG onlyentoAGadmaximum
oes
of 20 Nm; otherwise the threads
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– Replace subframe
bolts on both sides one after the
s securing ce
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other with locating pins -T10096- and tighten to 20 Nm.

un

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The position of the subframe is now fixed.
erm

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– Carefully lower subframe with attachments about 2 cm.

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– Unclip brake lines on both sides -arrow-.

spec
urposes, in part or in wh

t to the co

Note
rrectne

The clips will be destroyed and must be renewed.

ss o
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Prote AG.

184 Rep. gr.42 - Rear suspension

 Golf Variant 2007 ➤ , Jetta 2005 ➤
Running gear, axles, steering - Edition 07.2010

– Unclip brake line from clips -arrows- above drive shaft flange
on gearbox -1-.

Note

The clips will be destroyed and must be renewed.

– Carefully lower subframe with attachments.

Note

When lowering, ensure sufficient clearance of brake lines, elec‐

trical cables and centring pin to propshaft.
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Installing subframe with attachments lksw
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Install in reverse order. In the process, note ise the following:
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♦ Make sure that the plate between wheel bearing housing and
erm

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shock absorber is also installed.

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♦ Renew the damaged brake line clips on the subframe.

h re
hole

spec
Attach propshaft to rear final drive ⇒ Final drive 02D/0AV; Rep.
es, in part or in w

t to the co
gr. 39 ; Removing and installing propshaft .

Specified torques

rrectness of i
Component Specified torque
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Subframe to body 90 Nm + 90° further

♦ Use new bolts

nf
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Shock absorber to wheel bearing housing 180 Nm

atio
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Mounting bracket to body 50 Nm + 45° further
or c

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9. Assembly overview: subframe, final drive (four-wheel drive) 185

 Golf Variant 2007 ➤ , Jetta 2005 ➤
Running gear, axles, steering - Edition 07.2010

9.2 Repairing subframe swage

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

spec
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♦ Hydraulic press -VAS
6178- and thrust piece -
T10205/13-

rrectness of i
♦ Foot pump -VAS 6179-
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Pulling out front bonded rubber bush ⇒ page 186

Pulling in front bonded rubber bush ⇒ page 188
Pulling out rear bonded rubber bush ⇒ page 189
Pulling in rear bonded rubber bush ⇒ page 191
Pulling out front bonded rubber bush
– Remove rear wheels.
– Remove coil springs ⇒ page 218 .
– Remove rear silencer of exhaust system ⇒ Rep. gr. 26 ; Ex‐
haust system; Removing and installing parts of the exhaust
system .
– Disconnect electrical connections between rear axle and
body.
– Remove anti-roll bar ⇒ page 225 .
– Remove track rods ⇒ page 201 .

186 Rep. gr.42 - Rear suspension

 Golf Variant 2007 ➤ , Jetta 2005 ➤
Running gear, axles, steering - Edition 07.2010

– Remove clip -1-.

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

h re
hole

hicle using tensioning straps -T10038- .

spec
es, in part or in w

t to the co
WARNING

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

rrectness of i
the vehicle will slip off the lifting platform!
l purpos

nf
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orm
m

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

t

sd
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sal gearbox support -V.A.G 1359/2- beneath subframe and

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secure with strap.
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– Unscrew one hexagon bolt -1- or -2- on both sides.

Note

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

To fix position of subframe, locating pins -T10096- must be

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

9. Assembly overview: subframe, final drive (four-wheel drive) 187

 Golf Variant 2007 ➤ , Jetta 2005 ➤
Running gear, axles, steering - Edition 07.2010

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

tighten to 20 Nm.

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 subframe securing bolts on both sides one after the

other with locating pins -T10096- and tighten to 20 Nm.
The position of the subframe is now fixed.
– Lower subframe 10 cm using engine and gearbox jack -V.A.G
1383 A- .
– Mark installation position of bonded rubber bush relative to
subframe using e.g. a felt tip pen.

– Set up special tools as shown in figure.

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5 - Nut -T10263/5-

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– Pull out bonded rubber bush by actuating pump.
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Note

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The outer ring of the bush shears off when the bonded rubber
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nform
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– The bonded rubber bush must be removed from the tube -

m

T10356/6- once the bush has been pulled out.

a
com

tion in

– Clamp tube -T10356/6- on the intended surfaces in a vice.

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– Insert a screwdriver between tube -T10356/6- and bonded

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Pulling in front bonded rubber bush
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Install in reverse order. In the process, note the following:
cop Vo
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Prote AG.

188 Rep. gr.42 - Rear suspension

 Golf Variant 2007 ➤ , Jetta 2005 ➤
Running gear, axles, steering - Edition 07.2010

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.

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2 - Thrust piece -T10263/3-

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an
itte

3 - Bonded rubber bush

y li
erm

ab
ility
4 - Thrust piece -T10263/2-
ot p

wit
, is n

5 - Hydraulic press -VAS 6178- and thrust piece -T10205/13-

h re
hole

spec
6 - Nut -T10263/5-
es, in part or in w

t to the co
7 - Spindle -T10263/4-
– Take up play in special tools and bonded rubber bush.

rrectness of i
– Operate pump to carefully pull bonded rubber bush in until
l purpos

collar lies »flush« on subframe.

– Install track rods ⇒ page 201 .
nform
ercia

– Install anti-roll bar ⇒ page 225 .

m

at
om

– Join electrical connections between rear axle and body.

on
c

in t
or

– Install rear silencer of exhaust system ⇒ Rep. gr. 26 ; Exhaust

his
ate

system; Removing and installing parts of the exhaust system .

do
priv

cum
or

– Install coil springs ⇒ page 218 .

f

en
ng

t.
yi Co
op
– Fit rear wheels.
C py
t. rig
gh ht
yri by
Pulling out rear bonded rubber bush cop Vo
by lksw
cted agen
Prote AG.
– Remove rear wheels.
– Remove coil springs ⇒ page 218 .
– Remove rear silencer of exhaust system ⇒ Rep. gr. 26 ; Ex‐
haust system; Removing and installing parts of the exhaust
system .

9. Assembly overview: subframe, final drive (four-wheel drive) 189

 Golf Variant 2007 ➤ , Jetta 2005 ➤
Running gear, axles, steering - Edition 07.2010

– Remove clip -1-.

Note

Do not open brake line.

AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c

ce
e
nl

pt
du

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

an
itte

y li
hicle using tensioning straps -T10038- .
erm

ab
ility
ot p

wit
, is n

WARNING

h re
hole

spec
If the vehicle is not strapped down, there is a great danger that
es, in part or in w

the vehicle will slip off the lifting platform!

t to the co
rrectness of i
l purpos

nform
ercia

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

sal gearbox support -V.A.G 1359/2- beneath subframe and
m

at
om

secure with strap.

ion
c

in t
or

his
ate

do
priv

cum
for

en
ng

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

– Unscrew one hexagon bolt -1- or -2- on both sides.

Note

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

To fix position of subframe, locating pins -T10096- must be

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

190 Rep. gr.42 - Rear suspension

 Golf Variant 2007 ➤ , Jetta 2005 ➤
Running gear, axles, steering - Edition 07.2010

– Fix position of subframe using 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 subframe securing bolts on both asides

gen AGone after n
. Volkswagethe
AG do
es n
other with locating pins -T10096- andolksw
tighten to 20 Nm. ot g
yV u b ara
ed
The position of the subframe is now
tho
ris fixed. nte
e or
au ac
– Lower subframe 10 cm using
ss engine and gearbox jack -V.A.G

ce
1383 A- .
le
un

pt
an
d
itte

– Mark installation position of bonded rubber bush relative to

y li
erm

ab
subframe using e.g. a felt tip pen.

ility
ot p

wit
is n

– Set up special tools as shown in figure.

h re
ole,

spec
1 - Nut -T10263/5-
urposes, in part or in wh

t to the co
2 - Washer , from -T10263-
3 - Tube -T10263/6-

rrectne
4 - Hydraulic press -VAS 6178- and thrust piece -T10205/13-

s
5 - Nut -T10263/5-

s o
cial p

f
6 - Spindle -T10263/4-

inform
mer

– Take up play in special tools.

atio
om

n
– Pull out bonded rubber bush by actuating pump.
c

i
or

n thi
te

sd
iva

o
pr

Note
um
r
fo

en
ng

t.
yi Co
op
The outer ring of the bush shears off when the bonded rubber C py
t. rig
bush is pulled out. This occurs with a loud bang.
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
– The bonded rubber bush must be removed from the tube -
T10356/6- once the bush has been pulled out.
– Clamp tube -T10356/6- on the intended surfaces in a vice.
– Insert a screwdriver between tube -T10356/6- and bonded
rubber bush and lever bush out of tube -arrow-. If necessary,
apply a drift to bush and drive out with light hammer blows.
Pulling in rear bonded rubber bush
Install in reverse order. In the process, note the following:

9. Assembly overview: subframe, final drive (four-wheel drive) 191

 Golf Variant 2007 ➤ , Jetta 2005 ➤
Running gear, axles, steering - Edition 07.2010

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. AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c

ce
le
un

pt
an
d
itte

y li
erm

ab
ility
ot p

wit
is n

h re
ole,

– Set up special tools with bonded rubber bush on subframe as

spec
urposes, in part or in wh

shown.

t to the co
1 - Nut -T10263/5-
2 - Thrust piece -T10263/3-

rrectne
3 - Bonded rubber bush

s
4 - Thrust piece -T10263/2-

s o
cial p

f in
5 - Hydraulic press -VAS 6178- and thrust piece -T10205/13-

form
mer

6 - Nut -T10263/5-

atio
om

n
c

7 - Spindle -T10263/4-

i
or

n thi
te

sd
a

– Take up play in special tools and bonded rubber bush.

iv

o
pr

cum
r
fo

– Operate pump to carefully pull bonded rubber bush in until

en
ng

t.
collar lies »flush« on subframe.
yi Co
Cop py
t. rig
– Install rear silencer of exhaust system ⇒ Rep. gr. 26 ; Exhaust
gh ht
pyri by
system; Removing and installing parts of the exhaust system .
co Vo
by lksw
cted agen
Prote AG.
– Install coil springs ⇒ page 218 .
– Fit rear wheels.

Specified torques
Component Specified torque
Subframe to body 90 Nm + 90° further
♦ Use new bolts

192 Rep. gr.42 - Rear suspension

 Golf Variant 2007 ➤ , Jetta 2005 ➤
Running gear, axles, steering - Edition 07.2010

10 Assembly overview: transverse link, track rod (four-wheel drive)

-Arrow- indicates direction of travel.

1 - Eccentric bolt
❑ Check wheel alignment
whenever this compo‐
nent is loosened
⇒ page 261 .
❑ 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
❑ Always renew after re‐
moving.
❑ Always tighten threaded
connections in unladen
position ⇒ page 178
. Volkswagen AG
gen AG does
3 - Eccentric washer Volkswa not
by gu
❑ Inner hole with
ris
ed lug
ara
nte
tho eo
4 - Eccentric boltau ra
c
ss
❑ Check wheel alignment
ce
le
un

pt

whenever this compo‐

an
d
itte

nent is loosened
y li
rm

ab

⇒ page 261 .
pe

ility
ot

❑ Do not turn more than

wit
, is n

90° in either direction

h re
hole

(i.e. from minimum to

spec

maximum adjustment
es, in part or in w

t to the co

position).
5 - Eccentric washer
rrectness of i

❑ Inner hole with lug

l purpos

6 - Nut
❑ M12 x 1.5
nform
ercia

❑ 95 Nm
m

❑ Self-locking
a
com

tio

❑ Can be loosened and tightened up to 5 times for adjustment work

n in
r
te o

thi

❑ Always renew after removing.

s
iva

do
r

❑ Always tighten threaded connections in unladen position ⇒ page 178

rp

cum
fo

en
ng

t.
yi Co
Note t. Cop py
rig
gh ht
pyri by
Vo
o
7 - Subframe
by c lksw
cted agen
Prote AG.
8 - Bolt
❑ M12 x 1.5 x 125
❑ 90 Nm + 90° further

10. Assembly overview: transverse link, track rod (four-wheel drive) 193
 Golf Variant 2007 ➤ , Jetta 2005 ➤
Running gear, axles, steering - Edition 07.2010
❑ Always renew after removing.
9 - Lower transverse link
❑ Removing and installing ⇒ page 199 .
10 - Nut
❑ 90 Nm + 90° further
❑ Self-locking
❑ Always renew after removing.
❑ Always tighten threaded connections in unladen position ⇒ page 178
11 - Bolt
❑ M12 x 1.5 x 75
❑ Always renew after removing.
12 - Threaded rivet
❑ M6
AG. Volkswagen AG d
13 - Spreader rivet agen oes
olksw not
byV gu
ara
d
14 - Stone deflector
orise nte
h eo
ut ra
15 - Hexagon
ss a bolt c ce
le

❑ M6 x 12
un

pt
an
d

❑ 8 Nm
itte

y li
erm

ab

16 - Nut
ility
ot p

wit

❑ Self-locking
is n

h re
ole,

❑ Always renew after removing.

spec
urposes, in part or in wh

❑ Always tighten threaded connections in unladen position ⇒ page 178

t to the co

17 - Washer
18 - Bolt
rrectne

❑ M14 x 1.5 x 115

s

❑ 130 Nm + 90° further

s o
cial p

❑ Always renew after removing.

inform

❑ Always tighten threaded connections in unladen position ⇒ page 178

mer

atio
m

19 - Washer
o

n
c

i
or

n thi

20 - Upper transverse link

te

sd
va

❑ Removing and installing ⇒ page 197 .

i

o
pr

cum
r
fo

en
ng

21 - Washer
t.
yi Co
Cop py
22 - Nut ht. rig
rig ht
py by
❑ Self-locking co Vo
by lksw
cted agen
❑ Always renew after removing.
Prote AG.

23 - Wheel bearing housing

❑ Removing and installing ⇒ page 205 .
❑ Installing with wheel bearing housings made from cast steel is permissible ⇒ Electronic parts catalogue
„ETKA“
24 - Washer
25 - Bolt
❑ M14 x 1.5 x 115
❑ 130 Nm + 90° further
❑ Always renew after removing.
❑ Always tighten threaded connections in unladen position ⇒ page 178

194 Rep. gr.42 - Rear suspension

 Golf Variant 2007 ➤ , Jetta 2005 ➤
Running gear, axles, steering - Edition 07.2010

26 - Track rod
❑ Various versions
♦ Forwards closed (left and right track rods differ)
♦ Downwards open (left and right track rods
AG. Videntical)
olkswagen AG
agen does
ksw
❑ It is permitted to install mixedy V types.
ol not
gu
edb ara
❑ Allocation ⇒ Electronic horis parts catalogue „ETKA“ nte
eo
ut
❑ Removing and installing
ss a ⇒ page 201 . ra
c

ce
e

27 - Bolt
nl

pt
du

an
itte

❑ M12 x 1.5 x 125

y li
erm

ab
❑ 90 Nm + 90° further

ility
ot p

wit
❑ Always renew after removing.
, is n

h re
hole

28 - Bolt

spec
es, in part or in w

❑ M12 x 1.5 x 95

t to the co
❑ Always renew after removing.
❑ Always tighten threaded connections in unladen position ⇒ page 178

rrectness of i
29 - Nut
l purpos

❑ 90 Nm + 90° further
❑ Self-locking

nform
ercia

❑ Always renew after removing.

m

at
om

ion
c

in t
or

his
ate

do
priv

cum
for

en
ng

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

10. Assembly overview: transverse link, track rod (four-wheel drive) 195
 AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
e nte
Golf Variant 2007 ➤ , Jetta 2005 ➤ horis
eo
ut
Running gear, axles, steering - Edition 07.2010ss a ra
c

ce
e
nl

pt
du
10.1 Overview - rear left vehicle level sender -G76-

an
itte

y li
erm

ab
ility
ot p

wit
Note

, is n

h re
hole

spec
♦ The vehicle level sender is available as a replacement part only complete with coupling rod and upper and

es, in part or in w
lower retaining plates.

t to the co
♦ Renewing without removing subframe ⇒ page 196 .
♦ Control unit for headlight range control -J431-

rrectness of i
l purpos
1 - Subframe

nf
ercia

o
2 - Lower transverse link

rm
m

atio
m
3 - Bolt
o

n in
or c

❑ M5 x 20

thi
te

sd
iva

❑ 5 Nm

o
r
rp

cu
o

m
f

4 - Rear left vehicle level send‐

en
ng
t.
yi
er -G76-
Co
Cop py
t. rig
❑ Complete with attach‐
gh ht
yri by
ments
op Vo
by c lksw
cted agen
❑ Lever -arrow- must face
Prote AG.

outwards
❑ Renewing in vehicle
⇒ page 196
❑ Following renewal, ba‐
sic settings for headlight
must be performed.
Basic setting of headlights ⇒
"Guided fault-finding" function
of vehicle diagnostic, testing
and information system
VAS 5051

10.2 Renew vehicle level sender in vehicle

Special tools and workshop equipment required

196 Rep. gr.42 - Rear suspension

 Golf Variant 2007 ➤ , Jetta 2005 ➤
Running gear, axles, steering - Edition 07.2010

♦ Torque wrench -V.A.G 1410-

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

ce
le

– Separate connection -1-.

un

pt
an
d
itte

– Remove bolts -2- from lower transverse link.

y li
rm

ab
pe

ility
– Remove bolts -arrows- from subframe.
ot

wit
, is n

– Remove rear left vehicle level sender -G76- .

h re
hole

spec
Installing
es, in part or in w

t to the co
Install in reverse order. Note the following points:
The lever of rear left vehicle level sender -G76- must face outside

rrectness of i
of vehicle.
l purpos

– Following renewal, carry out basic setting of headlights ⇒

"Guided fault-finding" function of vehicle diagnostic, testing
and information system VAS 5051 .
nform
mercia

Specified torques
com

tion in
r

Component Specified torque

te o

thi
s
iva

do

Rear left vehicle level sender -G76- to lower transverse link 5 Nm

r
rp

cum

and subframe
fo

en
ng

t.
yi Co
Cop py
ht. rig
rig ht
py by
10.3 Removing and installing upper trans‐
co Vo
by lksw
cted agen
Prote
verse link
AG.

Special tools and workshop equipment required

♦ Torque wrench -V.A.G 1332-

Removing
– Remove wheel.
– Remove coil spring ⇒ page 218 .

10. Assembly overview: transverse link, track rod (four-wheel drive) 197
 Golf Variant 2007 ➤ , Jetta 2005 ➤
Running gear, axles, steering - Edition 07.2010

– Unhook speed sensor line -arrow A- from upper transverse

link.
– Remove bolt -1-.

– Mark position of eccentric bolt -arrow-olrelative to subframe us‐

. V kswagen AG
ing e.g. a felt tip pen. swa
gen AG does
k not
Vol gu
– Remove bolt -arrow-.
se
db
y ara
nte
i
th or eo
– Remove upper
au transverse link -1-. ra
c
ss
Installing

ce
e
nl

pt
du

an
itte

– Install upper transverse link on vehicle and tighten bolts hand

y li
erm

ab
tight.

ility
ot p

The transverse link may be bolted only when dimension „a“ has

wit
, is n

been attained ⇒ page 179 .

h re
hole

spec
es, in part or in w

t to the co
– Bolt upper transverse link -1- to subframe and tighten new nut
-arrow-.
rrectness of i

– Observe mark made for position of eccentric bolt -arrow- rel‐

ative to subframe.
l purpos

nf
ercia

orm
m

atio
om

n in
or c

thi
te

sd
iva

o
r
rp

cu
o

m
f

en
ng

t.
yi Co
– Tighten bolt -1- for upper transverse link. t. Cop py
rig
gh ht
pyri by
Vo
o
by c lksw
Note cted agen
Prote AG.

Ensure that a washer is installed between the bolt and the wheel
bearing housing.

– Attach speed sensor line -arrow A- from upper transverse link.

– Install coil spring ⇒ page 218 .
– Install wheel and tighten bolts or nuts ⇒ page 241 .
– Perform wheel alignment ⇒ page 261 .

Specified torques
Component Specified torque
Upper transverse link to wheel bearing housing 130 Nm + 90° further
♦ Use new nuts and bolts
♦ Tighten threaded connections only when vehicle is in
the normal running position

198 Rep. gr.42 - Rear suspension

 Golf Variant 2007 ➤ , Jetta 2005 ➤
Running gear, axles, steering - Edition 07.2010

Component Specified torque

Upper transverse link to subframe 95 Nm
♦ Use new nut ♦ To tighten nuts, set torque wrench -V.A.G
1332- to 80 Nm.
♦ Tighten threaded connections only when vehicle is in
the normal running position ♦ Applies only in conjunction with insert tool,
18 mm -T10179-

10.4 Removing and installing lower trans‐

verse link
Special tools and workshop equipment required
♦ Torque wrench -V.A.G 1332-

AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c
ce
le
un

pt
an
d
itte

y li
rm

ab
pe

ility
ot

wit
, is n

h re
hole

Removing
spec
es, in part or in w

– Remove wheel.
t to the co

– Remove coil spring ⇒ page 218 .

rrectness of i

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

Vehicles with dynamic headlight range control
l purpos

nform
mercia

a
com

tion in
r
te o

thi
s
iva

do
r
rp

cum
fo

en
ng

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

10. Assembly overview: transverse link, track rod (four-wheel drive) 199
 . Volkswage
Golf Variant 2007 wag➤
en,AJetta
G
2005 n➤AG does n
olks ot g
Running dgear,
by
V axles, steering - Edition 07.2010 ua
r
e an
ris tee
ho
– Removes abolts
ut
-1- from lower transverse link. or
ac
s
Continuation for all vehicles

ce
e
nl

pt
du

an
itte

– Mark position of eccentric bolt -arrow- relative to subframe us‐

y li
erm

ab
ing e.g. a felt tip pen.

ility
ot p

wit
– Disconnect and lower rear part of exhaust system.
, is n

h re
hole

– Remove bolt -arrow-.

spec
es, in part or in w

– Remove lower transverse link.

t to the co
Installing

rrectness of i
– Install lower transverse link on vehicle and tighten bolts hand
tight.
l purpos

The transverse link may be bolted only when dimension „a“ has
been attained ⇒ page 179 .

nform
mercia

– Bolt upper transverse link to subframe and tighten new nut

at
om

io
-arrow- only to specified torque.

n
c

in t
or

his
e

– Observe mark made for position of eccentric bolt -arrow- rel‐

at

do
riv

ative to subframe.
p

cum
for

– Reinstall rear section of exhaust system.

en
ng

t.
yi Co
op py
Vehicles with dynamic headlight range control
. C rig
ht ht
rig by
py
– Install bolts -1- in lower transverse link.
co Vo
by lksw
cted agen
Prote AG.
Continuation for all vehicles

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

– Install coil spring ⇒ page 218 .
– Install wheel and tighten bolts or nuts ⇒ page 241 .
– Perform wheel alignment ⇒ page 261 .

Specified torques
Component Specified torque
Lower transverse link to wheel bearing housing 90 Nm + 90° further
♦ Use new nuts and bolts
♦ Tighten threaded connections only when vehicle is in
the normal running position

Lower transverse link to subframe 95 Nm

♦ Use new nut
♦ Tighten threaded connections only when vehicle is in
the normal running position

200 Rep. gr.42 - Rear suspension

 Golf Variant 2007 ➤ , Jetta 2005 ➤
Running gear, axles, steering - Edition 07.2010

10.5 Removing and installing track rod

Special tools and workshop equipment required
♦ Torque wrench -V.A.G 1331-

♦ Torque wrench -V.A.G 1332-

Removing
n AG. Volkswagen AG do
– Remove wheel. lkswage es n
o ot g
byV ua
d ran
– Remove coil spring ⇒ page 218 o
ir se. tee
th or
u
– Remove nut -1- and pull coupling
ss
a rod -2- out of anti-roll bar. ac
ce
le

– Remove bolt -arrow- for track rod -3-.

un

pt
an
d
itte

y li
erm

ab
ility
ot p

wit
is n

h re
ole,

spec
urposes, in part or in wh

t to the co
rrectnes

– Remove bolts -arrows- for anti-roll bar clamp.

s o
cial p

If the upper bolt of the anti-roll bar clamp on the right side of the
inform

vehicle cannot be removed, then additional work must be per‐

mer

formed ⇒ page 201 .

atio
om

n
c

For the right side of the vehicle only (depending on equipment)

i
or

n thi
te

sd
iva

o
pr

cum
r
fo

en
ng

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

10. Assembly overview: transverse link, track rod (four-wheel drive) 201
 Golf Variant 2007 ➤ , Jetta 2005 ➤
Running gear, axles, steering - Edition 07.2010

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

hicle using tensioning straps -T10038- .

WARNING

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

the vehicle will slip off the lifting platform!

– Attach support -T10149- to wheel hub using wheel bolt.

– 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 nut -arrow- and remove bolt towards rear.

AG. Volkswagen AG d
– Remove track rod -1-. agen oes
olksw not
y V gu
b ara
Installing orise
d
nte
th eo
u
– Install track rod on vehicle and tighten bolts shand
sa tight. ra
c

ce
e
nl

pt
du

an
itte

Note

y li
erm

ab
ility
ot p

Note different versions of track rods: downwards open or forwards

wit
, is n

closed.
h re
hole

spec
es, in part or in w

The track rod may be bolted only when dimension „a“ has been t to the co
attained ⇒ page 179 .

– Bolt track rod -1- to subframe and tighten new nut -arrow-.
rrectness of i
l purpos

nf
ercia

orm
m

atio
om

n in
or c

thi
te

sd
iva

o
r
rp

cu
o

m
f

en
ng

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

202 Rep. gr.42 - Rear suspension

 Golf Variant 2007 ➤ , Jetta 2005 ➤
Running gear, axles, steering - Edition 07.2010

– Tighten bolts -arrows- for anti-roll bar clamp.

For the right side of the vehicle only (depending on equipment)
– 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- .
Continuation for both sides of vehicle:

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– Tighten
au bolt -arrow- for track rod -3-.
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Ensure that a washer is installed between the nut and the wheel

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bearing housing.

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– Connect coupling rod -2- to anti-roll bar and tighten nut -1-.
es, in part or in w

t to the co
– Install coil spring ⇒ page 218 .
– Install wheel and tighten bolts or nuts ⇒ page 241 .
– Perform wheel alignment ⇒ page 261 . rrectness of i
l purpos

Specified torques
nform
ercia

Component Specified torque

m

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

com

tion in

♦ Use new nuts and bolts

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te o

thi

♦ Tighten threaded connections only when vehicle is in

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Track rod to subframe 90 Nm + 90° further
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Anti-roll bar to subframe cted
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♦ Use new bolts
♦ Tighten threaded connections only when vehicle is in
the normal running position

Anti-roll bar to coupling rod 45 Nm

♦ Use new nut

10. Assembly overview: transverse link, track rod (four-wheel drive) 203
 Golf Variant 2007 ➤ , Jetta 2005 ➤
Running gear, axles, steering - Edition 07.2010

11 Assembly overview: wheel bearing housing, trailing arm (four-wheel

drive)
-Arrow- indicates direction of travel.

1 - Mounting bracket
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❑ 90 Nm + 90° further s

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4 - Coupling rod
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❑ Connects anti-roll bar to

h re
trailing arm and wheel
hole

spec
bearing housing
es, in part or in w

t to the co
5 - Bolt
❑ 90 Nm + 45° further

rrectness of i
❑ Observe tightening se‐
quence ⇒ page 207
l purpos

❑ Always renew after re‐

moving. nform
ercia

6 - Trailing arm
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❑ Removing and installing

ion in

⇒ page 211 .
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❑ Repairing ⇒ page 215

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7 - Drive shaft
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8 - Multi-point socket head bolt

❑ M14 x 1.5 x 45
❑ 70 Nm + 90° further
❑ Always renew after re‐
moving.
9 - Wheel bearing housing
❑ Removing and installing ⇒ page 205 .
10 - Rear right speed sensor -G44- / rear left speed sensor -G46-
❑ Can be checked in guided fault finding of the vehicle diagnostic, testing and information system -VAS
5051-
❑ Before inserting sensor, clean inner surface of hole and coat with lubricating paste -G 000 650- .
11 - Hexagon socket head bolt
❑ M6 x 16
❑ 8 Nm
12 - Bonded rubber bush
❑ Renewing ⇒ page 208 .
13 - Nut
❑ M12 x 25
❑ 45 Nm

204 Rep. gr.42 - Rear suspension

 Golf Variant 2007 ➤ , Jetta 2005 ➤
Running gear, axles, steering - Edition 07.2010
❑ Self-locking
❑ Always renew after removing.
14 - Bolt
❑ M10 x 35
❑ 50 Nm + 45° further
❑ Always renew after removing.
15 - Bolt
❑ 4 Nm
16 - Brake disc
17 - Bolt
❑ 70 Nm + 90° further
❑ Loosening and tightening ⇒ page 229
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18 - Wheel hub with wheel bearing
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❑ The ABS sensor ring is installed in the wheel hub

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❑ Removing and installing ⇒ page 210 .
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The wheel bearing and wheel hub are assembled in one housing. wit
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This wheel bearing/wheel hub unit is maintenance free and has no play. Adjustments and repairs are not
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t to the co

19 - Bolt
❑ M6 x 12
rrectness of i

❑ 12 Nm
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20 - Splash plate
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21 - Bonded rubber bush

❑ Renewing ⇒ page 161 .
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11.1 Removing and installing wheel bearing

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Special tools and workshop equipment required
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♦ Torque wrench -V.A.G 1332-
co Vo
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Removing
– Remove coil spring ⇒ page 218 .
– Loosen outer threaded connection for drive shaft
⇒ page 229 .

11. Assembly overview: wheel bearing housing, trailing arm (four-wheel drive) 205
 Golf Variant 2007 ➤ , Jetta 2005 ➤
Running gear, axles, steering - Edition 07.2010

– Remove wheel.
– Remove brake carrier with brake caliper and tie to body with
wire ⇒ Rep. gr. 46 .
– Remove ABS speed sensor from wheel bearing housing.
– Remove bolt -arrow-.

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

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es, in part or in w

t to the co
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nform
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– Remove bolt for track rod -1-, upper transverse link -2- and
lower transverse link -3- from wheel housing -4-.
m

at
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ion
c

– Unbolt coupling rod from wheel bearing housing -arrow-.

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or

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ate

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– Remove coupling rod -1- from trailing arm.

– Hold wheel bearing housing and unscrew bolts -arrows-.
– Take out wheel bearing housing.
Installing
Carry out installation in the reverse sequence, noting the follow‐
ing:

Note

Ensure that a plate/washer is installed between the track rod, up‐

per control arm, shock absorber and wheel bearing housing
respectively.

206 Rep. gr.42 - Rear suspension

 AG. Volkswagen AG d
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Golf Variant 2007 ➤ , Jetta 2005 ➤
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Running
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utho or
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Position: threaded
ss connection between trailing arm and wheel c
bearing housing

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Threaded connection for trailing arm and wheel bearing housing

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may be tightened only after all other components (particularly the

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been installed. To tighten, wheel suspension must be in extended
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position. Only then do trailing arm and wheel bearing housing
hole

spec
move to the necessary position -arrows-.
es, in part or in w

t to the co
– Install coil spring ⇒ page 218 .
It is important to keep to the specified sequence for the following
operations.

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

but do not tighten yet.

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– Attach coupling rod -1- to trailing arm but do not tighten nut

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– Lower wheel suspension again using engine and gearbox jack

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-V.A.G 1383 A- and remove support -T10149- from wheel hub.

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– Tighten trailing arm bolts -arrows- to specified torque, ensur‐
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ing that components are positioned as required ⇒ page 207 .

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– Bolt coupling rod -1- to wheel bearing housing and anti-roll bar.
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tightened only when the dimension between the centre of wheel
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hub and lower edge of wheel housing has been attained

⇒ page 179 .
– Attach brake carrier with brake caliper ⇒ Brake systems; Rep.
gr. 46 .
– Install wheel and tighten bolts or nuts ⇒ page 241 .

Specified torques
Component Specified torque
Upper transverse link to wheel bearing housing 130 Nm + 90° further
♦ Use new nuts and bolts
♦ Tighten threaded connections only when vehicle is in
the normal running position

Wheel bearing housing to lower suspension link 90 Nm + 90° further

♦ Use new nuts and bolts
♦ Tighten threaded connections only when vehicle is in
the normal running position

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

♦ Use new nuts and bolts
♦ Tighten threaded connections only when vehicle is in
the normal running position

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

♦ Use new bolts

Coupling rod to wheel bearing housing. 45 Nm

♦ Use new nut

Splash plate to wheel bearing housing 12 Nm

ABS speed sensor to wheel bearing housing 8 Nm
Shock absorber to wheel bearing housing 180 Nm
Brake disc to wheel bearing housing. 4 Nm

11. Assembly overview: wheel bearing housing, trailing arm (four-wheel drive) 207
 AG. Volkswagen AG d
Golf Variant 2007 ➤ , Jetta 2005 ➤ olkswagen oes
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Running gear, axles, steering -eEdition 07.2010 gu
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Component ss
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Drive shaft to hub 70 Nm + 90° further

un

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♦ Use new bolt

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11.2 Renewing bonded rubber bush for wheel bearing housing

spec
urposes, in part or in wh

t to the co
Special tools and workshop
equipment required

rrectne
♦ Press tool -30 - 506 B-

s
♦ Drift sleeve -41 - 501-

s o
cial p

f i
♦ Sleeve -3160-

nform
mer

♦ Assembly tool -3301-

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♦ Assembly tool -3346-

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♦ Assembly tool -3350-

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♦ Torque wrench -V.A.G 1332-

208 Rep. gr.42 - Rear suspension

 Golf Variant 2007 ➤ , Jetta 2005 ➤
Running gear, axles, steering - Edition 07.2010

Removing
– Remove wheel.
– Remove coil spring ⇒ page 218 .
– Remove brake carrier with brake caliper and tie to body with
wire ⇒ Rep. gr. 46 .

Note

Hang brake caliper from body.

– Remove cross-head screw for brake disc and remove brake

disc.
– Remove cover plate.
– Remove bolt -arrow-
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d link -1-.
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Pressing out
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es, in part or in w

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– Attach tools as shown in figure.

1 - -3346/3-
rrectness of i

2 - -3301-
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3 - -3301/3-
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4 - -41-501-
orm
m

atio

5 - -3350/1-
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6 - -3346/2-
thi
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– Pull out bonded rubber bush by tightening spindle.

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Pulling in bonded rubber bush

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11. Assembly overview: wheel bearing housing, trailing arm (four-wheel drive) 209
 Golf Variant 2007 ➤ , Jetta 2005 ➤
Running gear, axles, steering - Edition 07.2010

– Attach tools as shown in figure.

1 - -3346/3-
2 - -3301-
3 - -30-506 B-
4 - Bonded rubber bush
5 - -3160-
6 - -3350/2-
7 - -3346/2-
– Pull in bonded rubber bush by turning spindle.

Note

♦ Do not use lubricant.

♦ Install bonded rubber bush carefully so that it does not cant.
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Carry out installation in the reverse sequence,
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The threaded connections on the wheel bearing housing may be

un

pt
tightened only when the dimension measured between the centre

an
d
itte

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of wheel hub and lower edge of wheel housing before work was
erm

ab
started has been attained ⇒ page 179 .

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wit
is n

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Specified torques
ole,

spec
urposes, in part or in wh

Component Specified torque

t to the co
Wheel bearing housing to lower suspension link 90 Nm + 90°
♦ Use new nuts and bolts rrectne
♦ Tighten threaded connections only when vehicle is in
the normal running position
ss o
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Splash plate to wheel bearing housing 10 Nm

inform

Brake disc to wheel bearing housing. 4 Nm

mer

atio
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n
c

i
or

n thi
te

11.3 Removing and installing wheel bearing/

sd
iva

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wheel hub unit

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Special tools and workshop equipment required C py
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♦ Torque wrench -V.A.G 1332- cop Vo
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210 Rep. gr.42 - Rear suspension

 Golf Variant 2007 ➤ , Jetta 2005 ➤
Running gear, axles, steering - Edition 07.2010

♦ Torque wrench -V.A.G 1410-

Removing
– Remove coil spring ⇒ page 218 .
– Remove drive shaft ⇒ page 230 .
– Remove brake carrier with brake caliper and tie to body with
wire ⇒ Rep. gr. 46 .

Note

Do not suspend the brake caliper from the brake hose.

– Remove bolt for brake disc and remove brake disc.

– Remove bolts -2-.
– Pull wheel hub/wheel bearing unit out from wheel bearing
housing.
Installing
Carry out installation in the reverse sequence,Gnoting the follow‐
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– Use new bolt and tighten ⇒ ispage
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itte

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Specified torques
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wit
is n

Component Specified torque

h re
ole,

Wheel hub with wheel bearing to wheel bearing housing 70 Nm + 90° further
spec
urposes, in part or in wh

♦ Use new bolt

t to the co

Brake disc to wheel bearing housing. 4 Nm

rrectne

11.4 Removing and installing trailing arm with

ss o
cial p

mounting bracket
inform
mer

Special tools and workshop equipment required

atio
om

n
c

i
or

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te

sd
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fo

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t.
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11. Assembly overview: wheel bearing housing, trailing arm (four-wheel drive) 211
 Golf Variant 2007 ➤ , Jetta 2005 ➤
Running gear, axles, steering - Edition 07.2010

♦ Torque wrench -V.A.G 1332-

Removing
– Remove wheel.
– Remove coil spring ⇒ page 218 .
– Remove retainer -1- by pushing out inner pin of rivet -arrow-.

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– Unbolt coupling rod -1- from trailing arm. ut ho eo
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– Remove bolts -arrows-. ce
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pt
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– Mark installation position of mounting bracket on body. an

itte

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erm

ab
ility
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wit
, is n

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hole

spec
es, in part or in w

t to the co
rrectness of i

– Remove bolts -arrows-.

l purpos

– Remove trailing arm with mounting bracket.

nform
ercia

If the trailing arm is to be renewed, the mounting bracket must be

removed from the longitudinal member.
m

at
om

ion
c

The position of the mounting bracket must then be adjusted in

in t
or

relation to the trailing arm.

his
ate

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Prote AG.

212 Rep. gr.42 - Rear suspension

 Golf Variant 2007 ➤ , Jetta 2005 ➤
Running gear, axles, steering - Edition 07.2010

Determining position of mounting bracket in relation to trailing arm

Dimension -a- is 34 mm.wagen AG. Volkswagen AG does
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1 - Mounting bracket
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2 - Trailingaarm
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– Tighten bolt when dimension -a- is set.

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Installing
itte

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pe

Carry out installation in the reverse sequence, noting the follow‐

ility
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ing:

wit
, is n

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Threaded connection for trailing arm and wheel bearing housing
hole

spec
may be tightened only after all other components (particularly the
es, in part or in w

spring and shock absorber) of respective wheel suspension have

t to the co
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-.

rrectness of i
– Install coil spring ⇒ page 164 .
l purpos

Position: threaded connection between trailing arm and wheel

nform
ercia

bearing housing
m

a
It is important to keep to the specified sequence for the following
com

tion in
operations.
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thi
s
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cum
fo

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ng

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– Position trailing arm and mounting bracket on wheel bearing

housing using bolts -2- but do not tighten yet.
– Attach coupling rod -3- to trailing arm but do not tighten nut
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- on position of old imprint.

– Lower wheel suspension again using engine and gearbox jack
-V.A.G 1383 A- and remove support -T10149- from wheel hub.

11. Assembly overview: wheel bearing housing, trailing arm (four-wheel drive) 213
 Golf Variant 2007 ➤ , Jetta 2005 ➤
Running gear, axles, steering - Edition 07.2010

– Tighten bolts -2- for trailing arm to specified torque setting,

observing required positions of parts ⇒ page 213 .

– Bolt coupling rod -1- to wheel bearing housing and anti-roll bar.

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– Attach retainer -1- by pushing in new inner pin of rivet

pt
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an
-arrow-.
itte

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erm

ab
After installation, toe setting must be checked on wheel alignment

ility
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unit.

wit
, is n

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– Perform wheel alignment ⇒ page 261 .
hole

spec
es, in part or in w

t to the co
rrectness of i
l purpos

Specified torques
nf
ercia

orm
m

Component Specified torque

atio
om

n in
c

Trailing arm to wheel bearing housing 90 Nm + 90°

or

thi
e

♦ Use new bolts

t

sd
iva

o
r
rp

cu
o

Trailing arm to mounting bracket 90 Nm + 90°

m
f

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ng

t.
♦ Use new bolt Cop
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Mounting bracket to body 50 Nm + 45°
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♦ Use new bolts
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Coupling rod to trailing arm. 45 Nm

♦ Use new nut

Handbrake cable to trailing arm

⇒ Brake systems; Rep. gr. 46

214 Rep. gr.42 - Rear suspension

 AG. Volkswagen AG d
agen oes
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gu Golf Variant 2007 ➤ , Jetta 2005 ➤
Vol
by ara
d
orise Running gear,nteaxles, steering - Edition 07.2010
eo
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11.5 Repairing trailing arm
s

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nl

pt
du

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itte

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ab
Special tools and workshop

ility
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equipment required

wit
, is n

h re
♦ Assembly tool -T10230-
hole

spec
♦ Removal tool -3372-
es, in part or in w

t to the co
♦ Thrust plate -VW 401-
♦ Thrust plate -VW 402-

rrectness of i
l purpos

nf
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orm
m

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thi
te

sd
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Pressing out bonded rubber bush

– Remove trailing arm ⇒ page 211 .

11. Assembly overview: wheel bearing housing, trailing arm (four-wheel drive) 215
 Golf Variant 2007 ➤ , Jetta 2005 ➤
Running gear, axles, steering - Edition 07.2010

– Set up tools as shown in figure.

1- Tube -T10230/3-
2- Thrust piece -T10230/10-
3- Removal tool -3372-
4- Thrust plate -VW 401-
5- Thrust plate -VW 402-
– Press out bonded rubber bush.
Pressing in bonded rubber bush
– Place trailing arm on a flat surface.
– Mark a vertical line on trailing arm bush.

Dimension -A- = 114 mm

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There are two different types of bonded rubber bushes. On both

un

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an
d

types, the marked line must be between the projections -1- after
itte

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being pressed in.

erm

ab
ility
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is n

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ole,

spec
urposes, in part or in wh

t to the co
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f inform
mer

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c

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te

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t.
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Prote AG.

216 Rep. gr.42 - Rear suspension

 Golf Variant 2007 ➤ , Jetta 2005 ➤
Running gear, axles, steering - Edition 07.2010

– Set up tools as shown in figure.

1- Tube -T10230/5-
2- Thrust plate -T10230/12- (chamfer must face bonded rubber
bush)
3- Bonded rubber bush
4- Removal tool -3372-
5- Thrust plate -VW 402-
– Press bonded rubber bush in flush.
– Attach mounting bracket to trailing arm ⇒ page 213 .
– Install trailing arm ⇒ page 211 .

AG. Volkswagen AG d
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es, in part or in w

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or

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ate

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for

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Cop py
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rig ht
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cted agen
Prote AG.

11. Assembly overview: wheel bearing housing, trailing arm (four-wheel drive) 217
 Golf Variant 2007 ➤ , Jetta 2005 ➤
Running gear, axles, steering - Edition 07.2010

12 Assembly overview: shock absorber, coil spring (four-wheel drive)

1 - Lower spring seat

❑ End of coil spring turned
to stop
2 - Assembly aid n AG. Volkswagen AG do
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❑ Not necessary to rein‐ olks es n
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3 - Coil spring aut or
ac
ss
❑ Note different running

ce
le
un
gear versions

pt
an
d
itte

⇒ page 275 , vehicle

y li
rm

ab
data sticker.
pe

ility
❑ Removing and installing
ot

wit
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⇒ page 218 .

h re
hole

spec
4 - Upper spring seat
es, in part or in w

t to the co
5 - Bolt
❑ M14 x 1.5 x 70

rrectness of i
❑ 180 Nm
l purpos

6 - Bolt
❑ M10 x 35

nform
ercia

❑ 50 Nm + 45° further
❑ Always renew after re‐
m

a
com

ti
moving.

on in
r
te o

thi
7 - Shock absorber

s
iva

do
❑ Removing and installing
r
rp

cum
⇒ page 220 .
fo

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t.
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❑ Repairing ⇒ page 222
Co
Cop py
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❑ Note different running
gh ht
yri by
gear versions cop Vo
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cted
⇒ page 275 , vehicle
agen
Prote AG.
data sticker.
8 - Washer
9 - Lower transverse link
❑ Removing and installing ⇒ page 199 .
10 - Wheel bearing housing
❑ Removing and installing ⇒ page 205 .

12.1 Removing and installing coil spring

Special tools and workshop equipment required

218 Rep. gr.42 - Rear suspension

 Golf Variant 2007 ➤ , Jetta 2005 ➤
Running gear, axles, steering - Edition 07.2010

♦ Suspension strut clamp -V.A.G 1752-

AG. Volkswagen AG d
agen oes
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♦ Spring retainer -V.A.G 1752/4-
hole

spec
es, in part or in w

t to the co
rrectness of i
l purpos

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mercia

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tion in
r
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thi
s
iva

♦ Adapter -V.A.G 1752/9- , not illustrated

do
r
rp

cum
fo

Removing

en
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op
– Remove wheel.
C py
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gh ht
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– Insert spring compressor -3-. cop Vo
by lksw
cted agen
Prote AG.

WARNING

Make sure coil spring is properly seated in spring retainer -

V.A.G 1752/4- (risk of accident).

– Use a spanner or a reversible ratchet handle to compress

spring compressor.
– Compress coil spring until it can be removed.
– Remove spring.
1- Adapter -V.A.G 1752/9-
2- Bracket -V.A.G 1752/4-
3- Spring compressor -V.A.G 1752/1-
Installing
Carry out installation in the reverse sequence, noting the follow‐
ing:

12. Assembly overview: shock absorber, coil spring (four-wheel drive) 219
 Golf Variant 2007 ➤ , Jetta 2005 ➤
Running gear, axles, steering - Edition 07.2010

End of spring -arrow- must lie against stop on bottom

gen AG
spring
. Volkswseat.
agen AG
a does
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– Install spring together with spring seat.
db
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– The bottom spring seat has a upin.
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spec
urposes, in part or in wh

t to the co
– Insert this pin in holes in lower transverse link -arrows-.
– Then insert top spring seat into upper end of spring.

rrectne
– Release tension from spring. When doing so, locate upper
spring seat onto lug on body.

ss o
cial p

f
– Install wheel and tighten bolts or nuts ⇒ page 241 .

inform
mer

atio
om

n
c

i
or

n thi
te

sd
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pr

cum
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fo

en
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t.
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op
12.2 Removing and installing shock absorb‐
C py
ht. rig
rig ht
ers
py by
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by lksw
cted agen
Prote AG.
Special tools and workshop equipment required
♦ Torque wrench -V.A.G 1332-

Removing
– Remove wheel.
– Remove wheel housing liner ⇒ General body repairs, exterior;
Rep. gr. 66 .
– Remove coil spring ⇒ page 218 .

220 Rep. gr.42 - Rear suspension

 Golf Variant 2007 ➤ , Jetta 2005 ➤
Running gear, axles, steering - Edition 07.2010

– Remove bolts -arrows-.

– Remove bolt -arrow-.

– Remove shock absorber.
Installing
Install in reverse order. Note the following points:
The shock absorber may be bolted to the wheel bearing housing
only when dimension „a“ has been attained ⇒ page 179 .

– Install shock absorber and tighten bolts -arrows-.

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pt
du

an

– Tighten bolt -arrow-.

itte

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ab
ility
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wit

Note
, is n

h re
hole

spec

Make sure that the plate between wheel bearing housing and
es, in part or in w

shock absorber is also installed.

t to the co

– Install coil spring ⇒ page 218 .

rrectness of i

– Install wheel housing liner ⇒ General body repairs, exterior;

l purpos

Rep. gr. 66 .
– Install wheel and tighten bolts or nuts ⇒ page 241 .
nform
ercia

Specified torques
m

at
om

ion
c

Component Specified torque

in t
or

his
ate

Shock absorber to body 50 Nm + 45° further

do
priv

♦ Use new bolts

um
for

en
ng

t.
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Shock absorber to wheel bearing housing ht. Cop
180 Nm py
rig
rig ht
py by
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by lksw
cted agen
Prote AG.

12. Assembly overview: shock absorber, coil spring (four-wheel drive) 221
 Golf Variant 2007 ➤ , Jetta 2005 ➤ . Volkswagen AG
Running gear, axles, steering - Edition gen AG
wa07.2010 does
olks no t gu
yV
db ara
rise nte
tho eo
s au ra
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12.3 Repairing shock absorber
s

ce
le
un

pt
an
d
Special tools and workshop equipment required

itte

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rm

ab
♦ Torque wrench -V.A.G 1332- pe

ility
ot

wit
, is n

h re
hole

spec
es, in part or in w

t to the co
rrectness of i
l purpos

nform
mercia

a
com

tio
♦ Shock absorber set -T10001-

n in
r
te o

thi
s
iva

do
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rp

cum
fo

en
ng

t.
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Cop py
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gh ht
pyri by
Vo
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by
cted agen
Prote AG.

222 Rep. gr.42 - Rear suspension

 AG. Volkswagen AG d
agen oes
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e nte
horis
eo Golf Variant 2007 ➤ , Jetta 2005 ➤
ut
ss a Running ra
c gear, axles, steering - Edition 07.2010

ce
e
nl

pt
1 - Shock absorber
du

an
itte

y li
❑ Removing and installing
erm

ab
⇒ page 220 .

ility
ot p

wit
❑ Note different running
, is n

h re
gear versions
hole

spec
⇒ page 275 , vehicle
es, in part or in w

data sticker.

t to the co
2 - Protective cap
3 - Protective tube

rrectness of i
4 - Support ring
l purpos

❑ Allocation ⇒ Electronic
parts catalogue „ETKA“

nform
ercia

5 - Bump stop
m

at
om

i
❑ For shock absorbers

on
c

in t
with support ring
or

his
e

⇒ Item 4 (page 223)

at

do
priv

c
❑ Allocation ⇒ Electronic

um
for

parts catalogue „ETKA“

en
ng

t.
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op
6 - Shock absorber mounting
C py
t. rig
gh ht
yri
❑ For shock absorbers
p by
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with support ring Prote
cted AG.
agen
⇒ Item 4 (page 168)
❑ Allocation ⇒ Electronic
parts catalogue „ETKA“
7 - Nut
❑ M10 x 1.0
❑ 25 Nm
❑ Always renew after re‐
moving.
❑ Loosening and tighten‐
ing ⇒ page 224
8 - Cover
9 - Shock absorber mounting
❑ For shock absorbers without support ring ⇒ Item 4 (page 168)
❑ Allocation ⇒ Electronic parts catalogue „ETKA“
10 - Bump stop
❑ For shock absorbers without support ring ⇒ Item 4 (page 168)
❑ Allocation ⇒ Electronic parts catalogue „ETKA“

12. Assembly overview: shock absorber, coil spring (four-wheel drive) 223
 Golf Variant 2007 ➤ , Jetta 2005 ➤
Running gear, axles, steering - Edition 07.2010

Loosening and tightening threaded connection for shock absorb‐

er mounting
1 - Commercially available ratchet handle
2 - Socket -T10001/9-
3 - Ratchet handle -T10001/11-
4 - Socket -T10001/1-

AG. Volkswagen AG d
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nl

pt
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itte

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erm

ab
ility
ot p

wit
, is n

h re
hole

spec
es, in part or in w

t to the co
rrectness of i
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nf
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orm
m

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n in
or c

thi
te

sd
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t.
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Cop py
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gh ht
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Vo
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by
cted agen
Prote AG.

224 Rep. gr.42 - Rear suspension

 Golf Variant 2007 ➤ , Jetta 2005 ➤
Running gear, axles, steering - Edition 07.2010

13 Assembly overview: anti-roll bar (four-wheel drive)

-Arrow- indicates direction of travel.

1 - Anti-roll bar
❑ Note different running
gear versions
⇒ page 275 , vehicle
data sticker.
❑ Removing and installing n AG. Volkswagen AG do
⇒ page 225 . olks
wage es n
o V t gu
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2 - Mounting ris
ed nte
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❑ Always renewautmount‐ ra
c
ings/bushessson both

ce
le

sides of vehicle
un

pt
an
d
itte

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3 - Clamp
erm

ab
ility
ot p

4 - Multi-point socket head bolt

wit
is n

❑ M8 x 28

h re
ole,

❑ 25 Nm + 45° further

spec
urposes, in part or in wh

❑ Always renew after re‐

t to the co
moving.
5 - Wheel bearing housing

rrectne
6 - Nut

s
❑ 45 Nm

s o
cial p

f
❑ Self-locking
inform
❑ Always renew after re‐
mer

moving.
atio
om

n
c

7 - Multi-point socket head bolt

i
or

n thi
te

sd

❑ Always renew after re‐

iva

o
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moving.
p

cum
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en
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8 - Coupling rod
t.
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Cop py
❑ Connects anti-roll bar to
t. rig
gh ht
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trailing arm and wheel p by
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bearing housing Prote
cted AG.
agen

9 - Subframe

13.1 Removing and installing anti-roll bar

Special tools and workshop equipment required
♦ Torque wrench -V.A.G 1331-

13. Assembly overview: anti-roll bar (four-wheel drive) 225

 Golf Variant 2007 ➤ , Jetta 2005 ➤
Running gear, axles, steering - Edition 07.2010

Removing AG. Volkswagen AG d

agen oes
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– Remove rear wheels. d by
V gu
ara
ise nte
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h
aut ra
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Note s

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pt
du

an
The following procedure is for the left side of the vehicle. The

itte

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erm
procedure for the right side of the vehicle is identical.

ab
ility
ot p

wit
, is n
– Remove nut -1- and pull coupling rod -2- out of anti-roll bar.

h re
hole

spec
es, in part or in w

Note

t to the co
Do not loosen bolt -arrow- for track rod -3-.

rrectness of i
l purpos

nf
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orm
m

atio
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n in
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thi
– Remove bolts -arrows- for anti-roll bar clamp.
te

sd
iva

o
r

If the upper bolt of the anti-roll bar clamp on the right side of the
rp

cu
o

m
vehicle cannot be removed, then additional work must be per‐
f

en
ng

t.
yi
formed ⇒ page 226 .
Co
Cop py
t. rig
gh
For the right side of the vehicle only (depending on equipment)
ht
pyri by
Vo
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by c lksw
cted agen
Prote AG.

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

hicle using tensioning straps -T10038- .

WARNING

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

the vehicle will slip off the lifting platform!

– Attach support -T10149- to wheel hub using wheel bolt.

– 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.

226 Rep. gr.42 - Rear suspension

 Golf Variant 2007 ➤ , Jetta 2005 ➤
Running gear, axles, steering - Edition 07.2010

– Evenly tighten bolts -arrows- for anti-roll bar clamp.

For the right side of the vehicle only (depending on equipment)
– 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- .
Continuation for both sides of vehicle:

– Connect coupling rod -2- to anti-roll bar and tighten nut -1-.
– Install wheel and tighten. ⇒ page 241

Specified torques
n AG. Volkswagen AG do
Component olkswage es nSpecified torque
ot g
byV u
Anti-roll bar to subframe ir se
d 25 Nmar+ant45° further
♦ Use new bolts ut
ho ee
or
a ac
ss
♦ Tighten threaded connections only when vehicle is in
ce
e
nl

the normal running position

pt
du

an
itte

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Anti-roll bar to coupling rod 45 Nm ab

ility
ot p

♦ Use new nut wit

, is n

h re
hole

spec
es, in part or in w

t to the co
rrectness of i
l purpos

nf
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orm
m

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n in
or c

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te

sd
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f

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ng

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

13. Assembly overview: anti-roll bar (four-wheel drive) 227

 Golf Variant 2007 ➤ , Jetta 2005 ➤
Running gear, axles, steering - Edition 07.2010

14 Assembly overview: drive shaft

1 - Outer constant velocity joint

❑ Renew only as com‐
plete unit
❑ Removing ⇒ page 234 .
❑ Installing: drive onto
shaft to stop using a
plastic mallet
2 - Bolt
❑ 70 Nm + 90° further
❑ Always renew after re‐
moving. AG. Volkswagen AG d
agen oes
ksw
When bolt is loosened or tight‐ by
Vol not
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ara
ened, vehicle must not be rised
nte
standing on its wheels ut
ho eo
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3 - Drive shaft

ce
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un

pt
an
❑ Allocation ⇒ Electronic
d
itte

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parts catalogue „ETKA“
erm

ab
ility
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4 - Clamp

wit
is n

h re
❑ Always renew after re‐
ole,

moving.

spec
urposes, in part or in wh

❑ Tightening ⇒ page 236

t to the co
5 - Boot
❑ Check for splits and

rrectne
chafing
❑ Material: Hytrel (poly‐

ss
ester elastomer)

o
cial p

f in
6 - Clamp

form
mer

❑ Always renew after re‐ atio

m

moving.
o

n
c

i
or

❑ Tightening ⇒ page 236

thi
te

sd
iva

o
r

7 - Dished spring
p

cum
r
fo

en
ng

❑ With inner splines yi

t.
Co
op
❑ Installation position ⇒ page 235 .
C py
t. rig
gh ht
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8 - Retaining ring
op Vo
by c lksw
cted agen
❑ Always renew after removing. Prote AG.

❑ Insert in groove in shaft

9 - Boot for constant velocity joint
❑ Material: Hytrel (polyester elastomer)
❑ Without breather hole
❑ Check for splits and chafing
❑ Drive off constant velocity joint with a drift
❑ Coat sealing surface of constant velocity joint with -D 454 300 A2- before installing.
10 - Clamp
❑ Always renew after removing.
❑ Tightening ⇒ page 236

228 Rep. gr.42 - Rear suspension

 Golf Variant 2007 ➤ , Jetta 2005 ➤
Running gear, axles, steering - Edition 07.2010

11 - Locking plate
12 - Multi-point socket head bolt
❑ M8 x 48
❑ Initially tighten diagonally to 10 Nm and then tighten diagonally to specified torque
❑ 40 Nm
❑ Always renew bolts after removing
13 - Retaining ring
❑ Always renew after removing.
Volkswagen AG
en AG.-VW
❑ Remove and install with circlip
lksw
agpliers 161 A- does n
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14 - Seal ris
ed
b ara
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❑ Always renew after
aut removing.
h
ra
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❑ Adhesive surface on constant velocity joint must be free of oil and grease!

ce
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un

pt
an
15 - Inner constant velocity joint
d
itte

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ab
❑ Renew only as complete unit

ility
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❑ Pressing off ⇒ page 235

wit
is n

h re
❑ Pressing on ⇒ page 235
ole,

spec
❑ Checking ⇒ page 237
urposes, in part or in wh

t to the co
16 - Dished spring
❑ With inner splines

rrectne
❑ Installation position ⇒ page 235 .

ss o
cial p

f
14.1 Loosening and tightening 12-point
inform
flange bolt securing drive shaft
mer

atio
om

Special tools and workshop equipment required

n
c

i
or

n thi
e

♦ Socket, 24 mm -T10361-
t

sd
iva

o
pr

cum
r
fo

en
ng

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

♦ Angle wrench -V.A.G 1756-

14. Assembly overview: drive shaft 229

 Golf Variant 2007 ➤ , Jetta 2005 ➤
Running gear, axles, steering - Edition 07.2010

Wheel bearings must not be subjected to load after bolt securing

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 therefore important to note the following:
♦ Procedure for loosening 12-point flange bolt.
Do not attempt to move the vehicle without the drive shafts fitted
as this would damage the wheel bearing. If the vehicle does have
to be moved, always note the following points:
– Fit an outer joint in place of drive shaft.
– Tighten outer joint to 120 Nm.
Loosening 12-point bolt
– With vehicle still standing on its wheels, loosen the twelve-
point bolt a maximum of 90°, as the wheel bearing will other‐
wise be damaged.
– Raise vehicle so that wheels are off the ground.
– Have second mechanic apply brakes.
– Remove 12-point bolt -arrow-.
Fitting 12-point bolt
– Renew 12-point bolt.

Note

The wheels must not be in contact n AGwith

. Volksthe
wagground
en AG when the drive
wage
shaft bolt is tightened; Votherwise, the wheel bearing
does
nwill
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aged. sedb
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– Have second
ss
a
mechanic apply brakes. ac
ce
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nl

– Tighten 12-point bolt to 70 Nm.

pt
du

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itte

y li

– Lower vehicle onto its wheels.

erm

ab
ility
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– Turn 12-point bolt 90° further.

wit
, is n

h re
hole

14.2 Removing and installing drive shaft

spec
es, in part or in w

t to the co

Removing
– Remove drive shaft bolt at wheel hub ⇒ page 229 .
rrectness of i

– Remove wheel.
l purpos

– Unscrew bolts securing track rod -1- and lower transverse link
-3- from wheel bearing housing -4-.
nf
ercia

orm
m

atio
om

n in
or c

thi
te

sd
iva

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rp

cu
o

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f

en
ng

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

230 Rep. gr.42 - Rear suspension

 Golf Variant 2007 ➤ , Jetta 2005 ➤
Running gear, axles, steering - Edition 07.2010

– Remove bolt -arrow-.

– Loosen drive shaft at gearbox flange.
– Swing wheel bearing housing out and pull drive shaft out of gen AG. Volkswagen AG d
a
inner splines. Vol
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oes
not
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ed ran
– Remove drive shaft. oris tee
th or
au
Installing ss
ac

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un
Carry out installation in the reverse sequence, noting the follow‐

pt
an
d
ing:

itte

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rm

ab
pe
– Install wheel and tighten bolts or nuts ⇒ page 241 .

ility
ot

wit
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The threaded connections on the wheel bearing housing may be

h re
tightened only when the dimension measured between the centre
hole

spec
of wheel hub and lower edge of wheel housing before work was
es, in part or in w

started has been attained ⇒ page 179 .

t to the co
Note

rrectness of i
l purpos

Ensure that the washer between wheel bearing housing and

shock absorber is also installed on vehicles with aluminium wheel
bearing housing.

nform
mercia

a
com

tio
Specified torques

n in
r
te o

thi
Component Specified torque

s
iva

do
r
rp

cum
Drive shaft to hub 70 Nm + 90°
fo

en
g

♦ Use new bolt

n

t.
yi Co
Cop py
t. rig
Drive shaft to flange shaft/gearbox 40 Nm
gh ht
pyri by
♦ Use new bolts ♦ Initially tighten diagonally to 10 Nm
co Vo
by lksw
cted agen
Prote AG.
♦ Use new locking plates.

14. Assembly overview: drive shaft 231

 Golf Variant 2007 ➤ , Jetta 2005 ➤
Running gear, axles, steering - Edition 07.2010

14.3 Dismantling and assembling drive shaft

Special tools and workshop

equipment required
♦ Thrust plate -VW 401-
♦ Thrust plate -VW 402-
♦ Press tool -VW 408 A-
♦ Press tool -VW 411-
♦ Tube -VW 416 B-
♦ Thrust washer -VW 447 H-

AG. Volkswagen AG d
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un

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pe

ility
ot

wit
, is n

h re
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spec
es, in part or in w

t to the co
rrectness of i
l purpos

nform
mercia

a
com

tion in
r
te o

thi
s
iva

do
r
rp

cum
fo

en
ng

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

232 Rep. gr.42 - Rear suspension

 AG. Volkswagen AG d
agen GolfoVariant
es n 2007 ➤ , Jetta 2005 ➤
olksw ot g
V
ed by Running gear, axles, steering
ua
ran - Edition 07.2010
oris tee
th or
au ac
♦ Circlip pliers -VW 161 A- ss

ce
le
un

pt
♦ Torque wrench -V.A.G

an
d
itte

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1331-

rm

ab
pe

ility
♦ Torque wrench -V.A.G

ot

wit
1332-

, is n

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♦ Special pliers -V.A.G 1682- hole

spec
es, in part or in w

♦ Assembly tool -T10065-

t to the co
rrectness of i
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mercia

a
com

tion in
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te o

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ng

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

♦ Multi-purpose tool -VW 771-

14. Assembly overview: drive shaft 233

 Golf Variant 2007 ➤ , Jetta 2005 ➤
Running gear, axles, steering - Edition 07.2010

♦ Puller -T10382-

AG. Volkswagen AG d
agen oes
olksw not
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d by ara
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e
nl

pt
du

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Removing outer constant velocity joint
erm

ab
ility
ot p

– Clamp drive shaft in vice using protective jaw covers.

wit
, is n

h re
– Fold back boot.
hole

spec
– Set puller -T10382- up so that smooth side of puller plate -
es, in part or in w

t to the co
T10382/1- points to spindles -T10382/2- .
– Assemble puller -T10382- complete with multi-purpose tool -
VW 771- .

rrectness of i
– Pull constant velocity joint from drive shaft with puller -T10382-
l purpos

and multi-purpose tool -VW 771- .

1- Puller plate -T10382/1-

nf
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2- Spindles -T10382/2-
m

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n in
c

Driving on outer constant velocity joint

or

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Cop py
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pyri by
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by c lksw
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Prote AG.

Installation position of dished spring and thrust washer on outer

joint
1- Dished spring
– Install new retaining ring.
– If necessary, push new joint boot onto drive shaft.
– Drive onto shaft with plastic head hammer until retaining ring
engages.

234 Rep. gr.42 - Rear suspension

 Golf Variant 2007 ➤ , Jetta 2005 ➤
Running gear, axles, steering - Edition 07.2010

Pressing off inner constant velocity joint

– Drive joint protective boot off joint using a drift.
– Remove retaining ring.
– Remove both clamps and slide boot towards outer joint.
Assembling

Installation position of dished spring at inner joint

1- Dished spring

AG. Volkswagen AG d
agen oes
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Pressing on inner constant velocity joint ss

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Note
erm

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ility
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wit
Chamfer on internal circumference of ball hub (splines) must face
is n

contact shoulder on drive shaft. h re

ole,

spec
urposes, in part or in wh

– Press joint on to stop.

t to the co

– Install retaining ring.

rrectness o
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f inform
mer

atio
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n
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pr

cum
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fo

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

14. Assembly overview: drive shaft 235

 Golf Variant 2007 ➤ , Jetta 2005 ➤
Running gear, axles, steering - Edition 07.2010

Tighten clamp on outer joint

– Position clamp tensioner -V.A.G 1682- as shown in diagram.
Ensure jaws of tool contact corners -arrows B- of clamp.
– Tighten clamp by turning spindle with a torque wrench (do not
cant pliers).

Note agen
AG. Volkswagen AG d
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♦ Because a stainless steel boot clamp is required
ris ed b
due to the ara
nte
hard material of the joint boot (comparedut to rubber), it is pos‐
ho eo
ra
sible to tighten the clamp only with clamp
ss a tensioner -V.A.G c
1682- .

ce
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un

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an
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♦ Torque setting: 25 Nm.

itte

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erm

ab
♦ Use torque wrench -C- with adjustment range 5 … 50 Nm, (e.g.

ility
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torque wrench -V.A.G 1331- ).

wit
is n

h re
♦ Make sure thread of spindle -A- on pliers moves freely. Lubri‐
ole,

spec
cate with MoS2 grease if necessary.
urposes, in part or in wh

t to the co
♦ If the thread is tight (e.g. due to dirt), the required clamping
force for the boot clamp will not be attained although the cor‐
rect torque is applied.

rrectnes
Tightening clamp on small diameter

s o
cial p

f inform
mer

atio
om

n
c

i
or

n thi
te

sd
iva

o
pr

cum
r
fo

en
ng

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

14.4 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.

236 Rep. gr.42 - Rear suspension

 Golf Variant 2007 ➤ , Jetta 2005 ➤
Running gear, axles, steering - Edition 07.2010

– Turn cage until the two rectangular windows -arrow-

gen AG
. Volkswaalign with
gen AG
does
swa
joint body. y Volk not
gu b ara
ed nte
– Take out cage with hub. thoris e or
u a ac
ss

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erm

ab
ility
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wit
is n

h re
ole,

spec
urposes, in part or in wh

t to the co
– Swing segment of hub into square cage window.

rrectne
– Tip hub out of cage.
The six balls for each joint belong to a tolerance group. Check

s
stub axle, hub, cage and balls for small indentations (pitting) and

s o
cial p

f
traces of seizing. Too much circumferential backlash in the joint

inform
becomes noticeable during load change jolts; in such cases, the
mer

joint must be renewed. Smoothing and traces of wear of the balls

atio
m

are no reason to change the joint.

o

n
c

i
or

n
Installing

thi
te

sd
iva

o
– Pack half of total grease quantity (40 g) into joint body.
pr

cum
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fo

en
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– Fit cage with hub into joint body.

t.
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Cop py
– Press in opposing balls one after the other; the original position ht. rig
rig ht
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of the hub relative to the cage and joint body must be restored. copy Vo
by lksw
cted agen
Prote
– Fit new retaining ring into hub.
AG.

– Distribute remaining grease in boot.

– 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.

14.5 Checking inner constant velocity joint

Removing
The joint is to be dismantled to renew the grease if it is heavily
soiled, and to check the running surfaces and the balls for wear
and damage.
– Swing ball hub and ball cage.
– 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.

14. Assembly overview: drive shaft 237

 Golf Variant 2007 ➤ , Jetta 2005 ➤
Running gear, axles, steering - Edition 07.2010

– 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

G. Volkswagen AG d
– Insert hub into cage via the two chamfers. The hub can be lkswagen A oes
not
installed in any position. Press balls into cage. by
Vo gu
ara
d
ise nte
The ball hub has two different distances between the ball
ut
ho tracks:
r eo
ra
a smaller one and a larger one. ss
a c

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itte

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erm

ab
ility
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wit
is n

h re
ole,

spec
urposes, in part or in wh

t to the co
– Insert hub complete with cage and balls into joint body, making
sure that a smaller gap -b- faces open side of joint body.

rrectne
– Also make sure that chamfer on inner circumference of ball
hub is visible after swinging it into place.

ss o
cial p

f inform
mer

atio
om

n
c

i
or

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te

sd
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pr

cum
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fo

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t.
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op py
– Swing ball hub into place by swinging hub out of cage as t. C rig
gh ht
shown in figure -arrows-. pyri by
Vo
co lksw
by
cted agen
Prote AG.

238 Rep. gr.42 - Rear suspension

 Golf Variant 2007 ➤ , Jetta 2005 ➤
Running gear, axles, steering - Edition 07.2010

– 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.

AG. Volkswagen AG d
agen oes
olksw not
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ara
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nl

pt
du

an
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erm

ab
ility
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wit
, is n

h re
hole

spec
es, in part or in w

t to the co
rrectness of i
l purpos

nform
mercia

at
om

ion
c

in t
or

his
ate

do
priv

cum
for

en
ng

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

14. Assembly overview: drive shaft 239

 Golf Variant 2007 ➤ , Jetta 2005 ➤
Running gear, axles, steering - Edition 07.2010

44 – Wheels, tyres, vehicle geometry

1 Appraisal of accident vehicles
A checklist for evaluating running gear of accident vehicles can
be found under ⇒ page 1 .

AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
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or eo
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aut ra
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nl

pt
du

an
itte

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erm

ab
ility
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wit
, is n

h re
hole

spec
es, in part or in w

t to the co
rrectness of i
l purpos

nform
mercia

at
om

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in t
or

his
ate

do
priv

cum
for

en
ng

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

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

 Golf Variant 2007 ➤ , Jetta 2005 ➤
Running gear, axles, steering - Edition 07.2010

2 Torque settings for wheels

Wheel bolt to wheel hub for all vehicles
Torque setting: 120 Nm.

AG. Volkswagen AG d
agen oes
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nl

pt
du

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ab
ility
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wit
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spec
es, in part or in w

t to the co
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or

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ate

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for

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

2. Torque settings for wheels 241

 Golf Variant 2007 ➤ , Jetta 2005 ➤
Running gear, axles, steering - Edition 07.2010

3 Fitting wheel and tyre

3.1 General information

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 been modified, please contact the
manufacture of the unit.

3.2 Fittings instructions

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 must neither be n AG. Volkswagen AG

less than 15°C nor exceed 30°C in the core of the tyre.olkswage does
no
yV t gu
db ara
rise nte
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• To install tyres without damage, it is especially
s au important to ra
c
warm the upper part of the sidewall and thes inside of the upper
ce
e

bead to at least 15 °C.

nl

pt
du

an
itte

y li

• This internal temperature is referred to as the core tempera‐

erm

ab

ture.
ility
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wit
, is n

• Rubber is a poor conductor of heat, therefore a cold tyre must

h re

be left in an area with the correct temperature for a sufficiently

hole

spec

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

es, in part or in w

15 °C.
t to the co

• The surface temperature of the tyre during the warming up

phase is no indication of its internal temperature.
rrectness of i

• To enable cold tyres to absorb heat from the ambient air as

l purpos

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.
nf
ercia

orm

• Tyres must never be placed in front of a radiator or hot air

m

atio
m

blower for warming, since this can very quickly lead to critical
o

n in
c

surface temperatures.
or

thi
te

sd
a

• Except for warming with warm water or warm ambient air

iv

o
r

(max. 50 °C), there is no process available for warming tyres

rp

cu
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m
f

without damaging the tyre!

en
ng

t.
yi Co
op
• When cold tyres (below 0°C) are transferred to a warm envi‐
C py
ht. rig
ronment (above 0°C), a layer of condensation immediately
rig ht
py by
o Vo
forms on the surface of the tyre. This layer of condensation by c lksw
cted agen
Prote AG.

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

 Golf Variant 2007 ➤ , Jetta 2005 ➤
Running gear, axles, steering - Edition 07.2010

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.
• If the layer of condensation is in liquid form and leads to mois‐
ture on the surface, it should be dried off with a cloth otherwise
the continuation of the warming process might be curtailed by
cold due to evaporation.
Warming times:
♦ Assuming a minimum room temperature of 19 °C and a tyre
lkswagen AG
temperature of 0 °C or more, a tyre should AG. Voat
swabe
genkept least at does
19 °C for at least 2 hours by
Vol
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gu
a d ran
se
♦ Assuming a minimum room temperature
tho
ri of 19 °C and a tyre tee
or
temperature of below 0 °C,sas autyre should be kept at least at 19 ac
°C for at least 2.5 hours

ce
e
nl

pt
du

an
Warming recommendations:
itte

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erm

ab
♦ If possible, tyres should be stored in the workshop 1 day before

ility
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they are fitted (order preparation)

wit
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♦ Store on an insulated base, pallet or the like, as high up as
hole

spec
possible
es, in part or in w

t to the co
♦ Position the tyres individually to allow the warm air to „circu‐
late“ around them effectively
♦ Wipe off condensation

rrectness of i
♦ Never heat with a radiator or hot air blower!
l purpos

nf
ercia

orm
m

atio
om

n in
or c

thi
te

sd
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rp

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f

en
ng

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

3. Fitting wheel and tyre 243

 Golf Variant 2007 ➤ , Jetta 2005 ➤
Running gear, axles, steering - Edition 07.2010

4 Removing and fitting tyres (wheels

with tyre pressure monitoring)

4.1 Notes on safety and conditions for re‐

moving 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, testing and information system
VAS 5051.

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.
n AG. Volkswagen AG do
wage es n
4.2 Wheel change olks ot g
byV ua
d ran
ir se tee
If the wheels are changed (e.g. switch ufrom
tho summer to winter or
tyres), the wheel electronics transmitssdata as soon as the speed
a ac
of the new wheels exceeds 25 km/h. The new wheel electronics'
ce
le
un

pt
ID numbers are automatically detected and entered by the control
an
d
itte

unit.
y li
erm

ab
The acceleration data are additionally checked against the vehi‐ ility
ot p

cle speed. This process takes approx. 7 minutes. wit

is n

h re
ole,

The tyre pressure monitor control unit -J502- must first switch to
spec
urposes, in part or in wh

learning mode before it can automatically learn the wheel elec‐

t to the co

tronics.
To do this, the vehicle must remain stationary for 20 minutes.
Following the detection of a flat tyre, this time is 5 minutes.
rrectne

If the stationary time is not maintained and the control unit con‐
s

sequently does not switch to learning mode, the system detects

s o

interference in transmission and will learn the wheel electronics

cial p

f in

automatically only after a stationary period of 20 minutes.

form
mer

atio
om

Note
c

i
or

n thi
te

sd
va

♦ When changing wheels, note that only Volkswagen-approved

i

o
pr

cum

wheel and tyre combinations with the tyre inflation pressure

r
fo

en
ng

specified in the tank flap may be installed.

t.
yi Co
Cop py
♦ If unapproved wheel and tyre combinations are installed, they
t. rig
gh ht
yri
must possess a certificate from the responsible technical in‐
p by
co Vo
by lksw
spection authority (in Germany, TÜV) for the respective vehi‐ Prote
cted AG.
agen
cle, and a second wheel set must be learned via the Vehicle
diagnostic, testing and information system -VAS 5051B-
⇒ page 245 .
♦ Learning is also necessary if the tyre inflation pressure devi‐
ates from the tyre inflation pressure specified in the tank flap
⇒ page 245 .

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

 Golf Variant 2007 ➤ , Jetta 2005 ➤
Running gear, axles, steering - Edition 07.2010

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 n monitored
AG. Volkswagwith
en AGthe TPM
system. lkswage does
not
Vo y gu
db a
Nominal tyre inflation pressures
or
ise for the second wheel set must be
ran
te
specified to the system
auth with the Vehicle diagnostic, testing and e or a
information system ss -VAS 5051B- . c

ce
e
nl

pt
The wheel electronics for the wheels of the second wheel set are
du

an
itte

not automatically detected and learned by the TPM system (unlike

y li
erm

ab
the wheel electronics for the wheel set with Volkswagen-ap‐

ility
ot p

proved wheel and tyre combinations).

wit
, is n

h re
The following work has to be performed to switch to the second
hole

wheel set:

spec
es, in part or in w

t to the co
♦ Read ID numbers (IDs) of the wheel electronics (tyre pressure
sensors) prior to installation.
♦ Switch the TPM to wheel set 2.

rrectness of i
♦ Enter the necessary nominal tyre pressures and the IDs of the
l purpos

wheel electronics in the system.

4.3 Pressing tyre off wheel rim

nform
mercia

at
om

io
Caution

n
c

in t
or

his
ate

♦ Comply with the notes on safety and conditions

do
priv

c
⇒ page 244
um
for

en
ng

t.
yi Co
Cop py
. rig
– Deflate tyre by unscrewing nickel-plated valve core.
t
gh ht
pyri by
Vo
co
– When pressing off a tyre using tyre fitting equipment with a
by lksw
cted agen
Prote
press-off plate, always ensure that the tyre valve/ tyre pres‐
AG.

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 balance weights and excessive dirt from wheel.

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

4. Removing and fitting tyres (wheels with tyre pressure monitoring) 245
 Golf Variant 2007 ➤ , Jetta 2005 ➤
Running gear, axles, steering - Edition 07.2010

4.4 Removing tyre from wheel

Caution

♦ Comply with the notes on safety and conditions

⇒ page 244
♦ 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
– Turn wheel on tyre fitting unit so that tyre valve/ tyre pressure
sensor is in front of the assembly head. n AG. Volkswagen AG age does
ksw not
– Position assembly head near tyre valve/ y Vtyre pressure sensor
ol gu
db ara
so that an assembly lever can be inserted
rise approx. 30° next to nte
the tyre valve/ tyre pressure sensor
autho . eo
ra
ss c
– Now lever tyre bead over assembly finger on assembly head

ce
e
nl

using assembly lever then remove assembly lever.

pt
du

an
itte

y li
– Run tyre fitting machine clockwise until upper bead lies com‐
erm

ab
pletely above wheel rim flange.

ility
ot p

wit
, is n

– Turn wheel on tyre fitting unit so that tyre valve/ tyre pressure

h re
hole

sensor is in front of the assembly head.

spec
es, in part or in w

t to the co
Note

rrectness of i
♦ Check that the tyre pressure sensor is not loose or damaged.
If the screwed connection is loose, replace the union nut, the
l purpos

valve core, the seal, the sealing washer and the valve cap with
new parts from the repair set ⇒ Electronic parts catalogue
„ETKA“ . nform
ercia

♦ If the tyre pressure sensor is damaged, then replace the com‐

m

at
om

plete item ⇒ page 259 .

ion
c

in t
or

his
ate

do
riv

4.5 Fitting tyre to wheel rim

p

cum
for

en
ng

t.
yi Co
op py
Caution t. C rig
gh ht
pyri by
Vo
co lksw
♦ Note the instruction for warming cold tyres to minimum in‐
by
cted agen
Prote
stallation temperature ⇒ page 242 .
AG.

♦ Comply with the notes on safety and conditions

⇒ page 244

Note

When a tyre is changed, it is recommended also to change the

set of seals for the tyre pressure sensor.

– Coat wheel rim flanges, tyre beads and inside of upper tyre
bead generously with tyre assembly paste.
– First fit inner side of tyre.

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

 Golf Variant 2007 ➤ , Jetta 2005 ➤
Running gear, axles, steering - Edition 07.2010

– 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.
– Run tyre fitting machine clockwise.
– 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 .
– Inflate tyre to a pressure of max. 3.3 bar (bead seating pres‐
sure)

Caution
. Volkswagen AG
Never increase the inflation pressure when the tyre beadswa does
gen AG does
not lie completely against the wheel rim flange. by Volk not
gu
ara
d
ise nte
This would lead to damage to the tyre and/or
tho the wheel rim.
r eo
au ra
c
ss

ce
le
un

pt
– When the tyre bead does not lie completely against the wheel

an
d
itte

rim flange: deflate the tyre, press tyre bead off wheel rim flange

y li
rm

ab
and generously coat again with tyre assembly paste.
pe

ility
ot

wit
– Inflate tyre to a pressure of max. 3.3 bar (bead seating pres‐
, is n

h re
sure)
hole

spec
– If the tyre beads seat perfectly against the shoulder of the
es, in part or in w

t to the co
wheel rim, increase pressure to 4 bar to »seat« the tyre.
– Fit a new nickel-plated valve core and inflate tyre to prescribed
inflation pressure.
rrectness of i

– Then balance wheel.

l purpos

– Install wheel and tighten bolts to prescribed torque

⇒ page 241 .
nform
mercia

a
com

tion in
r
te o

thi
s
iva

do
r
rp

cum
fo

en
ng

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

4. Removing and fitting tyres (wheels with tyre pressure monitoring) 247
 Golf Variant 2007 ➤ , Jetta 2005 ➤
Running gear, axles, steering - Edition 07.2010

5 Removing and fitting tyres with run-

flat properties to wheel rims
agen
AG. Volkswagen AG d
oe
ksw s no
Vol t gu
d by ara
e nte
ris
5.1 Notes on safety ho
t eo
s au ra
c
s
• Only specially trained mechanics may remove or install tyres

ce
e
nl

pt
du

with run-flat properties.

an
itte

y li
erm

ab
• The special tools required must be in a perfect condition and

ility
ot p

must not be damaged. For information about appropriate ad‐

wit
, is n

ditional tools, directly contact the manufacture of the tyre fitting

h re
equipment in your workshop. The recommended optional ad‐
hole

spec
ditional tools can be located under the VAS number of the
es, in part or in w

listed tyre fitting equipment.

t to the co
• Use assembly paste recommended by the tyre manufacturer
if necessary.

rrectness of i
• The procedure for removing and fitting may differ depending
l purpos

on the type of equipment used and the manufacture of the

equipment.

nf
ercia

• The subsequent procedure describes in general the principles

or
of removing and fitting tyres with run-flat properties. It is im‐

m
m

atio
portant to identify a "run-flat" tyre before removing or fitting a
om

n in
tyre in order to follow the appropriate procedure.
or c

thi
te

sd
• Distinguishing features: the tyre can be identified by one of the
iva

o
r

following abbreviations DSST, Euforia, RFT, ROF, RSC, SSR

rp

cu
o

or ZP. The abbreviation is located on the flank of the tyre fol‐ m

f

en
ng

t.
yi
lowing the tyre designation of the respective tyre manufactur‐
Co
op py
er.
t. C rig
gh ht
pyri by
Vo
• It is extremely important to adhere to the instructions and
o
by c lksw
cted agen
warnings in the following descriptions. Prote AG.

• Check whether the tyre pressure sensor should also be re‐

placed (where fitted) ⇒ Vehicle diagnostic, testing and infor‐
mation system VAS 5051.

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.

5.2 Fittings instructions

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).

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

 Golf Variant 2007 ➤ , Jetta 2005 ➤
Running gear, axles, steering - Edition 07.2010

WARNING

The minimum installation temperature of a tyre must neither be

less than 15°C nor exceed 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‐ wagen AG. Volkswagen AG doe
ronment (above 0°C), a layer of condensation immediatelyy Volks s no
t gu
forms on the surface of the tyre. This layer of condensationise
d b ara
nte
indicates that the tyre is intensively absorbing heat tfrom
ho
r
its eo
environment through the process of water vapour ss in
au
the air ra
c
condensing out on the tyre surface.

ce
le
un

pt
an
d

• If the layer of condensation is in liquid form and leads to mois‐

itte

y li
ture on the surface, it should be dried off with a cloth otherwise
erm

ab
the continuation of the warming process might be curtailed by

ility
ot p

cold due to evaporation.

wit
is n

h re
ole,

Warming times:

spec
urposes, in part or in wh

♦ Assuming a minimum room temperature of 19 °C and a tyre

t to the co
temperature of 0 °C or more, a tyre should be kept at least at
19 °C for at least 2 hours rrectne

♦ 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
ss o
cial p

Warming recommendations:
inform
mer

♦ If possible, tyres should be stored in the workshop 1 day before

atio

they are fitted (order preparation)

om

n
c

i
or

♦ Store on an insulated base, pallet or the like, as high up as

thi
te

sd

possible
iva

o
pr

cum
r

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

fo

en
ng

late“ around them effectively

t.
yi Co
Cop py
t. rig
♦ Wipe off condensation opyri
gh by
Vo
ht
by c
♦ Never heat with a radiator or hot air blower!
lksw
cted agen
Prote AG.

5. Removing and fitting tyres with run-flat properties to wheel rims 249
 Golf Variant 2007 ➤ , Jetta 2005 ➤
Running gear, axles, steering - Edition 07.2010

5.3 Pressing tyre off wheel rim

Caution

♦ Observe the safety instructions ⇒ page 248 .

– Deflate tyre by unscrewing nickel-plated valve core.

– 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 balance weights and excessive dirt from wheel.

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

AG. Volkswagen AG d
agen oes
olksw not
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rise nte
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au ra
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un

pt

5.4 Removing tyre from wheel

an
d
itte

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erm

ab
ility
ot p

Caution
wit
is n

h re
ole,

♦ Observe the safety instructions ⇒ page 248 .

spec
urposes, in part or in wh

t to the co
rrectness o
cial p

f inform
mer

atio
om

n
c

i
or

n thi
te

sd
iva

o
pr

cum
r
fo

en
ng

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

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

 Golf Variant 2007 ➤ , Jetta 2005 ➤
Running gear, axles, steering - Edition 07.2010

– Turn wheel on tyre fitting unit so that tyre valve with tyre pres‐
sure sensor -2- is directly in front of assembly head -1-.

Caution

The assembly head -1- must never be within area -a- of tyre
valve/tyre pressure sensor, or the assembly head will damage
the tyre pressure sensor .

– Position assembly head -1- near tyre valve/ tyre pressure sen‐
sor so that an assembly lever can be inserted approx. 30° next
to the tyre valve/ tyre pressure sensor -2-.
– Seat depressor -3- on wheel rim opposite assembly head
-1-.
– Now lever tyre bead over assembly finger on assembly head
using assembly lever then remove assembly lever.

– Run tyre fitting machine clockwise until upper bead lies com‐
pletely above wheel rim flange.
This action will push the depressor -1- up against the assembly
head. This allows it to be removed easily.

AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
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ce
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un

pt
an
d
itte

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erm

ab
– Turn wheel on tyre fitting unit so that tyre valve with tyre pres‐
ility
ot p

sure sensor -2- is directly in front of assembly head -1-.

wit
is n

h re
ole,

spec

Caution
urposes, in part or in wh

t to the co

The assembly head -1- must never be within area -a- of tyre
valve/tyre pressure sensor, or the assembly head will damage
the tyre pressure sensor .
rrectness

– Position assembly head -1- near tyre valve/ tyre pressure sen‐
o
cial p

sor so that an assembly lever can be inserted approx. 30° next

inform

to the tyre valve/ tyre pressure sensor -2-.

mer

atio
m

– Now lever tyre bead over assembly finger on assembly head

o

n
c

using assembly lever -3-.

i
or

n thi
te

sd
a

– Additionally insert a plastic assembly lever -4-.

iv

o
pr

cum
r
fo

– Remove assembly lever -3-.

en
ng

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

5. Removing and fitting tyres with run-flat properties to wheel rims 251
 Golf Variant 2007 ➤ , Jetta 2005 ➤
Running gear, axles, steering - Edition 07.2010

– Hold bead over wheel rim flange from outside using plastic
assembly lever -1- and run tyre fitting machine clockwise until
tyre is pulled completely off wheel rim.

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 259 .

5.5 Fitting tyre to wheel rim

Caution
AG. Volkswagen AG d
agen oes
♦ Note the instruction for warming cold tyres
yV
olto
kswminimum in‐ not
gu
stallation temperature ⇒ page 248 .ised b ara
nte
r
ho eo
♦ Observe the safety instructionss a⇒
ut page 248 . ra
c
s

ce
e
nl

pt
du

an
– Coat wheel rim flanges, tyre beads and inside of upper tyre
itte

y li
erm

bead generously with tyre assembly paste.

ab
ility
ot p

– Turn wheel rim on tyre fitting unit so that tyre valve/ tyre pres‐

wit
, is n

sure sensor -1- is directly opposite assembly head -2-.

h re
hole

spec
– Run tyre fitting machine clockwise.
es, in part or in w

t to the co
rrectness of i
l purpos

nform
mercia

at
om

ion
c

in t

– Stop the fitting of lower bead before reaching tyre valve/ tyre
or

his
e

pressure sensor -arrow- to prevent damage to tyre pressure

at

do
riv

sensor .
p

cum
for

en
g

The tyre bead will now slide over the wheel rim flange. The wheel
n

t.
yi Co
op
rim may be turned only until the assembly head is just before the C py
t. rig
tyre valve/ tyre pressure sensor -arrow-. gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

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

 Golf Variant 2007 ➤ , Jetta 2005 ➤
Running gear, axles, steering - Edition 07.2010

– Turn wheel rim on tyre fitting unit so that tyre valve/ tyre pres‐
sure sensor -1- is directly opposite assembly head -2-.
– Fit depressor -3- on wheel rim.
– 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 -arrow- 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 -arrow-.
– Remove depressor from wheel rim.
– Inflate tyre to a pressure of max. 3.3 bar (bead seating pres‐
sure)

Caution AG. Volkswagen AG d

agen oes
olksw not
y V gu
d b ara
Never increase the inflation pressure whenotheris tyre bead does
e nte
eo
not lie completely against the wheel rimaflange.
ut
h
ra
ss c
This would lead to damage to the tyre and/or the wheel rim.
ce
e
nl

pt
du

an
itte

y li
erm

ab

– When the tyre bead does not lie completely against the wheel
ility
ot p

rim flange: deflate the tyre, press tyre bead off wheel rim flange
wit
, is n

and generously coat again with tyre assembly paste.

h re
hole

spec

– Inflate tyre to a pressure of max. 3.3 bar (bead seating pres‐

es, in part or in w

sure)
t to the co

– If the tyre beads seat perfectly against the shoulder of the

wheel rim, increase pressure to 4 bar to »seat« the tyre.
rrectness of i

– Fit a new nickel-plated valve core and inflate tyre to prescribed

l purpos

inflation pressure.
– Then balance wheel.
nform
ercia

– Install wheel and tighten bolts to prescribed torque

m

at

⇒ page 241 .
om

ion
c

in t
or

his
ate

do
priv

cum
for

en
ng

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

5. Removing and fitting tyres with run-flat properties to wheel rims 253
 Golf Variant 2007 ➤ , Jetta 2005 ➤
Running gear, axles, steering - Edition 07.2010
AG. Volkswagen AG d
agen oes
olksw not
V gu
6 Tyre pressure monitor display
by ara
d
rise nte
tho eo
au ra
ss c

ce
le

6.1 General
un

pt
an
d
itte

y li
erm

The tyre pressure monitor system is part of the software in the

ab
ility
ABS control unit -J104- . The system is used to detect slow tyre
ot p

wit
pressure loss from a wheel. Fault memory entries for the tyre
is n

h re
monitor display are stored in the ABS control unit -J104- . The tyre
ole,

spec
pressure display compares the wheel speeds and consequently
urposes, in part or in wh

the rolling circumference of the individual wheels via the ABS

t to the co
sensors.
After the following work or modifications, the tyre pressure mon‐

rrectne
itor display button -E492- must be pressed and held until a
confirmation is sounded.

s
♦ Change in tyre pressure

s o
cial p

f in
♦ Changing one or more wheels

form
mer

♦ Interchanging wheels, e.g. from front to rear

atio
om

n
c

A change in the wheel's rolling circumference will be indicated by

i
or

n thi
e

the TPM warning lamp -K220- lighting up in the instrument cluster.

t

sd
va

A tyre's rolling circumference may change as a result of:

i

o
pr

cum
r
fo

♦ Insufficient tyre inflation pressure.

en
ng

t.
yi Co
op py
♦ Structural tyre damage. t. C rig
gh ht
pyri by
♦ One-sided loading of vehicle
co Vo
by lksw
cted agen
Prote AG.
♦ Increased load on one axle, e.g. due to towing a trailer
♦ Use of snow chains.
♦ Spare wheel installed.
♦ Wheel renewal.

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

 Golf Variant 2007 ➤ , Jetta 2005 ➤
Running gear, axles, steering - Edition 07.2010

6.2 System fault in the ABS system

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
. Volkswage AG
button -E492- . In this case,
sw please
agen AG carry outn thedfollowing
oes steps:
k not
Vol g
– Connect vehicle by
ddiagnostic, testing and information system
ua
ran -
ise
VAS 5051- and thor select „Guided fault finding“ ⇒ Vehicle diag‐
tee
o
nostic, testing
ss
au and information system VAS 5051. ra
c

ce
e
nl

pt
Running gear
du

an
itte

y li
erm

Brake system

ab
ility
ot p

01 - Self-diagnosis

wit
, is n

h re
03-brake system ABS Mark 70 or
hole

spec
es, in part or in w

03-brake system ESP Mark 60

t to the co
Functions

rrectness of i
General functions
l purpos

Adaption of tyre pressure monitoring - TPM

Follow instructions on screen to perform basic setting. nform

ercia

6.3 Perform basic setting

m

at
om

ion
c

in t
r

Basic setting must be performed after every modification to the

o

his
e

wheels.
at

do
priv

cum

• Ignition must be switched on.

for

en
ng

t.
yi Co
• Handbrake of vehicle must be applied. t. Cop py
rig
gh ht
Vehicles up to model year 2009 yri
p by
co Vo
by lksw
cted
– Push SET button -2- in centre console until an audible signal
agen
Prote AG.
sounds.
The audible signal confirms basic setting.

6. Tyre pressure monitor display 255

 Golf Variant 2007 ➤ , Jetta 2005 ➤
Running gear, axles, steering - Edition 07.2010

Vehicles as of model year 2010

– Push SET button in glove compartment until an audible signal
sounds.
The audible signal confirms basic setting.

AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c

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nl

pt
du

an
itte

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erm

ab
ility
ot p

wit
, is n

h re
hole

spec
es, in part or in w

t to the co
rrectness of i
l purpos

nf
ercia

orm
m

atio
om

n in
or c

thi
te

sd
iva

o
r
rp

cu
o

m
f

en
ng

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

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

 Golf Variant 2007 ➤ , Jetta 2005 ➤
Running gear, axles, steering - Edition 07.2010

7 Tyre pressure monitor

For detailed information on the tyre pressure monitor (TPM), refer
to ⇒ Self-study programme No. 347 ; Tyre Pressure Monitoring
Systems .
The tyre pressure monitor system includes wheel electronics
mounted on each wheel.
At regular intervals, the wheel electronics transmit data which the
central locking and anti-theft alarm system aerial receives and
forwards to the tyre pressure monitor control unit -J502- .
This control unit is integrated with its own diagnostic address into
the convenience system central control unit -J393- .
The tyre pressure specifications (monitoring air pressures) are set
in the control unit as factory defaults.
The pressures, noted on the tank flap sticker, are valid for a set
of wheels with the Volkswagen-approved tyres.
The nominal tyre pressures for this set of wheels are specified for
the partially and fully laden vehicle and must not be changed.
Vehicles up to model year 2009
The driver can switch between partial and full load, poll the status
and switch the TPM system on or off via a SET button -2- in the
centre console.

n AG. Volkswagen AG do
lkswage es n
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byV ua
d ran
ir se tee
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rm

ab
pe

ility
Vehicles as of model year 2010
ot

wit
, is n

h re
The driver can switch between partial and full load, poll the status
hole

and switch the tyre pressure monitoring system on or off via but‐

spec
es, in part or in w

ton SET in the glove compartment.

t to the co
Caution
rrectness of i
This button is not available for the North American region
l purpos

(NAR). Therefore, the function described above is omitted in

this region.
nform
mercia

Messages and warnings are indicated via the lamp in the dash
com

tion in

panel insert and texts in the dash panel insert display.

r
te o

thi
s
iva

do

7.1 Button behaviour

r
rp

cum
fo

en
ng

t.
This table shows the button's behaviour in the case of various
yi Co
op
states or actions under consideration of different functions.
C py
t. rig
gh ht
pyri by
Vo
co lksw
by
Caution
cted agen
Prote AG.

This button is not available for the North American region

(NAR).

7. Tyre pressure monitor 257

 Golf Variant 2007 ➤ , Jetta 2005 ➤
Running gear, axles, steering - Edition 07.2010

Time for which the button is pressed

n AG. Volkswagen A
Up to 2 seconds 3-7 seconds olkswage8-10 seconds G does11-15
not seconds
yV gu
State or action Actual state Switchised b Confirm Deactivation
ara
n
r tee
ho
Messages: Messages:
sa
ut Messages: Messages:
or
ac
s
Desired functions:

ce
le
un

pt
Switch from full to Full tyre load moni‐ Partial tyre load on! On release:

an
d
itte

y li
partial load tored Confirmation of

rm

ab
(gong) switching via gong

pe

ility
ot

wit
, is n
Switch from partial to Partial tyre load Full tyre load on! On release:

h re
full load monitored Confirmation of
hole

spec
(gong) es, in part or in w switching via gong

t to the co
Switching on TPM off! Partial tyre load on! On release:
Confirmation of
switching via gong

rrectness of i
Deactivation Full tyre load moni‐ Partial tyre load on! TPM off!
tored or (gong)
l purpos

or Full tyre load on!

Partial tyre load

nform
ercia

monitored
(gong)
m

a
com

ti
Status query For example: After releasing:

on in
TPM off! Press longer to acti‐
r
te o

thi
or vate!

s
iva

do
Partial tyre load or
r
rp

cum
monitored Press longer to
fo

en
g

(gong) switch or deactivate!

n

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

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

 Golf Variant 2007 ➤ , Jetta 2005 ➤
Running gear, axles, steering - Edition 07.2010

7.2 Assembly overview: tyre pressure sensor

1 - Tyre pressure sensor

❑ Supplied complete as
spare part.
❑ Removing and installing
⇒ page 259 .
❑ Replace complete tyre
pressure sensor when
battery is dead
❑ After using breakdown
set, wipe clean hole for
valve and opening for
pressure sensor
2 - Valve core
❑ Allocation ⇒ Electronic
parts catalogue „ETKA“
❑ Always renew when
changing tyre

Note

3 - Sealing washer
4 - Sealing ring
5 - Wheel rim
❑ Fitting tyres of wheels
with tyre pressure mon‐
itoring ⇒ page 244
❑ Fitting tyres with run-flat
agen
AG. Volkswagen AG d
oes
properties ⇒ page
V olksw248 not
g y ua
db ran
6 - Union nut horise tee
t or
❑ 8 Nm au ac
ss
ce
e

7 - Valve cap
nl

pt
du

an
itte

❑ Use only genuine valve

y li
erm

ab

caps from repair set ⇒

ility
ot p

Electronic parts catalogue „ETKA“ .

wit
, is n

❑ Do not use convenience valve caps or metal valve caps.

h re
hole

spec
es, in part or in w

t to the co

7.3 Removing and installing tyre pressure

sensor
rrectness of i

Removing
l purpos

– Unscrew union nut -1-.

nf
ercia

– Remove tyre pressure sensor -2- from bed of wheel rim.

orm
m

atio

Installing
om

n in
or c

thi
e

Caution
t

sd
iva

o
r
rp

cu
o

Before installing tyre pressure sensor , clean valve hole.

f

en
ng

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

7. Tyre pressure monitor 259

 Golf Variant 2007 ➤ , Jetta 2005 ➤
Running gear, axles, steering - Edition 07.2010

– Install tyre pressure sensor -2- along with a new seal and
sealing washer and push it into wheel rim at the points marked
by -arrows-.
– Press tyre pressure sensor -2- into the wheel rim at the points
marked by -arrows-.
Screw union nut -1- onto tyre pressure sensor from outside.

– Press tyre pressure sensor -1- onto bed of rim at the points
marked by -arrows- and tighten union nut to 8 Nm.

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♦ Tighten nutth only to specified torque.
o tee
or
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♦ The sealing washer -2- will be deformed slightly when
ss
ce
e

tightened.
nl

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♦ The sealing washer may be installed only once. Install a y li

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ab
new sealing washer with rubber seal every time the part ility
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is fitted.
wit
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♦ Further tightening of the union nut is not permitted be‐

hole

spec

cause the seal may be damaged, leading to leaks.

es, in part or in w

t to the co

Specified torque
rrectness of i

Component Specified torque

l purpos

Union nut to tyre pressure sensor 8 Nm

nf
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orm
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atio
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thi
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gh ht
pyri by
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by
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Prote AG.

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

 Golf Variant 2007 ➤ , Jetta 2005 ➤
Running gear, axles, steering - Edition 07.2010

8 Wheel alignment

Special tools and workshop

equipment required
♦ Wheel alignment computer
-V.A.G 1813- or VW/Audi-
approved wheel alignment
computer
♦ Brake pedal depressor -
V.A.G 1869/2-
♦ Tool insert 18 mm -T10179-
♦ Shock absorber set -
T10001-

AG. Volkswagen AG d
agen oes
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nl

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ility
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wit
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spec
es, in part or in w

t to the co
rrectness of i
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atio

8.1 General
om

n in
or c

thi

Wheel alignment must always be checked with VW/Audi-ap‐

te

sd
a

proved wheel alignment equipment.

iv

o
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rp

cu
o

Whenever wheels are aligned, both the front and rear axles must
f

en
ng

t.
yi
be measured.
Co
Cop py
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Otherwise, the steering rack may not be centred! rig ht
py by
co Vo
by lksw
– Perform all measurements with wheel alignment computer. cted agen
Prote AG.

All the information required to perform alignment can be found in

the wheel alignment computer.
Current data »updates« are located on VW Service Net.
⇒ VW ServiceNet; Systems; Wheel alignment computer soft‐
ware; Wheel alignment; Beissbarth
⇒ VW ServiceNet; Systems; Wheel alignment computer soft‐
ware; Wheel alignment; Hunter
⇒ VW ServiceNet; Systems; Wheel alignment computer soft‐
ware; Wheel alignment; Corghi

8. Wheel alignment 261

 Golf Variant 2007 ➤ , Jetta 2005 ➤
Running gear, axles, steering - Edition 07.2010

⇒ VW ServiceNet; Systems; Wheel alignment computer soft‐

ware; Wheel alignment; 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.

Wheel alignment is necessary if:

♦ The vehicle does not handle properly.
♦ Vehicle has been involved in an accident and components
have been renewed.
♦ Axle components are removed or renewed.
♦ Tyres wear on one side.
Components have been renewed
Front axle component was Alignment necessary Rear axle component re‐ Alignment necessary
renewed. newed
Yes No Yes No
Lower suspension link X Lower transverse link X
Bonded rubber bush X 1) Upper transverse link X
for suspension link . Volkswagen AG
gen AG does
Wheel bearing housing X Track
Vol
ksw rod
a
not X
gu
by a
Track rod/track rod ball joint X ris
e Wheel bearing housing
d X rante
tho eo
Steering box X au Subframe X ra
c
ss
Subframe X Coil spring ce X
le
un

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Suspension strut X Shock absorber X

itte

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ab
Subframe bracket X Anti-roll bar X
pe

ility
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Anti-roll bar 1) Trailing arm X

wit

X
, is n

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hole

1)
spec

Prerequisite: the positions of the subframe and brackets were

es, in part or in w

fixed before the parts were removed ⇒ page 16 .

t to the co
rrectness of i

Components removed and installed

l purpos

Front axle component re‐ Alignment necessary Rear axle component re‐ Alignment necessary
moved and reinstalled moved and reinstalled
nform
ercia

Yes No Yes No
m

Lower suspension link X 1) Lower transverse link X

a
com

tion in

Wheel bearing housing X Upper transverse link X

r
te o

thi

Track rod/track rod ball X Track rod X

s
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joint
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Steering box X Wheel bearing housing X

n

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Subframe X 1) Subframe X
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Suspension strut X Coil spring X
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Subframe bracket 1) Shock absorber X
Prote
X
AG.

Anti-roll bar X 1) Anti-roll bar X

Trailing arm X

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

 Golf Variant 2007 ➤ , Jetta 2005 ➤
Running gear, axles, steering - Edition 07.2010

1) Prerequisite: the positions of the subframe and brackets were

fixed before the parts were removed ⇒ page 16 .

8.2 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! agen
AG. Volkswagen AG d
oes
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• The test equipment must be properly ed adjusted and attached
b ara
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is
to the vehicle; observe device manufacturer's
thor operating in‐ eo
structions. s au ra
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s

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e

If necessary, contact the manufacturer for familiarisation with the

nl

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proper use of the wheel alignment equipment.

an
itte

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ab
Wheel alignment platforms and wheel alignment units and com‐

ility
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puters can lose their calibration over a period of time.

wit
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Wheel alignment platforms and alignment units and computers
hole

spec
should be checked and adjusted as necessary during inspection
es, in part or in w

and maintenance at least once per year!

t to the co
– Treat these highly sensitive units carefully and conscientious‐
ly!
rrectness of i
8.3 Test preparations
l purpos

Special tools and workshop equipment required

nform
ercia

♦ Brake pedal depressor -V.A.G 1869/2-

m

at
om

ion
c

in t
or

his
ate

do
priv

cum
for

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

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.

8. Wheel alignment 263

 Golf Variant 2007 ➤ , Jetta 2005 ➤
Running gear, axles, steering - Edition 07.2010

– Apply brake pedal depressor -V.A.G 1869/2- .

– Use brake pedal depressor to depress brake pedal.

8.4 Specifications for wheel alignment Jetta

from 2006, Golf Variant from 2008
• These specifications are valid for all engines in the Jetta from
2006, Golf Variant from 2008.
• Specifications for wheel alignment, Jetta 2005 (North Ameri‐
ca) ⇒ page 265 .
• Specifications for wheel alignment, Bora from 2006 (Mexico)
⇒ page 266
• Specifications for wheel alignment, Jetta from 2006 (India)
⇒ page 267
♦ Explanation of PR Nos. can be found here ⇒ page 275 .
The ride height shown in the table refers to dimension -a-.

AG. Volkswagen AG d
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Front axle Standard running Sports running gear Sports running gear
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gear except 18' wheels with 18' wheels

wit
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PR numbers 2UA 2UC G02, G05, G07, 2UC

h re
hole

spec

Total toe (without load) 10' ± 10′ 10' ± 10′ 10' ± 10′
es, in part or in w

t to the co

Camber (in straight-ahead position) -30′ ± 30′ -41′ ± 30′ -41′ ± 30′
Maximum permissible difference be‐ max. 30' max. 30' max. 30'
tween sides
rrectness of i

Toe-out 1) on turns at 20° left and 1°38′ ± 20′ 1°40′ ± 20′ 1°40′ ± 20′
l purpos

right lock
Caster 7° 34′ ± 30′ 7° 47′ ± 30′ 7° 47′ ± 30′
nform
ercia

Maximum permissible difference be‐ max. 30' max. 30' max. 30'
m

tween sides
at
om

ion

Ride height 382 ± 10 mm 367 ± 10 mm 367 ± 10 mm

c

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ate

1)
Toe-out on turns can be displayed as a negative value on the
do
priv

wheel alignment computer, depending on the manufacturer.

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Front axle Heavy-duty running BlueMotion BlueMotion
py by
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cted gear
AG.
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Jetta from 2006 Golf Variant from
2008
PR numbers 2UB G13, 2UC G14, 2UC
Total toe (without load) 10' ± 10′ 10' ± 10′ 10' ± 10′
Camber (in straight-ahead position) -14′ ± 30′ -41′ ± 30′ -41′ ± 30′
Maximum permissible difference be‐ max. 30' max. 30' max. 30'
tween sides

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

 Golf Variant 2007 ➤ , Jetta 2005 ➤
Running gear, axles, steering - Edition 07.2010

Front axle Heavy-duty running BlueMotion BlueMotion

gear Jetta from 2006 Golf Variant from
2008
PR numbers 2UB G13, 2UC G14, 2UC
Toe-out on turns at 20° left and 1) 1°38′ ± 20′ 1°40′ ± 20′ 1°40′ ± 20′
right lock
Caster 7° 17′ ± 30′ 7° 47′ ± 30′ 7° 47′ ± 30′
Maximum permissible difference be‐ max. 30' max. 30' max. 30'
tween sides
Ride height 402 ± 10 mm 367 ± 10 mm 367 ± 10 mm
1)
Toe-out on turns can be displayed as a negative value on the
wheel alignment computer, depending on the manufacturer.

These specifications apply to all engines.

♦ Explanation of PR Nos. can be found here ⇒ page 275 .
Rear axle, front-wheel drive and Standard running Sports running gear Sports running gear
4WD gear except 18' wheels with 18' wheels
Camber -1° 20′ ± 30′ -1° 20′ ± 30′ -1°45' ± 30'
Maximum permissible difference be‐ max. 30' max. 30' max. 30'
tween sides
Total toe (at specified camber) +10′ ± 12.5′ +10′ ± 12.5′ +10′ ± 12.5′
Max. permissible deviation from di‐ max. 20' max. 20' max. 20'
rection of travel
Ride height 380 ± 10 mm 365 ± 10 mm 365 ± 10 mm

AG. Volkswagen AG d
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Rear axle, front-wheel drive and d by Heavy-duty running BlueMotion
gu
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4WD ise gear Jetta from
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Camber -1° 20′ ± 30′ -1° 20′ ± 30′ -1° 20′ ± 30′
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Maximum permissible difference be‐ max. 30' max. 30' max. 30'
itte

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tween sides
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Total toe (at specified camber) +10′ ± 12.5′ +10′ ± 12.5′ +10′ ± 12.5′
wit
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Max. permissible deviation from di‐ max. 20' max. 20' max. 20'
hole

rection of travel
spec
es, in part or in w

Ride height 400 ± 10 mm 365 ± 10 mm 365 ± 10 mm

t to the co
rrectness of i

8.5 Specifications for wheel alignment Jetta

l purpos

from 2005, Golf Variant from 2008, Bora

SportWagen from 2009 (North America)
nform
ercia

• These specifications are valid for all engines in the Jetta from
m

at
om

2005, Golf Variant from 2008, Bora SportWagen from 2009

ion
c

(North America).
in t
or

his
ate

• Specifications for wheel alignment, Jetta from 2006, Golf Var‐

do
priv

iant from 2008 ⇒ page 264 .

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t.
• Specifications for wheel alignment, Bora from 2006 (Mexico)
yi Co
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⇒ page 266 t. C rig
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• Specifications for wheel alignment, Jetta from 2006 (India)
co Vo
by lksw
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⇒ page 267
agen
Prote AG.

8. Wheel alignment 265

 Golf Variant 2007 ➤ , Jetta 2005 ➤
Running gear, axles, steering - Edition 07.2010

♦ Explanation of PR Nos. can be found here ⇒ page 275 .

The ride height shown in the table refers to dimension -a-.

Front axle Standard running Sports running gear Sports running gear
gear GLI
PR numbers 2UA 2UC G11
Total toe (without load) . Volk10°
swag±en10′ 10° ± 10′ 10° ± 10′
agen AG AG do
Camber (in straight-ahead position)
olks
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-41′ ± 30′ -41′ ± 30′
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Maximum permissibleodifference
ris
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tween sides aut
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ra
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Toe-out on turns 1) at 20° left and
s
1°38′ ± 20′ 1°40′ ± 20′ ce 1°40′ ± 20′
le
un

right lock
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Caster 7° 34′ ± 30′ 7° 47′ ± 30′ 7° 47′ ± 30′
erm

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ot p

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tween sides
is n

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Ride height 382 ± 10 mm 382 ± 10 mm 382 ± 10 mm

spec
urposes, in part or in wh

1)
t to the co

Toe-out on turns can be displayed as a negative value on the

wheel alignment computer, depending on the manufacturer.
rrectne

These specifications apply to all engines.

ss

♦ Explanation of PR Nos. can be found here ⇒ page 275 .

o
cial p

f inform

Rear axle Standard running Sports running gear Sports running gear
mer

gear GLI
atio
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n
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Camber -1° 20′ ± 30′ -1° 20′ ± 30′ -1° 20′ ± 30′
i
or

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Maximum permissible difference be‐ max. 30' max. 30' max. 30'
iva

o
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tween sides
p

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Total toe (at specified camber) +10′ ± 12.5′ +10′ ± 12.5′ +10′ ± 12.5′
t.
yi Co
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Max. permissible deviation from di‐ max. 20' max. 20' max. 20'
. C rig
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rection of travel py by
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Ride height 380 ± 10 mm 380 ± 10 mm 380 ± 10 mm
cted agen
Prote AG.

8.6 Specifications for wheel alignment Bora

from 2006 (Mexico)
• These specifications are valid for all engines in the Bora from
2006 (Mexico).
• Specifications for wheel alignment, Jetta from 2006, Golf Var‐
iant from 2008 ⇒ page 264 .
• Specifications for wheel alignment, Jetta 2005 (North Ameri‐
ca) ⇒ page 265 .

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

 Golf Variant 2007 ➤ , Jetta 2005 ➤
Running gear, axles, steering - Edition 07.2010

• Specifications for wheel alignment, Jetta from 2006 (India)

⇒ page 267
♦ Explanation of PR Nos. can be found here ⇒ page 275 .
The ride height shown in the table refers to dimension -a-.

Front axle Standard running gear Sports running gear GLI

PR numbers 2UD G10
Total toe (without load) 10' ± 10′ 10' ± 10′
Camber (in straight-ahead position) -22′ ± 30′ -41′ ± 30′
Maximum permissible difference between sides max.n A30'
G. Volkswagen AG d max. 30'
wage
ks1°
oes
Toe-out on turns 1) at 20° left and right lock yV
ol 16′ ± 20′ not gu1°40′ ± 20′
b ara
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Caster thoris 7° 26′ ± 30′ 7° 47′
nte
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au ra
Maximum permissible difference between sides ss max. 30' max. 30' c

ce
le

Ride height 393 ± 10 mm 382 ± 10 mm

un

pt
an
d
itte

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1)
Toe-out on turns can be displayed as a negative value on the
erm

ab
ility
wheel alignment computer, depending on the manufacturer.
ot p

wit
is n

h re
ole,

spec
urposes, in part or in wh

These specifications apply to all engines.

t to the co
♦ Explanation of PR Nos. can be found here ⇒ page 275 .
Rear axle Standard running gear Sports running gear GLI

rrectne
Camber -1° 20′ ± 30′ -1° 20′ ± 30′
Maximum permissible difference between sides max. 30' max. 30' ss o
cial p

Total toe (at specified camber) +10′ ± 12.5′ +10′ ± 12.5′

inform
mer

Max. permissible deviation from direction of max. 20' max. 20'

atio

travel
om

n
c

Ride height 389 ± 10 mm 380 ± 10 mm

or

n thi
te

sd
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8.7 Specifications for wheel alignment, Jetta

t.
yi Co
Cop py
from 2006 (India)
ht. rig
rig ht
py by
co Vo
by lksw
• These specifications are valid for all engines in the Jetta from cted agen
Prote AG.
2006 (India).
• Specifications for wheel alignment, Jetta from 2006, Golf Var‐
iant from 2008 ⇒ page 264 .
• Specifications for wheel alignment, Jetta 2005 (North Ameri‐
ca) ⇒ page 265 .
• Specifications for wheel alignment, Bora from 2006 (Mexico)
⇒ page 266

8. Wheel alignment 267

 Golf Variant 2007 ➤ , Jetta 2005 ➤
Running gear, axles, steering - Edition 07.2010

♦ Explanation of PR Nos. can be found here ⇒ page 275 .

The ride height shown in the table refers to wdimension
agen
AG. Volk-a-.
swagen AG
doe
ks s no
Vol t gu
d by ara
e nte
ris
utho eo
ra
a c
ss

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le
un

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d
itte

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erm

ab
ility
ot p

wit
is n

h re
ole,

spec
urposes, in part or in wh

t to the co
Front axle Standard running gear

rrectne
PR numbers G56, 2UE
Total toe (without load) 10' ± 10′

ss
Camber (in straight-ahead position) -18′ ± 30′

o
cial p

f in
Maximum permissible difference between sides max. 30'

form
mer

Toe-out on turns 1) at 20° left and right lock 1° 27′ ± 20′

atio
om

n
c

Caster 7° 21′ ± 30′

i
or

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Maximum permissible difference between sides max. 30'

t

sd
iva

o
pr

c
Ride height 397 ± 10 mm

um
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en
ng

t.
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1)
Toe-out on turns can be displayed as a negative value on the Cop py
t. rig
wheel alignment computer, depending on the manufacturer. opyri
gh by
Vo
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c by lksw
cted agen
Prote AG.

These specifications apply to all engines.

♦ Explanation of PR Nos. can be found here ⇒ page 275 .
Rear axle Standard running gear
Camber -1° 20′ ± 30′
Maximum permissible difference between sides max. 30'
Total toe (at specified camber) +10′ ± 12.5′
Max. permissible deviation from direction of travel max. 20'
Ride height 395 ± 10 mm

8.8 Overview - wheel alignment procedure

Always adhere to the following procedure!
– Observe instructions for your wheel alignment device.

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

 Golf Variant 2007 ➤ , Jetta 2005 ➤
Running gear, axles, steering - Edition 07.2010

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 270 .
↓ ↓
↓ ← ← ← ← ←
↓
Check rear axle camber → Is actual value within toler‐ → No
ance?
↓ ↓
↓ ← ← Yes Adjust ⇒ page 271 .
↓ ↓
↓ ← ← ← ← ←
↓
Check rear axle toe → Is actual value within toler‐ → No
ance?
↓ ↓
↓ ← ← Yes Adjust ⇒ page 273 .
↓ agen AG. Volkswagen AG
does ↓
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↓ ← ← Vol
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b gu
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↓ ris tee
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sa a
Check front axle caster → Is sactual valuewithin toler‐ → No c
ance?
ce
e
nl

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↓ ↓
itte

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↓ ← ← Yes Inspect axle components and

ility
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body
wit
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↓ ↓
hole

spec

↓ ← ← ← ← ←
es, in part or in w

t to the co

↓
Check front axle toe → Is actual value within toler‐ → No
ance?
rrectness of i

↓ ↓
l purpos

End ← Yes Adjust ⇒ page 273 .

↑ ↓
nform
ercia

↑ ← ← ← ← ←
m

at
om

io

1) If steering wheel is not centred, it must be straightened after

n
c

in t
or

wheel alignment is finished. Then perform basic settings for steer‐

his
ate

ing angle sensor -G85- using vehicle diagnostic, testing and

do
priv

information system -VAS 5051- .

cum
for

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ng

t.
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t. rig
gh ht
pyri by
Vo
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by
cted agen
Prote AG.

8. Wheel alignment 269

 Golf Variant 2007 ➤ , Jetta 2005 ➤
Running gear, axles, steering - Edition 07.2010 agen
AG. Volkswagen AG d
oes
olksw not
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b ara
8.9 Correcting front axle camber
d
rise nte
tho eo
au ra
Special tools and workshop equipment required ss c

ce
e
nl

pt
♦ Torque wrench -V.A.G 1332-

du

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itte

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erm

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ility
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wit
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hole

spec
es, in part or in w

t to the co
rrectness of i
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nform
mercia

at
Note
om

ion
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or

♦ Camber correction is necessary only after body repairs. The

his
ate

camber is not adjustable, but can be equalized by moving the

do
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brackets and/or the subframe.

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t.
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♦ Move subframe only to left or right, but never in or opposite to
Co
op py
direction of normal travel!
t. C rig
gh ht
pyri by
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co lksw
by
cted
– Remove noise insulation.
agen
Prote AG.

– Loosen bolts -1- for bracket attachment and subframe 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 .
– Specification for camber may be adjusted by moving subframe
at brackets.
– Tighten bolts for subframe and brackets to body to specified
torque plus extra turn angle.
Following the movement of the subframe and, consequently, the
steering box, clearance between the steering column universal
joint and the notch in the bulkhead must be checked.

– Unscrew securing nuts -arrows- and remove footwell trim -1-.

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

 Golf Variant 2007 ➤ , Jetta 2005 ➤
n AG. Volkswagen AG do
lkswage Running
es n gear, axles, steering - Edition 07.2010
Vo ot g
by ua
ed ran
There must be a clearance thor of 5 mm all round between universal
is tee
or
joint -2- and recess ins abulkhead.
u ac
s

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le
un

pt
an
d
itte

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erm

ab
ility
ot p

wit
is n

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ole,

spec
urposes, in part or in wh

t to the co
rrectne
Specified torques

ss
Component Specified torque

o
cial p

f in
Subframe to body 70 Nm + 90°

form
mer

♦ Use new bolts

atio
om

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c

i
Bracket to body 70 Nm + 90°
or

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♦ Use new bolts

t

sd
iva

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pr

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Cop py
.
8.10 Adjusting camber on rear axle
t rig
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Special tools and workshop equipment required
cted agen
Prote AG.

♦ Shock absorber set -T10001-

♦ Tool insert 18 mm -T10179-

8. Wheel alignment 271

 AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
Golf Variant 2007 r➤ is , Jetta 2005 ➤
ed
nte
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Running gear,aaxles,
ut
h
steering - Edition 07.2010 ra
ss c

ce
e
– Loosen upper transverse link nut -A- on subframe.

nl

pt
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erm

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ility
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spec
es, in part or in w

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– Adjust camber by turning eccentric bolt -B- with 18 mm socket

nf
ercia

-T10001- -1-.

orm
m

atio
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c

Note
or

thi
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The maximum adjustment range is 90° to the left or right of centre.

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Cop py
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rig ht
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Prote AG.

– Tighten nut -A-.

– Use socket (18 mm) -T10179-

– Check camber value again after tightening nut -A-.

Specified torques
Component Specified torque
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-

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

 Golf Variant 2007 ➤ , Jetta 2005 ➤
Running gear, axles, steering - Edition 07.2010

Component AG. Volkswagen AG d Specified torque

agen oes
lksw not
Upper transverse by V link to subframe (vehicles with
o gufront-
ara 95 Nm
wheel drive)
orise
d
nte ♦ To tighten nuts, set torque wrench -V.A.G
♦ Useaunew
th nut eo
ra 1332- to 80 Nm
ss c
♦ Tighten threaded connections only when vehicle is in ♦ Applies only in conjunction with insert tool,

ce
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nl

pt
the normal running position 18 mm -T10179-
du

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erm

ab
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wit
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h re
8.11 Adjusting toe at rear axle
hole

spec
es, in part or in w

Special tools and workshop equipment required

t to the co
♦ Torque wrench -V.A.G 1332-

rrectness of i
l purpos

nform
mercia

at
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c

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or

his
ate

do
priv

cum
for

en
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op py
– Loosen nut -1-.
t. C rig
gh ht
pyri by
Vo
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– Turn eccentric bolt -2- until specification is attained.
c by lksw
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Prote AG.
– Now tighten nut.

Specified torque
Component Specified torque
Lower transverse link to subframe 95 Nm
♦ Use new nut
♦ Tighten threaded connections only when vehicle is in
the normal running position

8.12 Adjusting front axle toe

Special tools and workshop equipment required

8. Wheel alignment 273

 Golf Variant 2007 ➤ , Jetta 2005 ➤
Running gear, axles, steering - Edition 07.2010

♦ Torque wrench -V.A.G 1332-

♦ Tool insert 24 mm -V.A.G 1332/11-

– Loosen lock nut -arrow 3- counterholding on track rod ball joint
-arrow 2-.
– Pull spring-type clip -arrow 1- off boot.
– Adjust toe by turning left and/or right track rod.
To do this, use an open-end spanner on hexagon flats on track
rod.
After turning track rods, ensure that boots are not twisted.
Twisted boots wear out quickly.
n AG. Volkswagen AG do
lkswage es n
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– Tighten locknut with tool insert
uth 24 mm -V.A.G 1332/11- while
o
or
counterholding track rod ball
ss joint -1-.
a ac
ce
e
nl

– Check toe values again.

pt
du

an
itte

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It is possible that the value will change slightly when lock nut is
erm

ab

tightened.
ility
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wit
, is n

However, if the measured toe value lies within the tolerance, the
h re

adjustment is correct.
hole

spec
es, in part or in w

– Fit spring-type clip to boot.

t to the co
rrectness of i
l purpos

Specified torques
Component Specified torque
nform
ercia

Track rod ball joint to track rod 55 Nm

m

at
om

ion
c

in t
or

his
te

8.13 Basic setting for steering angle sender -

a

do
priv

cum

G85-
for

en
ng

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op
If steering wheel was realigned, basic settings for steering angle C py
t. rig
sensor -G85- must be checked. ⇒ Perform basic settings in gui‐
gh ht
pyri by
ded fault finding using vehicle diagnostic, testing and information
co Vo
by lksw
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system -VAS 5051B- .
agen
Prote AG.

Select „Select function/component“ by pressing Go to button.

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

 Golf Variant 2007 ➤ , Jetta 2005 ➤
Running gear, axles, steering - Edition 07.2010

8.14 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. gen AG
. Volkswagen AG
a does
lksw not
The running gear version fitted in the vehicle
db
y is
Vo indicated on the gu
ara
vehicle data sticker by the PR number for
or
is the front axle.
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The vehicle data sticker can be found
ss in the spare wheel well and
a c
in the service booklet.

ce
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pt
du

an
Example of a vehicle data sticker
itte

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erm

ab
In this example the vehicle is equipped with the sports running

ility
ot p

gear 2UC -arrow-.

wit
, is n

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hole

spec
es, in part or in w

t to the co
rrectness of i
l purpos

nform
mercia

at
om

ion
c

in t
or

his
ate

do
priv

cum
for

en
ng

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

8. Wheel alignment 275

 Golf Variant 2007 ➤ , Jetta 2005 ➤
Running gear, axles, steering - Edition 07.2010

9 Wheels, tyres

9.1 Models with breakdown set

These vehicles are equipped with either a spare wheel or a break‐
down set.
The breakdown set is located in the luggage compartment where
normally the spare wheel would sit. It consists of a compressor
and a bottle of tyre sealant -1-.

9.2 Tyre sealant

AG. Volkswagen AG d
The tyre sealant in the bottle has a limited shelf-life. lksw
agen oes
not
Vo gu
by
The bottle -1- therefore has an expiry date -arrow-. rise d ara
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Renew tyre sealant when the expiry date is reacheds a (the tyre
u ra
c
sealant must not be older than 4 years). s

ce
e
nl

pt
du

If the bottle has been opened, e.g. to repair a tyre, then it must

an
itte

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also be renewed.
erm

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ility
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Observe regulations for disposal.

wit
, is n

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hole

spec
es, in part or in w

t to the co
rrectness of i
9.3 Removing a tyre
l purpos

Tyres which have been filled or sealed using tyre sealant must be
drained before removal.
nf
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orm
m

atio

WARNING
om

n in
or c

♦ Avoid eye and skin contact with tyre sealant.

thi
te

sd
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r

♦ It is a health hazard and may cause eye irritation and al‐

rp

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lergies.
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♦ Wear eye protection and protective gloves whilst working C py
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on the tyre.
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

– Place wheel on a flat surface.

– Remove valve core of tyre valve.

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

 Golf Variant 2007 ➤ , Jetta 2005 ➤
Running gear, axles, steering - Edition 07.2010

– 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 wheel rim.
– Clean wheel rim with, for example, a moist cloth.

9.4 Fitting a new tyre

• Ensure that the wheel rim is clean.
– Insert new tyre valve with -VAS 6459- -1-.
– Remove valve core.
– Inflate tyre to approx. 3 . . 4 bar. Bead of tyre must slip audibly
over hump of rim.
– Screw in valve core.
– Correct inflation pressure to prescribed pressure.
– Balance wheel.

9.5 Tyre sealant disposal swage

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♦ Tyre sealant or residue must not be mixed or disposed dof with
b ua
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ir se
other fluids. tho tee
or
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♦ Excess tyre sealant must be collected and stored in a plastic ss

ce
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container. The plastic container can be disposed of through

un

pt
the disposal system along with the breakdown set (when the

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expiry date is exceeded).
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♦ The items can be returned or disposed of through the existing

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workshop disposal system.

h re
ole,

spec
♦ Request information through your service provider or the dis‐
urposes, in part or in wh

posal representative at your distribution centre or importer. t to the co

9.6 Alloy wheels with metal valves

rrectne

Tyres with hollow chambers are installed in some models. These

hollow-chamber wheels are fitted with metal valves instead of the
ss o
cial p

f inform
mer

atio
om

n
c

i
or

n thi
te

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pr

cum
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fo

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

9. Wheels, tyres 277

 Golf Variant 2007 ➤ , Jetta 2005 ➤
Running gear, axles, steering - Edition 07.2010

usual rubber valves. Metal valves must be renewed completely

each time a tyre is changed.

1 - Wheel rim
2 - Valve cap
3 - Hexagon nut
❑ 4 Nm n AG. Volkswagen AG do
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4- Washer d byV ua
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5- Sealing ring autho
or
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6 - Metal valve

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es, in part or in w

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tion in
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te o

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cum
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en
ng

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

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

 Golf Variant 2007 ➤ , Jetta 2005 ➤
Running gear, axles, steering - Edition 07.2010

10 Instructions for changing or fitting

wheels

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.

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

are free of corrosion and dirt.
en AG. V
olkswagen AG
wag does
olks not
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– Check to ensure that contact surface -arrow- on centring seat
of brake disc are free of corrosion and dirt.

rrectness of i
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a
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tion in
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te o

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– Check to ensure that contact surface -arrow- on inner side of op
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wheel (rim) and also centring seat of rim are free of corrosion
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and dirt.
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– The concave seats * in the holes for the wheel bolts and the
cted agen
Prote AG.
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.

10. Instructions for changing or fitting wheels 279

 Golf Variant 2007 ➤ , Jetta 2005 ➤
Running gear, axles, steering - Edition 07.2010

– 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.
Remove dirt and corrosion, oil or grease from the contact surfa‐
ces, threads in the wheel hub and/or wheel bolts as necessary.

WARNING

Damaged, badly corroded or difficult to remove wheel bolts

must be renewed.

10.1 Fitting wheels

– Preserve wheel centring seat ⇒ page 281 .
1- When fitting the wheel, screw in all wheel bolts uniformly by
hand. wage
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2- Tighten the wheel bolts ineddiagonal
by
V
sequence to approx. ara
30 Nm. ho
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3- Lower the vehicle to
ss the floor and tighten all wheel bolts di‐ c
agonally to the specified torque using the torque wrench
ce
le
un

pt
⇒ page 241 .
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WARNING
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Do not use an impact driver when screwing in the bolts!

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urposes, in part or in wh

t to the co
rrectness o
cial p

f inform
mer

atio
om

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i
or

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

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

 Golf Variant 2007 ➤ , Jetta 2005 ➤
Running gear, axles, steering - Edition 07.2010

11 Protecting wheel centring seat

against corrosion
Applies to alloy and steel wheels
When a wheel is installed, wheel centring seat should be waxed
with
Wax spray -D 322 000 A2-
to prevent corrosion between the wheel centring seat and the
wheel rim.
– Remove wheel.
– Clean wheel centring seat of hub and centring ring of wheel
rim.
– Apply wax to centring ring -arrow- with a brush.
Volkswa AG. gen AG
agen do
Ensure that only centring ring olk-arrow-
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wheel rim has been waxed.ed b Otherwise, the brakes will be soiled,
ua
ran
ris
which would reduce tthe
ho braking efficiency.
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WARNING
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Wheel bolts, contact surfaces of wheel hub and wheel rim and
erm

ab
ility
wheel hub threads must not be waxed. Never treat wheel se‐
ot p

wit
curing bolts with lubricant or corrosion protection materials!
, is n

h re
hole

spec
es, in part or in w

– Install wheel and tighten bolts or nuts ⇒ page 241 .

t to the co
rrectness of i
l purpos

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ercia

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or c

thi
te

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

11. Protecting wheel centring seat against corrosion 281

 Golf Variant 2007 ➤ , Jetta 2005 ➤
Running gear, axles, steering - Edition 07.2010

12 Rough running due to wheels/tyres -

causes and rectification AG. Volkswagen AG d
agen oes
Causes of rough running ⇒ page 282 olksw not
byV gu
ara
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nte
Balancing wheels ⇒ page 282 horis
eo
aut ra
Conducting a road test before balancing wheels ⇒ page 282 ss c

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nl

pt
Balancing wheels on stationary wheel balancer ⇒ page 283

du

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erm
Vibration control system -VAS 6230- ⇒ page 285

ab
ility
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Finish balancer ⇒ page 285

wit
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Radial and lateral run-out on wheels and tyres ⇒ page 286
hole

spec
es, in part or in w

Checking radial and lateral runout on wheels and tyres with tyre

t to the co
gauge -V.A.G 1435- ⇒ page 286
Checking radial and lateral run-out on wheel rim ⇒ page 287

rrectness of i
Matching ⇒ page 288
l purpos

Flat spots caused by storage or handling ⇒ page 289

12.1 Causes of rough running

nf
ercia

orm
m

atio
Rough running can have a number of different causes. It can also
om

be caused by tyre wear. Tyre wear caused by driving is not always

n in
or c

evenly spread across the entire running surface of the tyre. This

thi
te

sd
a

causes slight imbalances which affect the smooth running of a

iv

o
r
rp

cu
wheel which was previously exactly balanced.
o

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f

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ng

t.
Minor imbalances will not be felt at the steering wheel, but that
yi Co
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does not mean that they are not there. They increase wear on the
C py
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tyre and thus reduce the tyre service life.
rig ht
py by
co Vo
by lksw
cted
Recommendation
agen
Prote AG.

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.

12.2 Balancing wheels

Before you start balancing the wheels, the following requirements
must be met.
• The tyre 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.

12.3 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.

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

 Golf Variant 2007 ➤ , Jetta 2005 ➤
Running gear, axles, steering - Edition 07.2010

♦ This will give you information about the nature of the rough
running.
♦ You will be able to determine in which speed range the 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 from vehicle.
– Balance the wheels.

12.4 Balancing wheels on stationary wheel

balancing machine
• Road test has been carried out ⇒ page 282 .
n AG. Volkswagen AG do
Clamp wheel into wheel balancing machine lkswage es n
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Note auth or
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When balancing wheels, please remember that cleanliness is ab‐

un

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an
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solutely essential, as indeed it is in the case of any other repair

itte

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work you carry out. Only then can you attain a flawless result!
erm

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Dirt and rust in the area of the contact surfaces and centre of the

h re
ole,

wheel distort the result.

spec
urposes, in part or in wh

– Clean the contact surfaces, the centre of the wheel and the

t to the co
recess on the inside of the wheel before mounting the wheel
on the wheel balancer.

rrectne
– Mount the wheel with tyre on the wheel balancer.

ss o
cial p

f inform
mer

atio
om

n
c

i
or

n thi
te

sd
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pr

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

12. Rough running due to wheels/tyres - causes and rectification 283

 Golf Variant 2007 ➤ , Jetta 2005 ➤
Running gear, axles, steering - Edition 07.2010

Note

♦ To clamp the wheel, use e.g. centring system for wheel bal‐
ancing machines -VAS 5271- .
♦ 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 tyresAG. Volkswagen

gen AG do
swa es n
– Rotate wheel and tyre on wheel
by
Vol balancer.
k ot g
ua
ed ran
– Check that the indicator ris
ho lines on the sidewall of the tyre near tee
the wheel rim flange autrun evenly. or
ac
s s

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le

– Check that the body of the tyre runs evenly while the wheel
un

pt
and tyre are rotating.

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rm

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ot

Note

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If one-sided wear, flat spots from braking or severely washed out
es, in part or in w

spots are apparent, balancing cannot achieve smooth running. In

t to the co
this case, the tyre must be renewed.

– Check the true running of the wheel and tyre. If the wheel and rrectness of i
tyre do not run true although there are no flat spots, radial or
l purpos

lateral runout may be the cause.

– Check the wheel for radial or lateral runout ⇒ page 286 .
nform
ercia

– If radial and lateral runout are within the specified tolerance,

m

balance the wheel and tyre.

a
com

tion in
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thi

Note
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rp

cum
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♦ More than 60 grams of weight per tyre should not be used.

en
ng

t.
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♦ If more weight is required, you may be able to achieve smooth‐ t. C rig
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er running by "matching" the tyre and rim. Matching tyres yri
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⇒ page 288 .
by c lksw
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Prote AG.
♦ The wheel balancer display should indicate 0 gram.
♦ As an alternative to match mounting, you could use the vibra‐
tion control system -VAS 6230- ⇒ page 285 .

– Bolt the wheel to the vehicle.

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

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

 Golf Variant 2007 ➤ , Jetta 2005 ➤
Running gear, axles, steering - Edition 07.2010

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 285

12.5 Vibration control system -VAS 6230-

Using the vibration control system -VAS 6230- 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- 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.

AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
d
12.6 Finish balancer ise nte
or eo
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nl

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Note
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erm

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

ility
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have been instructed by the manufacturer of the balancer. wit

, is n

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♦ To balance the wheels, set the wheels of the driven axle on
hole

spec

the sensor platforms (only the front wheels of a front-wheel

es, in part or in w

drive vehicle, all four wheels of a four-wheel drive vehicle).

t to the co

If you determine a residual imbalance greater than 20 grams

when balancing the wheels, you should rotate the mounting po‐
rrectness of i

sition of the wheel on the hub.

l purpos

– Mark the point at which the imbalance is indicated.

nform

– Unbolt the wheel and rotate its position on the hub so that the
ercia

marking points downwards.

m

at
om

ion
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The hub must not rotate during this procedure.

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– First hand-tighten the lowest wheel bolt to about 30 Nm. . C rig
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– Then tighten the remaining wheel bolts diagonally to about
co Vo
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30 Nm. This process ensures that the wheel is centred prop‐
agen
Prote AG.
erly on the hub.
– Check whether the imbalance is less than 20 grams using the
finish balancer.

12. Rough running due to wheels/tyres - causes and rectification 285

 Golf Variant 2007 ➤ , Jetta 2005 ➤
Running gear, axles, steering - Edition 07.2010

Note

The imbalance should always be less than 20 grams before you

change the balance weight.

– If necessary, remove the wheel bolts again.

– Rotate the wheel relative to the hub once more, turning it one
or two wheel bolt holes further.
– Tighten the wheel bolts using the method described above.

Note

Do not try to reduce the imbalance using balance weights until

the imbalance is less than 20 grams.

– Balance the wheels until the imbalance is less than 5 grams.

– Tighten wheel bolts to specified torque if you have not already
done so.
AG. Volkswagen AG d
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Always tighten wheel bolts to specified torque using
ss a
a torque c
wrench!

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12.7 Radial and lateral runout of wheels and
pe

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tyres

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Radial and lateral runout occur when the wheel and tyre do not
es, in part or in w

run absolutely true.

t to the co
For technical reasons, 100% true running is not possible.

rrectness of i
Therefore, the manufacturers of these components allow a pre‐
cisely determined tolerance.
l purpos

Mounting the tyre in an unfavourable position on the wheel can

cause the maximum allowed tolerance for wheel with tyre to be nform
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exceeded.
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The table shows the maximum permissible tolerances for a wheel

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with mounted tyre.

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Tolerances for radial and lateral runout of wheels with tyres

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Wheel with tyre Radial runout (mm) Lateral runout (mm)

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12.8 Checking radial and lateral runout on

wheels and tyres with tyre gauge -V.A.G
1435-
Checking lateral runout
– Preload tyre gauge about 2 mm.

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

 Golf Variant 2007 ➤ , Jetta 2005 ➤
Running gear, axles, steering - Edition 07.2010

– Set tyre gauge against sidewall of tyre.

– Slowly rotate the wheel.
– Note the smallest and the largest dial readings.

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 288 .
Extreme values on the tyre gauge due to small irregularities in the
rubber may be disregarded.
Checking radial runout
– Preload tyre gauge about 2 mm.

– Set the tyre gauge against the tyre tread.

– Slowly rotate the wheel.
– Note the smallest and the largest dial readings.

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 288 .

12.9 Checking radial and lateral runout on

wheel rim
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– Mount the wheel on the wheel balancer . Volkswa not
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– Use the wheel balancing machine centring
ris
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system -VAS nte
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– Preload tyre gauge about 2 mm.
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– Slowly rotate the wheel.

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– Note the smallest and the largest dial readings.

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S - Lateral runout
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H - Radial runout
es, in part or in w

t to the co

– Compare the measured values with the specifications in the

table ⇒ page 287 .
rrectness of i

Note
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Extreme values on the tyre gauge due to small irregularities may

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be disregarded.
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Specifications for radial and lateral runout on wheel rim

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Wheel rim Radial runout (mm) Lateral runout (mm)

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Steel wheel 0.5 0.5

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Cop py
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287
by c lksw
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12. Rough running due to wheels/tyres - causes and rectification
agen
Prote AG.
 Golf Variant 2007 ➤ , Jetta 2005 ➤
Running gear, axles, steering - Edition 07.2010

Wheel rim Radial runout (mm) Lateral runout (mm)

Alloy wheel 0.5 0.8

Note

If the measured value exceeds the specification, acceptably

smooth running cannot be attained.

12.10 Matching
General
When radial or lateral runout of the wheel and tyre coincide, the
imbalance of the wheel is amplified by the tyre.
For technical reasons, 100% true running is not possible
⇒ page 286 .
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 289 .
Procedure for match mounting AG. Volkswagen AG d
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– Deflate the tyre. olksw not
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– Press the tyre beads off the rim flanges. rise nte
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– Coat the tyre bead all round with tyre fitting paste . ss c

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pt
– Rotate the tyre 180° relative to the wheel.
du

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– Inflate the tyre to approx. 4 bar.

ab
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– Mount the wheel with tyre on the wheel balancer.

wit
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– Check true running, that is, radial and lateral runout.
hole

spec
es, in part or in w

t to the co
Note

rrectness of i
♦ If the specified values for radial and lateral runout are not ex‐
ceeded, the wheel can be balanced to 0 gram. Specified
l purpos

values appear on ⇒ page 286 .

♦ If the radial and lateral runout is not within the specifications,
nform
ercia

the tyre must be rotated again.

m

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io

– Deflate the tyre and press off the tyre beads from the rim
n
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flanges.
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– Rotate the tyre 90° with respect to the wheel (1/4 of a turn).
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– Inflate the tyre to 4 bar again and check true running.

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Note cop Vo
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♦ 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 the tyre off the rim flanges again as described above.
– Rotate the tyre 180° with respect to the wheel (1/2 a turn).

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

 Golf Variant 2007 ➤ , Jetta 2005 ➤
Running gear, axles, steering - Edition 07.2010

If the radial and/or lateral runouts are still not within the specifi‐
cations, check the radial and/or lateral runouts of the wheel:
⇒ page 287 .
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.
♦ Therefore, severe braking and acceleration manoeuvres must
be avoided for the first 100 or 200 km driven. The tyres may
otherwise rotate on the rims and your work will have been in
vain.

12.11 Flat spots caused by storage or handling

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 ⇒ Wheel and Tyre Guide - Series; Rep. gr. 44 ;
AG. Volkswagen AG d
Rolling noises due to tyres, locked
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Note tho or
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Flat spots caused by hard braking cannot be repaired. Such tyres

nl

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

wit
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♦ The vehicle has been left standing in one place without being
hole

spec

moved for several weeks.

es, in part or in w

t to the co

♦ The tyre inflation pressure is too low.

♦ The vehicle was placed in a paint shop drying booth after being
painted.
rrectness of i

♦ The vehicle was parked with warm tyres in a cool garage or

l purpos

similar for a long period of time. In this case, a standing flat

spot may even occur overnight.
nform
ercia

Eliminating flat spots caused by storage or handling

m

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om

♦ Flat spots caused by storage or handling cannot be eliminated

ion
c

from the tyre using workshop equipment.

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ate

♦ Flat spots caused by storage or handling can be removed only

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by running the tyres warm.

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♦ The method described below is not recommended in cold and
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Requirements and conditions:
co Vo
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Prote AG.
– Check and, if necessary, correct inflation pressures.
– Drive the car on a motorway where possible.

12. Rough running due to wheels/tyres - causes and rectification 289

 Golf Variant 2007 ➤ , Jetta 2005 ➤
Running gear, axles, steering - Edition 07.2010

– Traffic and road conditions permitting, drive a 20 to 30 km

stretch at a speed of 120 to 150 km/h.

WARNING

♦ Do not endanger yourself or other road users during this

road test.
AG. Volkswagen AG d
♦ Observe the highway code and speed limitations in force ksw
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not
when performing the road test. y Vol gu
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– Raise the vehicle immediately following the road
s test.

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– Remove the wheels from the vehicle.

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ab
– Balance the wheels on a stationary wheel balancer

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⇒ page 283 .

wit
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es, in part or in w

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Cop py
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Prote AG.

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

 Golf Variant 2007 ➤ , Jetta 2005 ➤
Running gear, axles, steering - Edition 07.2010

48 – Steering
1 Appraisal of accident vehicles
A checklist for evaluating running gear of accident vehicles can
be found under ⇒ page 1 .

AG. Volkswagen AG d
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1. Appraisal of accident vehicles 291

 Golf Variant 2007 ➤ , Jetta 2005 ➤
Running gear, axles, steering - Edition 07.2010

2 General repair instructions

To achieve the desired results when performing repairs on the
steering box 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 steering as‐
sembly, see ⇒ Self-study programme No. 317 ; The electro-
mechanical power steering with dual pinion .

2.1 Steering box

♦ Thoroughly clean all unions and the adjacent areas before
disconnecting.
♦ When installing the steering box, make sure that dowel
sleeves between bracket and steering box are seated correct‐
ly.
♦ 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.
♦ From model year 2009, a new, 3rd generation, steering box is
being used. Notes on differentiating between
agen
A2nd
G. Voand
lkswa3rd
gen AG
does
generations ⇒ page 360 . Volksw not
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ise
2.2 Gaskets and seals tho
r tee
or
au ac
ss
♦ Always renew gaskets and seals.
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♦ After removing all seals, inspect the contact faces on housings

an
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and shafts for burrs and damage and remove all which are
erm

ab

found.
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wit
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♦ Completely remove all residue from liquid sealants from the

h re
ole,

sealing surfaces, making sure that no residual sealant gets

spec

into the steering box housing.

urposes, in part or in wh

t to the co

2.3 Nuts and bolts

♦ Loosen and tighten bolts and nuts securing covers and hous‐
rrectne

ings diagonally.
♦ Do not cant sensitive parts but loosen and tighten them in
ss

stages in a crosswise pattern.

o
cial p

f inform

♦ The given torque settings are for unlubricated nuts, bolts and
mer

screws.
atio
om

♦ Always renew self-locking nuts and bolts.

c

i
or

n thi
te

sd
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pr

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en
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t.
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Cop py
t. rig
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by c lksw
cted agen
Prote AG.

292 Rep. gr.48 - Steering

 Golf Variant 2007 ➤ , Jetta 2005 ➤
Running gear, axles, steering - Edition 07.2010

2.4 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 box components.
– Before working on electrical components, touch an earthed
object, such as a water pipe or a lifting platform. Do not touch
the plug connector of the electrical connectors with bare
hands.

n AG. Volkswagen AG do
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2.5 Guided fault-finding, vehicle self-diag‐ lks es n
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nosis and test instruments
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♦ Before performing repair work on the electromechanical
ss steer‐

ce
e

ing box, determine the cause of damage as precisely as

nl

pt
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possible using the vehicle diagnostic, testing and information

an
itte

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system -VAS 5051B- in „guided fault finding“, „vehicle self-di‐
erm

ab
agnosis“ and „test instruments“ operating modes.

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wit
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spec
es, in part or in w

t to the co
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Prote AG.

2. General repair instructions 293

 Golf Variant 2007 ➤ , Jetta 2005 ➤
Running gear, axles, steering - Edition 07.2010

3 Steering wheel, steering column

3.1 Removing and installing steering wheel

Special tools and workshop equipment required
♦ Torque wrench -V.A.G 1332-

Removing
– Remove airbag in steering wheel ⇒ General body repairs, in‐
terior; Rep. gr. 69 ; Airbag; Removing and installing driver side
airbag unit .
– Separate connectors -1- and -2- for coil connector.

n AG. Volkswagen AG do
lkswage es n
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nl

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erm

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ility
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wit
, is n

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hole

spec
es, in part or in w

t to the co
rrectness of i
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nform
mercia

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om

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c

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or

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ate

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for

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Cop py
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co lksw
by
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294
Prote AG.
Rep. gr.48 - Steering
 Golf Variant 2007 ➤ , Jetta 2005 ➤
Running
gen AG. gear,
Volkswaaxles,
gen AGsteering - Edition 07.2010
d
wa oes
olks not
byV gu
ara
ed nte
ris
tho eo
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nl

pt
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erm

ab
ility
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wit
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hole

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es, in part or in w

t to the co
rrectness of i
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nf
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orm
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– Centre steering wheel (wheels in straight-ahead position).

– Remove bolt -3- and pull steering wheel from steering column.
Installing
– Set steering wheel onto steering column.
– Centre markings of steering wheel and steering column
-arrows- must align.

3. Steering wheel, steering column 295

 Golf Variant 2007 ➤ , Jetta 2005 ➤
Running gear, axles, steering - Edition 07.2010

AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
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spec
urposes, in part or in wh

t to the co
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– Guide connector for steering angle sender -G85- into intended
AG.

opening in the base of steering wheel.

– Join connector -1- with the connector -2- of the steering angle
sender -G85- .
– Secure steering wheel with bolt -3-.
Specified torque
Component Specified torque
Steering wheel to steering column 30 Nm + 90° further
♦ Always renew bolt

296 Rep. gr.48 - Steering

 Golf Variant 2007 ➤ , Jetta 2005 ➤
Running gear, axles, steering - Edition 07.2010

3.2 Assembly overview - steering column, Golf Variant up to model year 2009,
Jetta up to model year 2008

Note

♦ It is not permitted to weld or straighten load-bearing or wheel-guiding components of the suspension.

♦ Always renew self-locking nuts.
♦ Always renew corroded nuts and bolts.
AG. Volkswagen AG d
agen oes
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1 - Hexagon bolt rised
nte
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❑ 20 Nm aut ra
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ss
2 - Cross member for steering

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column

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3 - Mounting bracket

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❑ Removing and installing

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⇒ page 321 .

h re
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spec
4 - Bolt
es, in part or in w

t to the co
❑ 20 Nm
❑ Always renew after re‐
moving.

rrectness of i
5 - Steering column
l purpos

❑ Removing and installing

⇒ page 297 .

nform
ercia

6 - Handle
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7 - Bolt
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❑ 3 Nm
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8 - Crash bar for brake pedal

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9 - Crash bar for clutch pedal

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10 - Bolt
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❑ 30 Nm
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❑ Always renew after re‐ Prote AG.

moving.
11 - Strut
❑ Removing and installing
⇒ page 323 .
12 - Bolt
❑ 20 Nm
13 - Bolt
❑ 20 Nm

3.3 Removing and installing steering col‐

umn, Golf Variant up to model year
2009, Jetta up to model year 2008
Special tools and workshop equipment required

3. Steering wheel, steering column 297

 Golf Variant 2007 ➤ , Jetta 2005 ➤
Running gear, axles, steering - Edition 07.2010

♦ Torque wrench -V.A.G 1331-

♦ Torque wrench -V.A.G 1332-

Removing
Only the complete steering column is supplied as a replacement
part. Repair is not possible.
Steering lock housing can be transferred ⇒ Electrical system;
Rep. gr. 94 ; Ignition switch and lock cylinder .
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WARNING lkswage es n
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The following are prerequisites before
utho starting work on the or
electrical system and removing the
ss steering wheel:
a ac
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e

♦ Disconnect earth strap from battery ⇒ Electrical system;

nl

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Rep. gr. 27 ; Battery; Disconnecting and reconnecting

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battery
erm

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ility
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♦ Wheels must be in straight-ahead position.

wit
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h re

Failure to comply with these precautions may lead to subse‐

hole

spec

quent failure of the airbag system!

es, in part or in w

t to the co

– Turn wheels to straight-ahead position.

rrectness of i

– Pull down lever beneath steering column.

l purpos

– Swing steering column down as far as possible and pull out.

– Press lever under steering column back up.
nform
ercia

– Remove airbag in steering wheel ⇒ General body repairs, in‐

m

at
om

terior; Rep. gr. 69 ; Airbag; Removing and installing driver side

ion
c

airbag unit .
in t
or

his
te

– Remove steering wheel ⇒ page 294 .

a

do
priv

cum
or

– Remove steering column switch trim ⇒ General body repairs,

f

en
ng

t.
interior; Rep. gr. 68 ; Compartments, covers and trims; Re‐ op
yi Co
moving and installing steering column trim .
C py
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Vo
co lksw
by
cted agen
Prote AG.

298 Rep. gr.48 - Steering

 Golf Variant 2007 ➤ , Jetta 2005 ➤
Running gear, axles, steering - Edition 07.2010

– Remove left trim on driver side ⇒ General body repairs, inte‐

rior; Rep. gr. 68 ; Compartments, covers and trims; Removing
and installing left driver side trim .
– Remove steering column switch ⇒ Electrical system; Rep. gr.
94 ; Steering column switch; Removing and installing steering
column switch .
– Remove footwell vent below steering column ⇒ Heating, air
conditioning; Rep. gr. 80 ; Repairing heating .
– Separate connection -1-.
AG. Volkswagen AG d
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urposes, in part or in wh

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– Remove cable duct -1- below steering column. To do this,
raise lugs -arrow- slightly on both sides and pull cable duct out
from guide on steering column.

rrectness o
cial p

f inform
mer

atio
om

n
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or

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– Unscrew securing nuts -arrows- and remove footwell trim -1-.
Co
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Prote AG.

– Remove bolt -1- and pull universal joint -2- off steering box.

3. Steering wheel, steering column 299

 Golf Variant 2007 ➤ , Jetta 2005 ➤
Running gear, axles, steering - Edition 07.2010

– Remove earth cable -arrow- and cable -1- from steering col‐
umn.
– Remove bolts -2-.
Vehicles with crash bars

– Remove earth cable -arrow- and cable -1- from steering col‐
umn.
– Remove bolts -2-.

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aut ra
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– Remove bolt -3- and remove crash bar for brake pedal -4-.

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Continuation for all vehicles
is n

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– Lower steering column slightly and carefully pull out upwards.

spec
urposes, in part or in wh

Installing

t to the co
– Hook steering column into installation aid on mounting brack‐
et.

rrectness o
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– Align steering column to mounting bracket.

mer

atio

In the process, the pins -arrows A- of mounting bracket must be

om

aligned with and inserted into the holes -arrows B- of the steering
c

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column
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p

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the mounting bracket is guaranteed only in this way.

en
ng

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Prote AG.

300 Rep. gr.48 - Steering

 Golf Variant 2007 ➤ , Jetta 2005 ➤
Running gear, axles, steering - Edition 07.2010

– Tighten steering column bolts -2-.

– Attach earth wire -arrow- and wire -1- to steering column.
Vehicles with crash bars

G. Volkswagen AG d
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t to the co
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rrectne
– Fit crash bar for brake pedal -4- and tighten bolt -3-.
ss o
cial p

f inform
mer

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Continuation for all vehicles Prote
cted AG.
agen

3. Steering wheel, steering column 301

 Golf Variant 2007 ➤ , Jetta 2005 ➤
Running gear, axles, steering - Edition 07.2010

– Fit universal joint -2- onto steering box pinion and tighten bolt
-1-.

– Install footwell trim -1- and secure with nuts -arrows-.

– Install cable duct -1- below steering column.

The lugs -arrow- must engage in the guide on both sides.

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– Join connector -1-.
ot p

wit
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– Install footwell vent below steering column ⇒ Heating, air con‐

h re
ole,

ditioning; Rep. gr. 80 ; Repairing heating . spec

urposes, in part or in wh

– Install steering column switch ⇒ Electrical system; Rep. gr.

t to the co

94 ; Steering column switch; Removing and installing steering

column switch .
rrectne

– Install steering column switch trim ⇒ General body repairs,

interior; Rep. gr. 68 ; Compartments, covers and trims; Re‐
moving and installing steering column trim .
ss o
cial p

– Install left trim on driver side ⇒ General body repairs, interior;

inform

Rep. gr. 68 ; Compartments, covers and trims; Removing and

mer

installing left driver side trim .

atio
om

n
c

– Install steering wheel ⇒ page 294 .

i
or

n thi
te

sd

– Install airbag in steering wheel ⇒ General body repairs, inte‐

iva

o
r

rior; Rep. gr. 69 ; Airbag; Removing and installing driver side

p

cum
r
fo

airbag unit .
en
ng

t.
yi Co
op
– Perform basic settings for steering angle sensor -G85- using
C py
t. rig
gh
vehicle diagnostic, testing and information system -VAS
ht
pyri by
Vo
5051B- .
o
by c lksw
cted agen
Prote AG.

302 Rep. gr.48 - Steering

 Golf Variant 2007 ➤ , Jetta 2005 ➤
Running gear, axles, steering - Edition 07.2010

Specified torques AG. Volkswagen AG d

agen oes
olksw not
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Component rised Specified torque ara
nte
ho eo
Universal joint to steering box aut 30 Nm ra
s c
♦ Use new bolt s

ce
le
un

pt
an
d
Steering column to mounting bracket 20 Nm

itte

y li
erm

ab
ility
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wit
is n

h re
3.4 Assembly overview - steering column, left-hand drive, Jetta as of model year

ole,

spec
urposes, in part or in wh
2009

t to the co
Note

rrectne
♦ It is not permitted to weld or straighten load-bearing or wheel-guiding components of the suspension.

ss o
♦ Always renew self-locking nuts.
cial p

f inform
♦ Always renew corroded nuts and bolts.
mer

atio
om

n
c

i
or

n thi
1 - Assembly carrier
te

sd
iva

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2 - Mounting bracket
p

cum
r
fo

en
ng

t.
3 - Steering column
yi Co
Cop py
❑ Removing and installing
t. rig
gh ht
yri
⇒ page 304 .
p by
o Vo
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4 - Bolt
Prote AG.

❑ 20 Nm
❑ Observe tightening se‐
quence ⇒ page 308
5 - Crash bar for brake pedal
6 - Bolt
❑ 20 Nm
❑ Observe tightening se‐
quence ⇒ page 308
7 - Crash bar for clutch pedal
8 - Bolt
❑ 30 Nm
❑ Always renew after re‐
moving.
9 - Bolt
❑ 20 Nm
10 - Bolt
❑ 25 Nm
11 - Bolt
❑ 20 Nm
12 - Strut
13 - Bolt
❑ 20 Nm

3. Steering wheel, steering column 303

 Golf Variant 2007 ➤ , Jetta 2005 ➤
Running gear, axles, steering - Edition 07.2010

3.5 Removing and installing steering col‐

umn, left-hand drive, Jetta as of model
year 2009
Special tools and workshop equipment required
♦ Torque wrench -V.A.G 1331-

n AG. Volkswagen AG do
lkswage es n
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ss

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ab
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♦ Torque wrench -V.A.G 1332-

wit
is n

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ole,

spec
urposes, in part or in wh

t to the co
rrectness o
cial p

f inform
mer

atio
om

n
c

Removing
i
or

n thi
te

sd
a

Only the complete steering column is supplied as a replacement

iv

o
pr

part. Repair is not possible.

um
r
fo

en
ng

t.
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Steering lock housing can be transferred ⇒ Electrical system;
Co
op py
Rep. gr. 94 ; Ignition switch and lock cylinder . t. C rig
gh ht
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Vo
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WARNING Prote AG.

The following are prerequisites 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
battery
♦ Wheels must be in straight-ahead position.
Failure to comply with these precautions may lead to subse‐
quent failure of the airbag system!

– Turn wheels to straight-ahead position.

– Pull down lever on side of steering column.
– Swing steering column down as far as possible and pull out.
– Press lever on side of steering column back up.

304 Rep. gr.48 - Steering

 Golf Variant 2007 ➤ , Jetta 2005 ➤
Running gear, axles, steering - Edition 07.2010

– Remove airbag in steering wheel ⇒waGeneralgen AG body repairs,

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does
s
terior; Rep. gr. 69 ; Airbag; Removing
yV
olk and installing driver sidenot gu
airbag unit . ris
ed
b ara
nt ee
tho or
– Remove steering wheel
s a ⇒ page 294 .
u ac
s

ce
e
– Remove steering column switch trim ⇒ General body repairs,

nl

pt
du
interior; Rep. gr. 68 ; Compartments, covers and trims; Re‐

an
itte

y li
moving and installing steering column trim .
erm

ab
ility
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– Remove steering column switch ⇒ Electrical system; Rep. gr.

wit
, is n

94 ; Steering column switch; Removing and installing steering

h re
column switch .
hole

spec
es, in part or in w

– Separate connection -1-.

t to the co
– Remove footwell vent below steering column ⇒ Heating, air
conditioning; Rep. gr. 80 ; Repairing heating .

rrectness of i
l purpos

nf
ercia

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– Press lugs -arrow- on both side of cable channel -1- inwards
f

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and pull cable channel -1- out of guides on steering column.
Co
Cop py
ht. rig
– Disconnect earth cable from steering column . rig ht
py by
co Vo
by lksw
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Prote AG.

– Remove footwell trim -1-.

3. Steering wheel, steering column 305

 Golf Variant 2007 ➤ , Jetta 2005 ➤
Running gear, axles, steering - Edition 07.2010

– Remove bolt -1- and pull universal joint -2- off steering box.

Vehicles with manual gearboxes

– Remove left bolt -1- and remove crash bar for clutch pedal
-2-.

Vehicles with dual clutch gearbox or automatic gearbox

– Remove left bolt -1- for steering column.
Continuation for all vehicles

AG. Volkswagen AG d
agen oes
olksw not
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rise nte
tho eo
au ra
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ce
le

– Remove right bolt -1- and remove crash bar for brake pedal
un

pt
an

-2-.
d
itte

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spec
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cial p

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mer

atio
om

n
c

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pr

cum
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t.
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Cop py
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pyri by
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306
c by lksw
cted agen
Rep. gr.48 - Steering Prote AG.
 Golf Variant 2007 ➤ , Jetta 2005 ➤
Running gear, axles, steering - Edition 07.2010

– Remove bolts -1- and firmly hold steering column.

– Lower steering column -1- slightly and carefully pull column

out of guides on mounting bracket -arrow-.

Caution

Take great care to ensure the steering column is handled and

transported correctly ⇒ page 320 .

AG. Volkswagen AG d
Installing agen oes
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rise nte
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au ra
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ce

– Hook steering column -1- with cut-out into guide on mounting

e
nl

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bracket -arrow-.
an
itte

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erm

ab

The correct installation position of the steering column relative to

ility
ot p

the mounting bracket is guaranteed only in this way.

wit
, is n

h re
hole

spec

Note
es, in part or in w

t to the co

When installing steering column, adhere strictly to bolting se‐

quence.
rrectness of i
l purpos

– Secure steering column with bolts -1-.

nform
mercia

at
om

ion
c

in t
or

his
ate

do
priv

cum
for

en
ng

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

3. Steering wheel, steering column 307

 Golf Variant 2007 ➤ , Jetta 2005 ➤
Running gear, axles, steering - Edition 07.2010

– Fit crash bar for brake pedal -1- and bolt -2- on.

Vehicles with dual clutch gearbox or automatic gearbox

– Fit bolt -1-.

AG. Volkswagen AG d
agen oes
olksw not
y V gu
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rise nte
tho eo
au ra
ss c

ce
e
nl

pt
du

an
itte

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erm

Vehicles with manual gearboxes

ab
ility
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– Fit crash bar for clutch pedal -1- and bolt -2- on.

wit
, is n

h re
Continuation for all vehicles
hole

spec
es, in part or in w

t to the co
rrectness of i
l purpos

nform
mercia

– Tighten bolts -1- to -4- to specified torque in sequence shown.

at
om

ion
c

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or

his
ate

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priv

cum
for

en
ng

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

308 Rep. gr.48 - Steering

 Golf Variant 2007 ➤ , Jetta 2005 ➤
Running gear, axles, steering - Edition 07.2010

– Install cable duct -1- below steering column.

The lugs -arrow- must engage in the guide on both sides.
– Reconnect earth cable to steering column .

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

ce
e
nl

pt
du

an
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ab
ility
ot p

wit
, is n

h re
– Fit universal joint -2- onto steering box pinion and tighten bolt
hole

spec
-1-.
es, in part or in w

t to the co
rrectness of i
l purpos

nf
ercia

orm
m

atio
om

n in
or c

thi
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– Install footwell trim -1-.

iv

o
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rp

cu
o

– Install footwell vent below steering column ⇒ Heating, air con‐

f

en
ng

t.
yi
ditioning; Rep. gr. 80 ; Repairing heating .
Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

3. Steering wheel, steering column 309

 Golf Variant 2007 ➤ , Jetta 2005 ➤
Running gear, axles, steering - Edition 07.2010
n AG. Volkswagen AG do
swage es n
– Plug in connectorb-1-. yV
olk ot g
ua
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ir se
– Install steeringth column switch ⇒ Electrical system; Rep. gr.
o tee
or
94 ; Steering
ss
au
column switch; Removing and installing steering ac
column switch .

ce
e
nl

pt
du

an
– Install steering column switch trim ⇒ General body repairs,
itte

y li
interior; Rep. gr. 68 ; Compartments, covers and trims; Re‐
erm

ab
moving and installing steering column trim .

ility
ot p

wit
, is n

– Install steering wheel ⇒ page 294 .

h re
hole

spec
– Install airbag in steering wheel ⇒ General body repairs, inte‐
es, in part or in w

rior; Rep. gr. 69 ; Airbag; Removing and installing driver side

t to the co
airbag unit .
– Perform basic settings for steering angle sensor -G85- using

rrectness of i
vehicle diagnostic, testing and information system -VAS
5051- .
l purpos

Specified torques

nform
ercia

Component Specified torque

m

at
om

io
Universal joint to steering box 30 Nm

n
c

in t
r

♦ Use new bolt

o

his
ate

do
riv

Steering column to mounting bracket 20 Nm

p

cum
for

en
ng

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

310 Rep. gr.48 - Steering

 Golf Variant 2007 ➤ , Jetta 2005 ➤
Running gear, axles, steering - Edition 07.2010

3.6 Assembly overview - steering column, right-hand drive, Jetta as of model

year 2009

Note

♦ It is not permitted to weld or straighten load-bearing or wheel-guiding components of the suspension.

♦ Always renew self-locking nuts.
♦ Always renew corroded nuts and bolts.

1 - Bolt
❑ 20 Nm
2 - Assembly carrier
3 - Bolt
AG. Volkswagen AG d
❑ 20 Nm agen oes
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4 - Strut rise
d
nte
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5 - Mounting bracket ss au ra
c

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le

6 - Bolt
un

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an
d
itte

❑ 20 Nm

y li
erm

ab
ility
7 - Steering column
ot p

wit
is n

❑ Removing and installing

h re
⇒ page 311 .
ole,

spec
urposes, in part or in wh

8 - Bolt

t to the co
❑ 30 Nm
❑ Always renew after re‐

rrectne
moving.
9 - Crash bar for brake pedal

ss o
10 - Bolt
cial p

f inform
❑ 20 Nm
mer

❑ Observe tightening se‐

atio
m

quence ⇒ page 316

o

n
c

i
or

n thi
e

11 - Crash bar for clutch pedal

t

sd
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12 - Bolt
um
r
fo

en
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❑ 20 Nm
t.
yi Co
Cop py
❑ Observe tightening se‐
t. rig
gh ht
yri
quence ⇒ page 316 p by
co Vo
by lksw
cted agen
13 - Bolt Prote AG.

❑ 20 Nm

3.7 Removing and installing steering col‐

umn, right-hand drive, Jetta as of model
year 2009
Special tools and workshop equipment required

3. Steering wheel, steering column 311

 Golf Variant 2007 ➤ , Jetta 2005 ➤
Running gear, axles, steering - Edition 07.2010

♦ Torque wrench -V.A.G 1331-

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

ce
e
nl

pt
du

an
itte

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♦ Torque wrench -V.A.G 1332-
erm

ab
ility
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wit
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h re
hole

spec
es, in part or in w

t to the co
rrectness of i
l purpos

nf
ercia

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atio
Removing
om

n in
c

Only the complete steering column is supplied as a replacement

or

thi
e

part. Repair is not possible.

t

sd
iva

o
r
rp

cu
Steering lock housing can be transferred ⇒ Electrical system;
o

m
f

en
ng

Rep. gr. 94 ; Ignition switch and lock cylinder .

t.
yi Co
Cop py
ht. rig
rig ht
WARNING py by
co Vo
by lksw
cted agen
Prote AG.
The following are prerequisites 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
battery
♦ Wheels must be in straight-ahead position.
Failure to comply with these precautions may lead to subse‐
quent failure of the airbag system!

– Turn wheels to straight-ahead position.

– Pull down lever on side of steering column.
– Swing steering column down as far as possible and pull out.
– Press lever on side of steering column back up.
– Remove airbag in steering wheel ⇒ General body repairs, in‐
terior; Rep. gr. 69 ; Airbag; Removing and installing driver side
airbag unit .
– Remove steering wheel ⇒ page 294 .
– Remove steering column switch trim ⇒ General body repairs,
interior; Rep. gr. 68 ; Compartments, covers and trims; Re‐
moving and installing steering column trim .

312 Rep. gr.48 - Steering

 Golf Variant 2007 ➤ , Jetta 2005 ➤
Running gear, axles, steering - Edition 07.2010

– Remove steering column switch ⇒ Electrical system; Rep. gr.

94 ; Steering column switch; Removing and installing steering
column switch .
– Separate connection -1-.
– Remove footwell vent below steering column ⇒ Heating, air
conditioning; Rep. gr. 80 ; Repairing heating .

– Press lugs -arrow- on both side of cable channel -1- inwards

and pull cable channel -1- out of guides on steering column.olksw
AG. V agen AG
agen does
– Disconnect earth cable from steering column .Volksw not
gu
y
db ara
rise nte
tho eo
s au ra
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itte

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wit
is n

h re
ole,

spec
urposes, in part or in wh

t to the co
rrectness o
cial p

f i
– Unscrew nuts -1- to remove footwell trim -2-.
nform
mer

atio
om

n
c

i
or

n thi
te

sd
iva

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pr

cum
r
fo

en
ng

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

3. Steering wheel, steering column 313

 Golf Variant 2007 ➤ , Jetta 2005 ➤
Running gear, axles, steering - Edition 07.2010

– Remove bolt -1- for universal joint and pull universal joint -2-
off steering box.

Vehicles with manual gearboxes

– Remove left bolt -1- and remove crash bar for clutch pedal
-2-.

AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
Vehicles with dual clutch sgearbox
au or automatic gearbox ra
c
s
ce
e

– Remove left bolt -1- for steering column.

nl

pt
du

an
itte

Continuation for all vehicles

y li
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ility
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wit
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h re
hole

spec
es, in part or in w

t to the co
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– Remove right bolt -1- and remove crash bar for brake pedal
-2-.
nf
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f

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

314 Rep. gr.48 - Steering

 Golf Variant 2007 ➤ , Jetta 2005 ➤
Running gear, axles, steering - Edition 07.2010

– Remove bolts -1- and firmly hold steering column.

– Lower steering column -1- slightly and carefully pull column

out of guides on mounting bracket -arrow-.

Caution

Take great care to ensure the steering. Volkcolumn

swagen Ais handled and
transported correctly ⇒ page gen A.G
wa320
G do
es n
olks o t gu
yV
db ara
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Installing au ra
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– Hook steering column -1- with cut-out into guide on mounting ility
ot p

bracket -arrow-. wit

is n

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ole,

The correct installation position of the steering column relative to

spec

the mounting bracket is guaranteed only in this way.

urposes, in part or in wh

t to the co

Note
rrectne

When installing steering column, adhere strictly to bolting se‐

quence.
ss o
cial p

f inform
mer

atio
m

– Secure steering column with bolts -1-.

o

n
c

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or

n thi
te

sd
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pr

cum
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fo

en
ng

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

3. Steering wheel, steering column 315

 Golf Variant 2007 ➤ , Jetta 2005 ➤
Running gear, axles, steering - Edition 07.2010

– Fit crash bar for brake pedal -1- and bolt -2- on.

Vehicles with dual clutch gearbox or automatic gearbox

– Fit bolt -1-.

AG. Volkswagen AG d
Vehicles with manual gearboxes
lksw
agen oes
not
o
yV gu
– Fit crash bar for clutched b pedal -1- and bolt -2- on. ara
ris nte
tho eo
Continuation fors all vehicles
au ra
c
s
ce
le
un

pt
an
d
itte

y li
erm

ab
ility
ot p

wit
is n

h re
ole,

spec
urposes, in part or in wh

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– Tighten bolts -1- to -4- to specified torque in sequence shown.

rrectness o
cial p

f inform
mer

atio
om

n
c

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te

sd
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ng

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

316 Rep. gr.48 - Steering

 Golf Variant 2007 ➤ , Jetta 2005 ➤
Running gear, axles, steering - Edition 07.2010

– Install cable duct -1- below steering column.

The lugs -arrow- must engage in the guide on both sides.
– Reconnect earth cable to steering column .

– Fit universal joint -2- onto steering box pinion and tighten bolt
-1-.

n AG. Volkswagen AG do
lkswage es n
o ot g
– Install footwell trim -2- and install nuts -1-. ed by V ua
ran
ir s tee
o
– Install footwell vent below steering column au ⇒ Heating, air con‐
th or
ac
ditioning; Rep. gr. 80 ; Repairing heating
ss .
ce
e
nl

pt
du

an
itte

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erm

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ility
ot p

wit
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hole

spec
es, in part or in w

t to the co
rrectness of i
l purpos

nform
mercia

at
om

ion
c

in t
or

his
ate

do
priv

cum
for

en
ng

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

3. Steering wheel, steering column 317

 Golf Variant 2007 ➤ , Jetta 2005 ➤
Running gear, axles, steering - Edition 07.2010

– Plug in connector -1-.

– Install steering column switch ⇒ Electrical system; Rep. gr.
94 ; Steering column switch; Removing and installing steering
column switch . gen AG
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a does
lksw n
– Install steering column dswitch
by
Vo trim ⇒ General body repairs,
ot g
ua
interior; Rep. gr. 68or;isCompartments,
e covers and trims; Re‐ rante
moving and installing
au
th steering column trim . eo
ra
ss c
– Install steering wheel ⇒ page 294 .

ce
e
nl

pt
du

an
– Install airbag in steering wheel ⇒ General body repairs, inte‐
itte

y li
rior; Rep. gr. 69 ; Airbag; Removing and installing driver side
erm

ab
ility
airbag unit .
ot p

wit
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– Perform basic settings for steering angle sensor -G85- using

h re
hole

vehicle diagnostic, testing and information system -VAS

spec
5051- .
es, in part or in w

t to the co
Specified torques

rrectness of i
Component Specified torque
l purpos

Universal joint to steering box 30 Nm

♦ Use new bolt

nform
ercia

Steering column to mounting bracket 20 Nm

m

at
om

ion
c

in t
or

his
e

3.8 Basic setting for steering angle sensor

at

do
priv

G85 steering angle sender must be

um
for

en
ng

checked after the following repair work:

t.
yi Co
Cop py
t. rig
gh ht
♦ When vehicle steering angle sensor -G85- is removed or re‐ yri
p by
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newed;
c by lksw
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Prote AG.
♦ If steering column was removed or renewed;
♦ If steering lock housing with steering column switch was re‐
moved or renewed;
♦ If steering box was removed or renewed;
♦ If steering wheel was repositioned.

3.9 Handling and transporting steering col‐

umn, Golf Variant up to model year
2009, Jetta up to model year 2008

WARNING

♦ Adherence to proper steering column handling is essen‐

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

318 Rep. gr.48 - Steering

 Golf Variant 2007 ➤ , Jetta 2005 ➤
Running gear, axles, steering - Edition 07.2010

Proper steering column handling and transport

♦ Use both hands to transport steering column.
♦ Hold steering column upper jacket tube and in area of upper
universal joint.
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erm

ab
ility
ot p

wit
, is n

h re
hole

spec
es, in part or in w

t to the co
rrectness of i
Improper handling of steering column
l purpos

Transportation using the following parts leads to primary steering

column damage:

nf
ercia

1- Clamping lever

orm
m

atio
2- Weight compensation springs
om

n in
c

3- Deformation element
or

thi
te

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iva

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cu
o

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f

en
ng

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Cop py
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rig ht
py by
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cted agen
Prote AG.

Improper handling of steering column with safety risks

Following methods of handling will damage universal joint bushes
of lower steering column bearing:
♦ Transporting steering column with one hand on jointed shaft.
♦ Bending joints more than 90°.

3. Steering wheel, steering column 319

 Golf Variant 2007 ➤ , Jetta 2005 ➤
Running gear, axles, steering - Edition 07.2010

3.10 Handling and transporting steering col‐

umn, Jetta as of model year 2009

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

♦ Use both hands to transport steering column.
♦ Hold steering column upper jacket tube and in area of upper
universal joint.

AG. Volkswagen AG d
agen oes
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Improper handling of steering column

pt
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Transportation using the clamping lever leads to primary steering

erm

ab

column damage.
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urposes, in part or in wh

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cial p

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atio
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cum
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en
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t.
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Cop py
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Prote AG.

320 Rep. gr.48 - Steering

 Golf Variant 2007 ➤ , Jetta 2005 ➤
Running gear, axles, steering - Edition 07.2010

Improper handling of steering column with safety risks

Following methods of handling will damage universal
n AG.joint
Volkswbushes
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and lower steering column bearing: lkswage does
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♦ Transporting steering column with
or
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♦ Bending joints more than 90°.
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rrectness of i
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3.11 Checking steering column for damage

nform
mercia

at
Visual check
om

ion
c

in t
– Check all steering column parts for damage.
or

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ate

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Checking function
p

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– Check that steering column turns smoothly and easily.

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ng

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op
– Check that steering column can be adjusted in reach and
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cted
3.12 Removing and installing mounting
agen
Prote AG.

bracket, Golf Variant up to model year

2009, Jetta up to model year 2008
Special tools and workshop equipment required
♦ Torque wrench -V.A.G 1331-

Removing
– Remove steering column ⇒ page 297 .
– Remove dash panel insert ⇒ Electrical system; Rep. gr. 90 ;
Dash panel insert; Removing and installing dash panel insert .

3. Steering wheel, steering column 321

 Golf Variant 2007 ➤ , Jetta 2005 ➤
Running gear, axles, steering - Edition 07.2010

– Remove bolts -arrows- under bracket.

– Push connector -1- in -direction of arrow- and remove from

support in mounting bracket.
– Unscrew bolt -arrow A-.
– Remove bolts -arrows B- securing bracket to body.

Note

Bolts -arrows B- are screwed in from cross member.

– Unscrew bolts -1- and -2- and remove mounting bracket from
body.
Installing

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agen oes
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pt
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erm

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ility
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– Insert mounting bracket and screw in bolts -1- and -2-.

wit
, is n

h re
hole

spec
es, in part or in w

t to the co
rrectness of i
l purpos

nf
ercia

orm
m

atio
om

n in
or c

thi
te

sd
iva

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r
rp

cu
o

m
f

en
ng

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

322 Rep. gr.48 - Steering

 Golf Variant 2007 ➤ , Jetta 2005 ➤
Running gear, axles, steering - Edition 07.2010

– Install bolts -arrows B-.

Note

Bolts -arrows B- are screwed in from cross member.

– Screw in bolt -arrow A-.

– Insert connector -1- into support in mounting bracket and push
to stop opposite -direction of arrow-.

– Install bolts -arrows- under bracket.

– Install steering column ⇒ page 300 .
– Install dash panel insert ⇒ Electrical system; Rep. gr. 90 ;
Dash panel insert; Removing and installing dash panel insert .
– Perform basic settings for steering angle sensor -G85- using
vehicle diagnostic, testing and information system -VAS
5051B- .

Specified torques AG. Volkswagen AG d

agen oes
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Component d by gu
ara Specified torque
rise nte
o
Mounting bracket to body auth eo
r a 20 Nm
s c
Strut to mounting bracket s
20 Nm
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nl

pt
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Steering column to mounting bracket 20 Nm

an
itte

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erm

ab
ility
ot p

wit
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3.13 Removing and installing strut, Golf Var‐

h re
hole

iant up to model year 2009, Jetta up to

spec
es, in part or in w

model year 2008

t to the co

Special tools and workshop equipment required

rrectness of i

♦ Torque wrench -V.A.G 1331-

l purpos

nform
mercia

at
om

ion
c

in t
or

his
ate

do
priv

cum
for

en
ng

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

– Remove plenum chamber bulkhead ⇒ General body repairs,

exterior; Rep. gr. 50 ; Assembly overview - plenum chamber
bulkhead .

3. Steering wheel, steering column 323

 Golf Variant 2007 ➤ , Jetta 2005 ➤
Running gear, axles, steering - Edition 07.2010

– Remove bolt -arrow- in plenum chamber.

– Remove steering column ⇒ page 297 .

– Remove bolts -1-.

– Remove bolt -2- and remove strut -3-.
Installing
AG. Volkswagen AG d
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pt
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erm

ab
ility
ot p

wit
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– Secure strut to body by tightening bolt -arrow-.
hole

spec
es, in part or in w

t to the co
rrectness of i
l purpos

nf
ercia

orm
m

atio
om

n in
or c

thi
e

– Install securing bolt -2- and tighten.

t

sd
iva

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rp

cu
– Tighten bolt -1- for strut -3-.
o

m
f

en
ng

t.
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– Install steering column ⇒ page 300 . t. Cop py
rig
gh ht
– Install plenum chamber bulkhead ⇒ General body repairs, pyri by
Vo
co
exterior; Rep. gr. 50 ; Assembly overview - plenum chamber
by lksw
cted agen
Prote
bulkhead .
AG.

– Perform basic settings for steering angle sensor -G85- using

vehicle diagnostic, testing and information system -VAS
5051B- .

Specified torques
Component Specified torque
Strut to mounting bracket 20 Nm
Strut to body 20 Nm

324 Rep. gr.48 - Steering

 Golf Variant 2007 ➤ , Jetta 2005 ➤
Running gear, axles, steering - Edition 07.2010

4 Electromechanical steering box up to

model year 2008

4.1 Assembly overview - electromechanical steering box, left-hand drive vehi‐

cle (2nd generation) up to model year 2008

Note

♦ There are no 2nd generation steering boxes available as spare parts.

♦ If the steering box has to be replaced, a new 3rd generation steering box will have to be fitted.
♦ In addition, the electrical wiring harness from the E-box to the steering box will then also have to be renewed.
This is included with the order for the new steering box via the ⇒ Electronic parts catalogue„ETKA“ .
♦ The electrical wiring harness will be delivered with the cable for the service interval display.
♦ In vehicles without a service interval display, the unused 3-pin connector must be sealed by a flat contact
housing with connector position assurance -1J0 973 803- ⇒ Electronic parts catalogue„ETKA“ .

1 - Universal joint
2 - Hexagon bolt
❑ 30 Nm
❑ Always renew after re‐
moving.
3 - Wiring AG. Volkswagen AG d
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4 - Powerissteering
ed b box ara
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or
❑ auWith
th power steering eo
ra
s control unit -J500-
s c
ce
le

❑ With electromechanical
un

pt
an
d

power steering motor -

itte

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V187-
rm

ab
pe

ility

❑ With steering torque

ot

wit
, is n

sender -G269-
h re
hole

❑ Can be checked using

spec

guided fault finding in

es, in part or in w

t to the co

the vehicle diagnosis,

testing and information
system -VAS 5051B-
rrectness of i

❑ Removing and installing

⇒ page 328 .
l purpos

❑ Observe notes
⇒ page 325 .
nform
ercia

5 - Wheel bearing housing

m

a
com

tio

6 - Nut
n in
r
te o

❑ M12 x 1.5
thi
s
iva

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❑ 20 Nm + 90° further
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rp

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fo

❑ Self-locking
en
ng

t.
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❑ Always renew after re‐ Cop py
t. rig
moving. opyri
gh by
Vo
ht
by c lksw
7 - Subframe with brackets
Prote
cted AG.
agen

8 - Bolt
❑ 50 Nm + 90° further

4. Electromechanical steering box up to model year 2008 325

 Golf Variant 2007 ➤ , Jetta 2005 ➤
Running gear, axles, steering - Edition 07.2010
❑ Always renew clamp for steering box
❑ Always renew after removing.
9 - Shield
10 - Torx bolt
❑ 6 Nm
❑ Self-locking
AG. Volkswagen AG d
agen oes
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d by ara
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ility
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wit
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hole

spec
es, in part or in w

t to the co
rrectness of i
l purpos

nform
mercia

a
com

tion in
r
te o

thi
s
iva

do
r
rp

cum
fo

en
ng

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

326 Rep. gr.48 - Steering

 Golf Variant 2007 ➤ , Jetta 2005 ➤
Running gear, axles, steering - Edition 07.2010

4.2 Assembly overview - electromechanical steering box, right-hand drive ve‐

hicle (2nd generation) up to model year 2008

Note AG. Volkswagen AG d

agen oes
o lksw not
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♦ There are no 2nd generation steering boxes available ise d as spare parts. ara
nte
or eo
h
♦ If the steering box has to be replaced, a news au3rd
t
generation steering box will have to be fitted.
ra
c
s
♦ In addition, the electrical wiring harness from the E-box to the steering box will then also have to be renewed.

ce
e
nl

pt
du
This is included with the order for the new steering box via the ⇒ Electronic parts catalogue„ETKA“ .

an
itte

y li
erm

ab
♦ The electrical wiring harness will be delivered with the cable for the service interval display.

ility
ot p
♦ In vehicles without a service interval display, the unused 3-pin connector must be sealed by a flat contact

wit
, is n

h re
housing with connector position assurance -1J0 973 803- ⇒ Electronic parts catalogue„ETKA“ .
hole

spec
es, in part or in w

t to the co
1 - Universal joint
2 - Bolt

rrectness of i
❑ M8 x 35
l purpos

❑ 30 Nm
❑ Always renew after re‐

nform
ercia

moving.
m

at
3 - Wiring
om

ion
c

in t
r

4 - Shield
o

his
ate

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riv

5 - Torx bolt
p

cum
or

❑ 6 Nm
f

en
ng

t.
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❑ Self-locking t. Cop py
rig
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yri
6 - Clamp p by
o Vo
by c lksw
❑ Always renew after re‐
cted agen
Prote AG.
moving.
7 - Rubber mounting
8 - Power steering box
❑ With power steering
control unit -J500-
❑ With electromechanical
power steering motor -
V187-
❑ With steering torque
sender -G269-
❑ Can be checked in gui‐
ded fault finding of the
vehicle diagnostic, test‐
ing and information sys‐
tem -VAS 5051B- .
❑ Removing and installing
⇒ page 336 .
❑ Observe notes
⇒ page 327 .
9 - Connecting piece
10 - Wheel bearing housing
11 - Nut
❑ M12 x 1.5
❑ 50 Nm

4. Electromechanical steering box up to model year 2008 327

 Golf Variant 2007 ➤ , Jetta 2005 ➤
Running gear, axles, steering - Edition 07.2010
❑ Self-locking
❑ Always renew after removing.
12 - Subframe
13 - Bolt
❑ M10 x 70
❑ 50 Nm + 90° further
❑ Always renew after removing.

4.3 Removing and installing steering box, left-hand drive vehicle (2nd genera‐
tion) up to model year 2008

Special tools and workshop

equipment required
♦ Torque wrench -V.A.G
1331-
♦ Torque wrench -V.A.G
1332- AG. Volkswagen AG d
agen oes
olksw not
V gu
♦ Engine and gearbox jack - d by ara
ise nte
V.A.G 1383 A- hor eo
aut ra
c
♦ Ball joint puller -3287 A- ss

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le
un

pt
an
d
itte

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rm

ab
pe

ility
ot

wit
, is n

h re
hole

spec
es, in part or in w

t to the co
rrectness of i
l purpos

nform
mercia

a
com

tion in
r
te o

thi
s
iva

do
r
rp

cum
fo

en
ng

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

328 Rep. gr.48 - Steering

 Golf Variant 2007 ➤ , Jetta 2005 ➤
Running gear, axles, steering - Edition 07.2010

Removing steering box

Note

♦ There are no 2nd generation steering boxes available as spare

parts.
♦ If the steering box has to be replaced, a new 3rd generation
steering box will have to be fitted.
♦ In addition, the electrical wiring harness from the E-box to the
steering box will then also have to be renewed. This is included
with the order for the new steering box via the ⇒ Electronic
parts catalogue„ETKA“ .
♦ The electrical wiring harness will be delivered with the cable
for the service interval display.
♦ In vehicles without a service interval display, the unused 3-pin
connector must be sealed by a flat contact housing with con‐
nector position assurance -1J0 973 803- ⇒ Electronic parts
catalogue„ETKA“ .
. Volkswagen AG
gen AG does
swa
– Disconnect battery ⇒ Electrical
by
Vol system; Rep. gr. 27 ; Battery;
k not
gu
Disconnecting and reconnecting
ris
ed battery. ara
nt ee
tho or
– Remove nuts -arrows-
sa
u and remove footwell trim -1-. ac
s

ce
le
un

pt
an
d
itte

y li
erm

ab
ility
ot p

wit
is n

h re
ole,

spec
urposes, in part or in wh

t to the co
rrectne

– Remove bolt -1- and pull universal joint -2- off steering box.
ss o
cial p

– Remove front wheels.

inform
mer

– Loosen nut on track rod ball joint but do not remove complete‐
atio

ly.
om

n
c

i
or

n thi
te

Caution
sd
iva

o
pr

cum
r
fo

Leave nut screwed on a few turns to protect thread on pin.

en
ng

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

4. Electromechanical steering box up to model year 2008 329

 Golf Variant 2007 ➤ , Jetta 2005 ➤
Running gear, axles, steering - Edition 07.2010

– Press track rod ball joint off wheel bearing housing using ball
joint puller -3287A- and now remove nut.
– Remove lower noise insulation ⇒ General body repairs, ex‐
terior; Rep. gr. 50 ; Assembly overview - noise insulation .
– Remove coupling rod from anti-roll bar.

– Remove nuts -arrows-.

– Disconnect pendulum support from gearbox by removing bolts

-14-.
– Remove exhaust system retainer on subframe.

AG. Volkswagen AG d
agen oes
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d by ara
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or eo
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un

pt
an
d
itte

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erm

ab
ility
ot p

wit
is n

h re
ole,

spec
urposes, in part or in wh

t to the co

– Remove bolts -arrows- from heat shield.

rrectne

– Remove heat shield from subframe.

ss o
cial p

f inform
mer

atio
om

n
c

i
or

n thi
te

sd
iva

o
pr

cum
r
fo

en
ng

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

330 Rep. gr.48 - Steering

 Golf Variant 2007 ➤ , Jetta 2005 ➤
Running gear, axles, steering - Edition 07.2010

– Now remove bolts g-3-, en A-6-,

G. Vo-11-
lkswaand
gen A-16-
G do for steering box and
anti-roll bar. Volkswa es n
ot g
y ua
db r
– Fix subframe
or
ise and brackets in place ⇒ page 16 .antee
th or
au ac
ss

ce
le
un

pt
an
d
itte

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erm

ab
ility
ot p

wit
is n

h re
ole,

spec
urposes, in part or in wh

t to the co
rrectness o
cial p

f inform
mer

– Position

atio
m

engine and gearbox jack -V.A.G 1383 A- under subframe.

o

n
c

i
or

n thi
– Place, for example, a wooden block -1- between engine and
te

sd
a

gearbox jack -V.A.G 1383 A- and subframe.

iv

o
pr

cum
r
fo

en
ng

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

– Remove bolts -4- and -5- and lower subframe with brackets
slightly, observing electrical wires.

4. Electromechanical steering box up to model year 2008 331

 Golf Variant 2007 ➤ , Jetta 2005 ➤
Running gear, axles, steering - Edition 07.2010

– Remove heat shield -1- over steering box.

– Remove bolts -arrows-.

– Remove cable guide from subframe -arrow-.

– Unclip all remaining cable clips on steering box.
– Disconnect all electrical connections on steering box.
– Lower subframe carefully with engine/gearbox jack -V.A.G
1383 A- .
– Unbolt steering box from subframe.

AG. Volkswagen AG d
agen oes
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d by ara
ise nte
or eo
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ss c
ce
le
un

pt
an
d
itte

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erm

ab
ility
ot p

wit
is n

h re
ole,

spec
urposes, in part or in wh

t to the co
rrectness o
cial p

f inform
mer

atio
om

n
c

i
or

n thi
te

sd
iva

o
pr

cum
r
fo

en
ng

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

332 Rep. gr.48 - Steering

 Golf Variant 2007 ➤ , Jetta 2005 ➤
Running gear, axles, steering - Edition 07.2010

– Set steering box down as illustrated. AG. Volkswagen AG d

agen oes
ol ksw not
yV gu
This prevents damage to the control unit ed b-1-. ara
nte
ris
ho eo
Installing steering box aut ra
c
ss
Install in reverse order.

ce
e
nl

pt
du

an
itte
Threaded sleeves of steering box must seat in holes in brackets.

y li
erm

ab
ility
ot p

wit
, is n

Note

h re
hole

spec
♦ Coat seal on steering box with suitable lubricant, e.g. soft
es, in part or in w

soap, before installing steering box.

t to the co
♦ After fitting the steering box to the universal joint, make sure
that the seal is not kinked when lying against the assembly

rrectness of i
plate and that the opening to the footwell is correctly sealed.
Otherwise, this can result in water leaks and/or noise.
l purpos

♦ Ensure sealing surfaces are clean.

nf
ercia

or
Before inserting subframe bolts, position steering box on sub‐

m
m

atio
m

frame and insert bolts for steering box and anti-roll bar.
o

n in
or c

– Connect electrical connections to steering box.

thi
te

sd
iva

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

o
r
rp

cu
Rep. gr. 50 ; Assembly overview - noise insulation .
o

m
f

en
ng

t.
yi Co
Cop py
t. rig
gh ht
Note yri
p by
o Vo
by c lksw
cted agen
Prote
Ensure that bellows are not damaged or twisted.
AG.

– Bolt universal joint to steering box.

– Connect battery ⇒ Electrical system; Rep. gr. 27 ; Battery;
Disconnecting and connecting battery .
– Perform basic settings for steering angle sensor -G85- using
⇒ Vehicle diagnostic, testing and information system
VAS 5051.
After installation, check position of steering wheel during road
test.
If steering wheel is crooked or a new steering box was installed,
wheels must be aligned.
– Check wheel alignment ⇒ page 261 .
If new steering box has been installed, adapt electromechanical
steering using vehicle diagnostic, testing and information system
-VAS 5051- .
– Carry out adaption of electromechanical steering using vehicle
diagnostic, testing and information system -VAS 5051- ⇒ Ve‐
hicle diagnostic, testing and information system VAS 5051.
Running gear

Electromechanical power steering

01 - System capable of self-diagnosis

Electromechanical steering system

Functions

Adapting electromechanical steering

4. Electromechanical steering box up to model year 2008 333

 Golf Variant 2007 ➤ , Jetta 2005 ➤
Running gear, axles, steering - Edition 07.2010

Note
AG. Volkswagen
♦ If parking aid 2 is fitted in the vehicle,
lksw the power steering con‐
agen AG do
es n
trol unit -J500- must be recoded
db
y V following the installation of at gua
o o
new steering box⇒ Vehicleori diagnostic, testing and information
se ran
tee
system VAS 5051. aut h or
ac
ss
♦ Parking aid 2 is fitted only in vehicles having 2nd generation

ce
e
nl

pt
steering boxes.
du

an
itte

y li
erm

ab
ility
ot p

Specified torques

wit
, is n

h re
Component Specified torque
hole

spec
Subframe to body 70 Nm + 90°
es, in part or in w

t to the co
♦ Use new bolts

Anti-roll bar to subframe 20 Nm + 90°

rrectness of i
♦ Use new bolts
l purpos

Anti-roll bar to coupling rod 65 Nm

♦ Use new nut

nf
ercia

o
♦ Counterhold on multi-point socket of joint pin

rm
m

atio
om

Swivel joint to cast steel suspension link 60 Nm

n in
or c

♦ Use new nuts

thi
te

sd
iva

o
r
rp

cu
Swivel joint to sheet steel or forged aluminium suspension 100 Nm
o

m
f

en

link
ng

t.
yi Co
♦ Use new nuts t. Cop py
rig
gh ht
yri by
Shield to subframe 6 Nm
cop Vo
by lksw
♦ Bolt M6 is self-locking
cted agen
Prote AG.

Steering box to subframe 50 Nm + 90°

♦ Use new bolts
♦ Always renew clamp

Universal joint to steering box 30 Nm

♦ Use new bolt

Shield to steering box 6 Nm

♦ Bolt M6 is self-locking

Track rod ball joint to wheel bearing housing 20 Nm + 90°

♦ Use new nut

Exhaust system bracket to subframe

⇒ Engine; Rep. gr. 26

334 Rep. gr.48 - Steering

 Golf Variant 2007 ➤ , Jetta 2005 ➤
Running gear, axles, steering - Edition 07.2010

Torque specifications for pendulum support to gearbox

Caution

From model year 08, HeliCoil inserts are installed in the pen‐
dulum support connection in the 02Q gearboxes. Identification
⇒ Rep. gr. 34 .
Use a bolt with hardness class 10.9 for this and all other gear‐
boxes.
If there is no HeliCoil insert in the 02Q gearbox, use bolts with
the strength class 8.8 and the corresponding torque setting.

Bolt AG. Volkswagen AG d Specified torque

agen oes
lksw not
M10 x 35 strength class 8.8 yV
o gu
ara 40 Nm + 90° further
db
♦ Use new bolt rise nte
utho eo
ra
a
M10 x 35 strength class 10.9 ss c
50 Nm + 90° further

ce
le

♦ Use new bolt

un

pt
an
d
itte

y li
M10 x 75 strength class 8.8 40 Nm + 90° further
rm

ab
pe

♦ Use new bolt

ility
ot

wit
, is n

h re
M10 x 75 strength class 10.9 50 Nm + 90° further
hole

spec
♦ Use new bolt
es, in part or in w

t to the co
rrectness of i
l purpos

nform
mercia

a
com

tion in
r
te o

thi
s
iva

do
r
rp

cum
fo

en
ng

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

4. Electromechanical steering box up to model year 2008 335

 Golf Variant 2007 ➤ , Jetta 2005 ➤
Running gear, axles, steering - Edition 07.2010

4.4 Removing and installing steering box, right-hand drive vehicle (2nd gener‐
ation) up to model year 2008

Special tools and workshop

equipment required
♦ Torque wrench -V.A.G
1331-
♦ Torque wrench -V.A.G
1332- agen
AG. Volkswagen AG d
oes
olksw not
♦ Engine and gearbox jack ed by-
V gu
ara
V.A.G 1383 A- horis nte
eo
aut ra
♦ Ball joint puller -3287
ss A- c

ce
le
un

pt
an
d
itte

y li
rm

ab
pe

ility
ot

wit
, is n

h re
hole

spec
es, in part or in w

t to the co
rrectness of i
l purpos

nform
mercia

a
com

tion in
r
te o

thi
s
iva

do
r
rp

cum
fo

en
ng

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

336 Rep. gr.48 - Steering

 Golf Variant 2007 ➤ , Jetta 2005 ➤
Running gear, axles, steering - Edition 07.2010

Removing

Note

♦ There are no 2nd generation steering boxes available as spare

parts.
♦ If the steering box has to be replaced, a new 3rd generation
steering box will have to be fitted.
♦ In addition, the electrical
agen
AG. Vwiring
olkswagharness
en AG
do from the E-box to the
steering box Vowill
lkswthen also have to be renewed.
es n
ot g This is included
with the sedorder
by for the new steering box via the
ua
ra⇒
nte Electronic
parts
thocatalogue„ETKA“
ri
. eo
au ra
♦ The
ss electrical wiring harness will be delivered with the cable c

ce
e

for the service interval display.

nl

pt
du

an
itte

♦ In vehicles without a service interval display, the unused 3-pin

y li
erm

ab
connector must be sealed by a flat contact housing with con‐

ility
ot p

nector position assurance -1J0 973 803- ⇒ Electronic parts

wit
, is n

catalogue„ETKA“ .

h re
hole

spec
– Disconnect battery ⇒ Rep. gr. 27 ; Battery; Disconnecting and
es, in part or in w

t to the co
reconnecting battery .
– Unscrew nuts -1- to remove footwell trim -2-.
rrectness of i
l purpos

nform
mercia

at
om

ion
c

in t
or

his
ate

do
priv

cum
for

en
ng

t.
yi Co
Cop py
t. rig
– Remove bolt -1- for universal joint and pull universal joint -2-
gh ht
yri by
off steering box. cop Vo
by lksw
cted agen
Prote AG.
– Remove front wheels.
– Remove front wheels.
– 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.

4. Electromechanical steering box up to model year 2008 337

 Golf Variant 2007 ➤ , Jetta 2005 ➤
Running gear, axles, steering - Edition 07.2010

– Press track rod ball joint off wheel bearing housing using ball
joint puller -3287A- and now remove nut.
– Remove lower noise insulation ⇒ Rep. gr. 50 ; Assembly
overview - noise insulation .
– Remove coupling rod from anti-roll bar.

– Remove nuts -arrows-.

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

ce
le
un

pt
an
d
itte

y li
erm

ab
ility
ot p

wit
is n

h re
ole,

spec
urposes, in part or in wh

– Disconnect pendulum support from gearbox by removing bolts

t to the co
-13-.

rrectness o
cial p

f inform
mer

atio
om

n
c

i
or

n thi
te

sd
iva

o
pr

cum
r
fo

en
ng

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

– Detach exhaust system bracket from subframe -arrows-.

Vehicles with front-wheel drive

338 Rep. gr.48 - Steering

 Golf Variant 2007 ➤ , Jetta 2005 ➤
Running gear, axles, steering - Edition 07.2010

– Remove bolts -arrows- from heat shield.

– Remove heat shield from subframe.

AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c

ce
le
un

pt
an
d
itte

y li
rm

ab
pe

ility
– Remove bolts -5- and -6- for steering box.
ot

wit
, is n

h re
hole

spec
es, in part or in w

t to the co
rrectness of i
l purpos

nform
mercia

a
com

tion in
r
te o

thi
s
iva

do
r
rp

cum
fo

en
ng

t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
– Remove bolts -7- and -8- for anti-roll bar.
co lksw
by
cted agen
Prote AG.
– Fix position of subframe ⇒ page 16 .
– Separate connector for extended service intervals on oil sump.

4. Electromechanical steering box up to model year 2008 339

 Golf Variant 2007 ➤ , Jetta 2005 ➤
Running gear, axles, steering - Edition 07.2010

– Position
engine and gearbox jack -V.A.G 1383 A- under subframe.
– Place, for example, a wooden block -1- between engine and
gearbox jack -V.A.G 1383 A- and subframe.
n AG. Volkswagen AG do
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss

ce
e
nl

pt
du

an
itte

y li
erm

ab
ility
ot p
– Remove bolts -9- and -10- and lower subframe slightly. In the

wit
, is n

h re
process, observe electrical wiring.
hole

spec
es, in part or in w

t to the co
rrectness of i
l purpos

nform
mercia

at
om

ion
c

in t
or

his
ate

do
priv

cum
for

en
ng

t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted
– Remove heat shield -1- over steering box.
agen
Prote AG.

– Remove bolts -arrows-.

– Remove cable guide from subframe -arrow-.

– Unclip all remaining cable clips on steering box.
– Separate connectors from steering box.
– Lower subframe carefully with engine/gearbox jack -V.A.G
1383 A- .

340 Rep. gr.48 - Steering

 Golf Variant 2007 ➤ , Jetta 2005 ➤
Running gear, axles, steering - Edition 07.2010

– Now lift anti-roll bar -1- forwards over subframe -2- and down
while turning anti-roll bar slightly.
– Unbolt steering box from subframe.

AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c

ce
e
nl

pt
du

an
itte

y li
erm

ab
ility
ot p

wit
, is n

h re
hole

spec
es, in part or in w

t to the co
rrectness of i
l purpos

nf
ercia

orm
m

atio
om

n in
or c

thi
te

sd
iva

o
r
rp

cu
o

m
f

en
ng

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

4. Electromechanical steering box up to model year 2008 341

 Golf Variant 2007 ➤ , Jetta 2005 ➤
Running gear, axles, steering - Edition 07.2010

– Set steering box down as illustrated.

This prevents damage to the control unit -1-.
Installing
Install in reverse order.
Threaded sleeve of steering box must be located in subframe
hole.

Note

♦ Coat seal on steering box with suitable lubricant, e.g. soft

soap, before installing steering box.
♦ After fitting the steering box 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.
Otherwise, this can result in water leaks and/or noise.
♦ Ensure sealing surfaces are clean.

Before inserting subframe bolts, position steering box on sub‐

frame and insert bolts for steering box and anti-roll bar.
– Attach lower noise insulation ⇒ Rep. gr. 50 ; Assembly over‐
view - noise insulation .
– Bolt universal joint to steering box.
– Connect battery ⇒ Rep. gr. 27 ; Battery; Disconnecting and
AG. Volkswagen AG d
reconnecting battery . lksw
agen oes
n
Vo ot g
by ua
– Carry out basic setting for steering
ris
ed angle sender -G85- using ran
tee
vehicle diagnostic, testinguand
tho information system -VAS 5051- or
⇒ Vehicle diagnostic, testing
ss
a and information system ac
VAS 5051.
ce
e
nl

pt
du

an

After installation, check position of steering wheel during road

itte

y li

test.
erm

ab
ility
ot p

If steering wheel is crooked or a new steering box was installed,

wit
, is n

wheels must be aligned.

h re
hole

spec

– Check wheel alignment ⇒ page 261 .

es, in part or in w

t to the co

If new steering box has been installed, adapt electromechanical

steering using vehicle diagnostic, testing and information system
-VAS 5051- .
rrectness of i

– Carry out adaption of electromechanical steering using vehicle

l purpos

diagnostic, testing and information system -VAS 5051- ⇒ Ve‐

hicle diagnostic, testing and information system VAS 5051.
nf
ercia

Running gear
rm
m

atio
m

Electromechanical power steering

o

n in
or c

thi
e

01 - System capable of self-diagnosis

t

sd
iva

o
r
rp

cu

Electromechanical steering system

o

m
f

en
ng

t.
yi
Functions op
Co
py
. C rig
ht ht
Adapting electromechanical steering rig by
copy Vo
by lksw
cted agen
Prote AG.

342 Rep. gr.48 - Steering

 Golf Variant 2007 ➤ , Jetta 2005 ➤
Running gear, axles, steering - Edition 07.2010
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
Note horis nte
eo
aut ra
ss c
If parking aid 2 is fitted in the vehicle, the power steering control

ce
le
un
unit -J500- must be recoded ⇒ Vehicle diagnostic, testing and

pt
an
d

information system VAS 5051.

itte

y li
erm

ab
ility
ot p

wit
is n

Specified torques

h re
ole,

spec
Component Specified torque
urposes, in part or in wh

t to the co
Subframe to body 70 Nm + 90°
♦ Use new bolts

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

ss o
Anti-roll bar to coupling rod 65 Nm
cial p

f in
♦ Use new nut

form
mer

♦ Counterhold on multi-point socket of joint pin

atio
om

n
c

i
or

n
Swivel joint to cast steel suspension link 60 Nm

thi
te

sd
♦ Use new nuts
iva

o
pr

cum
r
fo

Swivel joint to sheet steel or forged aluminium suspension 100 Nm

en
ng

t.
yi Co
link Cop py
♦ Use new nuts ht. rig
rig ht
py by
co Vo
by lksw
Shield to subframe cted
6 Nm
agen
Prote AG.
♦ Bolt M6 is self-locking

Steering box to subframe 50 Nm + 90°

♦ Use new bolts
♦ Always renew clamp

Universal joint to steering box 30 Nm

♦ Use new bolt

Shield to steering box 6 Nm

♦ Bolt M6 is self-locking

Track rod ball joint to wheel bearing housing 20 Nm + 90°

♦ Use new nut

Exhaust system bracket to subframe

⇒ Engine; Rep. gr. 26

Torque specifications for pendulum support to gearbox

Caution

From model year 08, HeliCoil inserts are installed in the pen‐
dulum support connection in the 02Q gearboxes. Identification
⇒ Rep. gr. 34 .
Use a bolt with hardness class 10.9 for this and all other gear‐
boxes.
If there is no HeliCoil insert in the 02Q gearbox, use bolts with
the strength class 8.8 and the corresponding torque setting.

4. Electromechanical steering box up to model year 2008 343

 Golf Variant 2007 ➤ , Jetta 2005 ➤
Running gear, axles, steering - Edition 07.2010

Bolt Specified torque

M10 x 35 strength class 8.8 40 Nm + 90° further
♦ Use new bolt

M10 x 35 strength class 10.9 50 Nm + 90° further

♦ Use new bolt

M10 x 75 strength class 8.8 40 Nm + 90° further

♦ Use new bolt

M10 x 75 strength class 10.9 50 Nm + 90° further

♦ Use new bolt

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

pt
du

an
itte

y li
erm

ab
ility
ot p

wit
, is n

h re
hole

spec
es, in part or in w

t to the co
rrectness of i
l purpos

nf
ercia

orm
m

atio
om

n in
or c

thi
te

sd
iva

o
r
rp

cu
o

m
f

en
ng

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

344 Rep. gr.48 - Steering

 Golf Variant 2007 ➤ , Jetta 2005 ➤
Running gear, axles, steering - Edition 07.2010

5 Electromechanical steering box from

model year 2009

5.1 Assembly overviewlkswage

n AG. - electromechanical
Volkswagen AG
does
not
steering box, left-hand drive vehi‐
cle (3rdsedgeneration)
by
Vo
from model year gu 2009
ara
n
ri tee
utho or
a ac
1 - Wiring ss

ce
e
nl

pt
du

2 - Universal joint

an
itte

y li
erm

ab
3 - Bolt

ility
ot p

❑ M8 x 35

wit
, is n

h re
❑ 30 Nm
hole

spec
❑ Always renew after re‐
es, in part or in w

moving.

t to the co
4 - Torx bolt
❑ 6 Nm

rrectness of i
❑ Self-locking
l purpos

5 - Shield

nform
ercia

6 - Power steering box

m

❑ With power steering

at
om

i
control unit -J500-
on
c

in t
or

❑ With electromechanical
his
ate

power steering motor -

do
priv

V187-
um
for

en
g

❑ With steering torque

n

t.
yi Co
op
sender -G269- C py
t. rig
gh ht
❑ With steering angle yri
p by
o Vo
sender -G85-
c by lksw
cted agen
Prote AG.
❑ Can be checked in gui‐
ded fault finding of the
vehicle diagnostic, test‐
ing and information sys‐
tem -VAS 5051B- .
❑ Removing and installing
⇒ page 347 .
7 - Left wheel bearing housing
8 - Nut
❑ M12 x 1.5
❑ 20 Nm + 90° further
❑ Self-locking
❑ Always renew after removing.
9 - Bolt
❑ 50 Nm + 90° further
❑ Always renew after removing.
10 - Subframe
11 - Right wheel bearing housing

5. Electromechanical steering box from model year 2009 345

 Golf Variant 2007 ➤ , Jetta 2005 ➤
Running gear, axles, steering - Edition 07.2010

5.2 Assembly overview - electromechanical steering box, right-hand drive ve‐

hicle (3rd generation) from model year 2009

1 - Universal joint
2 - Bolt
❑ M8 x 35
AG. Volkswagen AG d
❑ 30 Nm ksw
agen oes
not
Vol
❑ Always renew afteredre‐
by gu
ara
moving. horis nte
e t or
au ac
3 - Wiring ss

ce
le
un

pt
4 - Shield

an
d
itte

y li
5 - Torx bolt
erm

ab
ility
ot p

❑ 6 Nm

wit
is n

❑ Self-locking

h re
ole,

spec
6 - Power steering box
urposes, in part or in wh

t to the co
❑ With power steering
control unit -J500-
❑ With electromechanical

rrectne
power steering motor -
V187-

ss
❑ With steering torque

o
cial p

f
sender -G269-
inform
❑ With steering angle
mer

atio

sender -G85-
om

n
c

❑ Can be checked in gui‐

i
or

n thi

ded fault finding of the

te

sd
va

vehicle diagnostic, test‐

i

o
pr

ing and information sys‐

um
r
fo

en
ng

tem -VAS 5051B- .

t.
yi Co
op
❑ Removing and installing
C py
ht. rig
⇒ page 353 .
rig ht
py by
co Vo
by lksw
cted
7 - Left wheel bearing housing
agen
Prote AG.

8 - Nut
❑ M12 x 1.5
❑ 20 Nm + 90° further
❑ Self-locking
❑ Always renew after removing.
9 - Bolt
❑ 50 Nm + 90° further
❑ Always renew after removing.
10 - Subframe
11 - Right wheel bearing housing

346 Rep. gr.48 - Steering

 n AG. Volkswagen AG do
lkswage es n
o ot g
byV ua
d ran
ir se
tho Golf Variant 2007tee
or ➤ , Jetta 2005 ➤
u
ss
a
Running gear, axles, steering ac
- Edition 07.2010

ce
e
nl

pt
du
5.3 Removing and installing steering box, left-hand drive vehicle (3rd genera‐

an
itte

y li
erm
tion) from model year 2009

ab
ility
ot p

wit
, is n

h re
Special tools and workshop

hole

spec
equipment required
es, in part or in w

t to the co
♦ Torque wrench -V.A.G
1331-

rrectness of i
♦ Torque wrench -V.A.G
1332-
l purpos

♦ Engine and gearbox jack -

V.A.G 1383 A-

nform
ercia

♦ Ball joint puller -3287 A-

m

at
om

ion
c

in t
or

his
ate

do
priv

cum
for

en
ng

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

Removing steering box

– Disconnect battery. ⇒ Rep. gr. 27 ; Battery; Disconnecting
and reconnecting battery.
– Remove footwell trim by removing nuts -arrows-.

5. Electromechanical steering box from model year 2009 347

 Golf Variant 2007 ➤ , Jetta 2005 ➤
Running gear, axles, steering - Edition 07.2010

– Remove bolt -1- and pull universal joint -2- off steering box.
– Remove front wheels.
– 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.

– Press track rod ball joint off wheel bearing housing with
-3287A-.
– Remove lower noise insulation ⇒ Rep. gr. 50 ; Assembly
overview - noise insulation .

– Disconnect pendulum support from gearbox by removing bolts

-14-.
AG. Volkswagen AG d
– Remove exhaust system retainer on subframe. lksw
agen oes
not
Vo gu
d by ara
ise nte
or eo
h
aut ra
ss c

ce
le
un

pt
an
d
itte

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rm

ab
pe

ility
ot

wit
, is n

h re
hole

spec
es, in part or in w

t to the co
rrectness of i
l purpos

– Remove bolts -arrows- from heat shield.

nform
ercia

– Remove heat shield from subframe.

m

a
com

tion in
r
te o

thi
s
iva

do
r
rp

cum
fo

en
ng

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

348 Rep. gr.48 - Steering

 Golf Variant 2007 ➤ , Jetta 2005 ➤
Running gear, axles, steering - Edition 07.2010

– Remove bolts -3- and -5- for steering box. agen

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oes
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ara
ed
ris nte
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aut ra
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ce
le
un

pt
an
d
itte

y li
rm

ab
pe

ility
ot

wit
, is n

h re
hole

spec
es, in part or in w

t to the co
rrectness of i
l purpos

nform
mercia

– Remove bolts -11- and -16- for anti-roll bar.

a
com

tion in
– Fix subframe and brackets in place ⇒ page 16 .
r
te o

thi
s
iva

do
r
rp

cum
fo

en
ng

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

– Position
engine and gearbox jack -V.A.G 1383 A- under subframe.
– Place a wooden block -1- or similar between V.A.G 1383 A
and subframe.

5. Electromechanical steering box from model year 2009 349

 Golf Variant 2007 ➤ , Jetta 2005 ➤
Running gear, axles, steering - Edition 07.2010

– Remove bolts -4 and 5- and lower subframe with brackets

slightly, observing electrical wires.

AG. Volkswagen AG d
– Remove heat shield -1- over lsteering
ksw
agen box. oes
not
o
yV gu
– Remove bolts -arrows-. ris
edb ara
nte
ho eo
aut ra
ss c ce
e
nl

pt
du

an
itte

y li
erm

ab
ility
ot p

wit
, is n

h re
hole

spec
es, in part or in w

t to the co

– Remove cable guide from subframe -arrow-.

rrectness of i

– Unclip all remaining cable clips on steering box.

l purpos

– Disconnect all electrical connections on steering box.

– Lower subframe using engine and gearbox jack -V.A.G 1383
nform
ercia

A- far enough that the steering box can be removed.

m

at
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ion
c

in t
or

his
ate

do
priv

cum
for

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

350 Rep. gr.48 - Steering

 Golf Variant 2007 ➤ , Jetta 2005 ➤
Running gear, axles, steering - Edition 07.2010

– Set steering box down as illustrated.

This prevents damage to the control unit -1-.
Installing steering box
Install in reverse order.
Threaded sleeves of steering box must seat in holes in left brack‐
et.

Note

♦ Coat seal on steering box with suitable lubricant, e.g. soft

soap, before installing steering box.
♦ After fitting the steering box to the jointed shaft, ensure that
the seal is not kinked when lying against the assembly plate
and that the opening to the footwell is correctly sealed. Oth‐
erwise, this can result in water leaks and/or noise.
♦ Ensure sealing surfaces are clean.

Before inserting subframe bolts, position steering box on sub‐

frame and insert bolts for steering box and anti-roll bar.
– Connect electrical connections to steering box.
– Install lower noise insulation. ⇒ Rep. gr. 50 ; Assembly over‐
view - noise insulation .

AG. Volkswagen AG d
Note
agen oes
olksw not
y V gu
d b ara
Ensure thatorbellows
ise are not damaged or twisted. nte
eo
th
au ra
ss c
– Bolt universal joint to steering box.
ce
e
nl

pt
du

an

– Connect battery. ⇒ Rep. gr. 27 ; Battery; Disconnecting and

itte

y li

reconnecting battery.
erm

ab
ility
ot p

– Carry out basic setting for -G85 - steering angle sender- using
wit
, is n

vehicle diagnostic, testing and information system -VAS 5051-

h re

⇒ Vehicle diagnostic, testing and information system

hole

spec

VAS 5051.
es, in part or in w

t to the co

After installation, check position of steering wheel during road

test.
rrectness of i

If steering wheel is not in straight-ahead position or if a new steer‐

ing box was installed, front axle tracking must be checked and if
l purpos

necessary adjusted!
– Check wheel alignment ⇒ page 261 .
nform
ercia

If new steering box has been installed, adapt electromechanical

m

at

steering using vehicle diagnostic, testing and information system

om

ion

-VAS 5051- .
c

in t
or

his
te

– Carry out adaption of electromechanical steering using vehicle

a

do
riv

diagnostic, testing and information system -VAS 5051- ⇒ Ve‐

p

cum
or

hicle diagnostic, testing and information system VAS 5051.

f

en
ng

t.
yi Co
Cop py
Running gear gh
t. rig
ht
pyri by
Vo
co
Electromechanical power steering by lksw
cted agen
Prote AG.
01 - System capable of self-diagnosis

Electromechanical steering system

Functions

5. Electromechanical steering box from model year 2009 351

 Golf Variant 2007 ➤ , Jetta 2005 ➤
Running gear, axles, steering - Edition 07.2010

Adapting electromechanical steering

Specified torques
Component Specified torque
Subframe to body 70 Nm + 90°
♦ Use new bolts

Anti-roll bar to subframe 20 Nm + 90°

♦ Use new bolts

Anti-roll bar to coupling rod 65 Nm

♦ Use new nut
♦ Counterhold on multi-point socket of joint pin

Swivel joint to cast steel suspension link 60 Nm

♦ Use new nuts

Swivel joint to sheet steel or forged aluminium suspension 100 Nm

link
♦ Use new nuts
n AG. Volkswagen AG do
wage es n
Shield to subframe yV
olks ot g
ua
6 Nm
♦ Bolt M6 is self-locking ir se
d b ran
tee
tho
u or
Steering box to subframess a ac
50 Nm + 90°
♦ Use new bolts ce
le
un

pt
an
d
itte

Universal joint to steering box y li 30 Nm

erm

ab
♦ Use new bolt ility
ot p

wit
is n

Shield to steering box 6 Nm

h re
ole,

♦ Bolt M6 is self-locking
spec
urposes, in part or in wh

t to the co

Track rod ball joint to wheel bearing housing 20 Nm + 90°

♦ Use new nut
rrectne

Exhaust system bracket to subframe

⇒ Engine; Rep. gr. 26
ss o
cial p

f inform

Torque specifications for pendulum support to gearbox

mer

atio
m

Bolt Specified torque

o

n
c

i
or

n thi
e

M10 x 35 50 Nm + 90° further

t

sd
va

♦ Use new bolt

i

o
pr

cum
r
fo

en
ng

M10 x 75 50 Nm + 90° further

t.
yi Co
op
♦ Use new bolt
C py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

352 Rep. gr.48 - Steering

 Golf Variant 2007 ➤ , Jetta 2005 ➤
Running gear, axles, steering - Edition 07.2010

5.4 Removing and installing steering box, right-hand drive vehicle (3rd gener‐
ation) from model year 2009

Special tools and workshop

equipment required
♦ Torque wrench -V.A.G
1331-
♦ Torque wrench -V.A.G
1332-
♦ Engine and gearbox jack - n AG. Volkswagen AG do
V.A.G 1383 A- wage es n
olks o V t gu
by ara
♦ Ball joint puller -3287
ris A-
ed nte
tho eo
s au ra
c
s

ce
e
nl

pt
du

an
itte

y li
erm

ab
ility
ot p

wit
, is n

h re
hole

spec
es, in part or in w

t to the co
rrectness of i
l purpos

nf
ercia

orm
m

atio
om

n in
or c

thi
te

sd
iva

o
r
rp

cu
o

m
f

en
ng

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

Removing
– Disconnect battery ⇒ Rep. gr. 27 ; Battery; Disconnecting and
reconnecting battery .
– Unscrew nuts -1- to remove footwell trim -2-.

5. Electromechanical steering box from model year 2009 353

 Golf Variant 2007 ➤ , Jetta 2005 ➤
Running gear, axles, steering - Edition 07.2010

– Remove bolt -1- for universal joint and pull universal joint -2-
off steering box.
– Remove front wheels.
– 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.

– Press track rod ball joint off wheel bearing housing using ball
joint puller -3287A- and now remove nut.
– Remove lower noise insulation ⇒ Rep. gr. 50 ; Assembly
overview - noise insulation .
– Remove coupling rod from anti-roll bar.
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
ss c

ce
le
un

pt
an
d
itte

y li
rm

ab
pe

ility
– Remove nuts -arrows-.
ot

wit
, is n

h re
hole

spec
es, in part or in w

t to the co
rrectness of i
l purpos

nform
mercia

a
com

tio
– Disconnect pendulum support from gearbox by removing bolts n in
r

-14-.
te o

thi
s
iva

do
r
rp

cum
fo

en
ng

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

354 Rep. gr.48 - Steering

 Golf Variant 2007 ➤ , Jetta 2005 ➤
Running gear, axles, steering - Edition 07.2010

– Detach exhaust system bracket from subframe -arrows-.

Vehicles with front-wheel drive

– Remove bolts -arrows- from heat shield.

– Remove heat shield from subframe.
Continuation for all vehicles

– Remove bolts -5- and -6- for steering box.

n AG. Volkswagen AG do
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss
ce
e
nl

pt
du

an
itte

y li
erm

ab
ility
ot p

wit
, is n

h re
hole

spec
es, in part or in w

t to the co
rrectness of i
l purpos

nf
ercia

orm
m

atio
om

n in
or c

thi
te

sd
iva

o
r
rp

cu
o

m
f

en
ng

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

5. Electromechanical steering box from model year 2009 355

 Golf Variant 2007 ➤ , Jetta 2005 ➤ AG. Volkswagen
n AG do
Running gear, axles, steering wage
olks- Edition 07.2010
es n
V o t gu
by ara
ed nte
– Remove bolts -11- and -16- ho for anti-roll
ris
bar. eo
aut ra
– Fix position of subframe
ss ⇒ page 16 . c

ce
e
nl

pt
– Separate connector for extended service intervals on oil sump.
du

an
itte

y li
erm

ab
ility
ot p

wit
, is n

h re
hole

spec
es, in part or in w

t to the co
rrectness of i
l purpos

nform
mercia

at
om

ion
c

in t
or

his
e

– Position
at

do
riv

engine and gearbox jack -V.A.G 1383 A- under subframe.

p

cum
for

en
g

– Place, for example, a wooden block -1- between engine and

n

t.
yi Co
gearbox jack -V.A.G 1383 A- and subframe. t. Cop py
rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

– Remove bolts -4- and -5- and lower subframe slightly. In the
process, observe electrical wiring.

356 Rep. gr.48 - Steering

 AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
rised
Golf Variant 2007 ➤ nt,eJetta 2005 ➤
o eo
aut
h
Running gear, axles, steering - Edition r a 07.2010
ss c

ce
e
– Remove heat shield -1- over steering box.

nl

pt
du

an
itte

y li
– Remove bolts -arrows-.

erm

ab
ility
ot p

wit
, is n

h re
hole

spec
es, in part or in w

t to the co
rrectness of i
l purpos

– Remove cable guide from subframe -arrow-.

nform
ercia

– Unclip all remaining cable clips on steering box.

m

at
om

ion
c

in t
or

his
ate

do
priv

cum
for

en
ng

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

– Separate connectors from steering box.

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

– Now lift anti-roll bar -1- forwards over subframe -2- and down
while turning anti-roll bar slightly.
– Unbolt steering box from subframe.

5. Electromechanical steering box from model year 2009 357

 Golf Variant 2007 ➤ , Jetta 2005 ➤
Running gear, axles, steering - Edition 07.2010

– Set steering box down as illustrated.

This prevents damage to the control unit -1-.
Installing
Install in reverse order.
Threaded sleeve of steering box must be located in subframe
hole.

Note

♦ Coat seal on steering box with suitable lubricant, e.g. soft

soap, before installing steering box.
. Volkswagen AG
gen AG
♦ After fitting the steeringVobox
lksw to the universal joint, e
omake
s no sure
a d
t
that the seal is not ekinked
db
y when lying against the assemblygu
ara
plate and that theh orisopening to the footwell is correctly sealed.
nte
eo
Otherwise, this
sa
ut
can result in water leaks and/or noise. ra
c
s
♦ Ensure sealing surfaces are clean.

ce
le
un

pt
an
d
itte

y li
Before inserting subframe bolts, position steering box on sub‐
erm

ab
ility
frame and insert bolts for steering box and anti-roll bar.
ot p

wit
is n

– Attach lower noise insulation ⇒ Rep. gr. 50 ; Assembly over‐

h re
ole,

view - noise insulation .

spec
urposes, in part or in wh

– Bolt universal joint to steering box.

t to the co
– Connect battery ⇒ Rep. gr. 27 ; Battery; Disconnecting and
reconnecting battery .
rrectne

– Carry out basic setting for steering angle sender -G85- using
vehicle diagnostic, testing and information system -VAS 5051-
ss

⇒ Vehicle diagnostic, testing and information system

o
cial p

VAS 5051.
inform
mer

After installation, check position of steering wheel during road

atio
m

test.
o

n
c

i
or

If steering wheel is crooked or a new steering box was installed,

thi
te

sd
a

wheels must be aligned.

iv

o
pr

cum
r
fo

– Check wheel alignment ⇒ page 261 .

en
ng

t.
yi Co
op
If new steering box has been installed, adapt electromechanical C py
t. rig
steering using vehicle diagnostic, testing and information system
gh ht
yri by
-VAS 5051- .
cop Vo
by lksw
cted agen
Prote AG.
– Carry out adaption of electromechanical steering using vehicle
diagnostic, testing and information system -VAS 5051- ⇒ Ve‐
hicle diagnostic, testing and information system VAS 5051.
Running gear

Electromechanical power steering

01 - System capable of self-diagnosis

Electromechanical steering system

Functions

Adapting electromechanical steering

358 Rep. gr.48 - Steering

 Golf Variant 2007 ➤ , Jetta 2005 ➤
Running gear, axles, steering - Edition 07.2010

Note

If parking aid 2 is fitted in the vehicle, the power steering control

unit -J500- must be recoded ⇒ Vehicle diagnostic, testing and
information system VAS 5051.

Specified torques
Component Specified torque
Subframe to body 70 Nm + 90°
♦ Use new bolts

Anti-roll bar to subframe 20 Nm + 90°

♦ Use new bolts

Anti-roll bar to coupling nrod

AG. Volkswagen AG d 65 Nm
wage oes
♦ Use new nut yV
olks not
g
b ua
ed ran
♦ Counterhold
ho
ris on multi-point socket of joint pin tee
t or
au ac
ss
Swivel joint to cast steel suspension link ce 60 Nm
le

♦ Use new nuts

un

pt
an
d
itte

y li
erm

ab
Swivel joint to sheet steel or forged aluminium suspension 100 Nm
ility
ot p

link
wit

♦ Use new nuts

is n

h re
ole,

spec

Shield to subframe 6 Nm
urposes, in part or in wh

♦ Bolt M6 is self-locking
t to the co

Steering box to subframe 50 Nm + 90°

♦ Use new bolts
rrectne

Universal joint to steering box 30 Nm

ss

♦ Use new bolt

o
cial p

f inform

Shield to steering box 6 Nm

mer

♦ Bolt M6 is self-locking
atio
om

n
c

i
or

Track rod ball joint to wheel bearing housing 20 Nm + 90°

thi
te

♦ Use new nut

sd
iva

o
pr

cum
r
fo

Exhaust system bracket to subframe

en
ng

t.
yi
⇒ Engine; Rep. gr. 26
Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote
Torque specifications for pendulum support to gearbox
AG.

Bolt Specified torque

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

M10 x 75 50 Nm + 90° further

♦ Use new bolt

5. Electromechanical steering box from model year 2009 359

 Golf Variant 2007 ➤ , Jetta 2005 ➤
Running gear, axles, steering - Edition 07.2010

6 Differentiating between 2nd and 3rd

generation steering boxes
From model year 2009, a new, 3rd generation, steering box is
being used. It replaces the 2nd generation steering box.
To identify the type of steering box while it is fitted, count the
number of bolts with which the steering box is attached to the
subframe.
– Raise vehicle.
The 2nd generation steering box is attached to the subframe with
4 bolts and the 3rd generation steering box is attached with 3.

AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c
ce
e
nl

pt
du

an
itte

y li
erm

ab
ility
ot p

wit
, is n

h re
hole

spec
es, in part or in w

t to the co
rrectness of i
l purpos

nform
mercia

at
om

ion
c

in t
or

his
ate

do
priv

cum
for

en
ng

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

360 Rep. gr.48 - Steering

 Golf Variant 2007 ➤ , Jetta 2005 ➤
Running gear, axles, steering - Edition 07.2010

7 Repairing electromechanical 2nd

and 3rd generation steering boxes
At present, there is no provision for performing repairs on the 2nd
and 3rd generation steering boxes.

7.1 Removing and installing boot

Special tools and workshop

equipment required
♦ Hose clip pliers -V.A.G
1275-
♦ Torque wrench -V.A.G
1332-
♦ Tool insert 24 mm -V.A.G
1332/11-
♦ Locking pliers for Phaeton
steering box -VAS 6199-

AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c
ce
le
un

pt
an
d
itte

y li
rm

ab
pe

ility
ot

wit
, is n

h re
hole

spec
es, in part or in w

t to the co

Removing boot
rrectness of i

Note
l purpos

If boot is defective, moisture and dirt will enter steering box. There
nform
ercia

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 box must
m

be renewed. Also renew steering box if there are signs of corro‐

com

tion in

sion, damage or wear to the steering rack.

r
te o

thi
s
iva

do

– Turn steering wheel to straight-ahead position.

r
rp

cum
fo

en
g

– Remove wheel.
n

t.
yi Co
Cop py
– Clean outside of steering box in vicinity of boots.
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted
361
agen
Prote AG.
7. Repairing electromechanical 2nd and 3rd generation steering boxes
 Golf Variant 2007 ➤ , Jetta 2005 ➤
Running gear, axles, steering - Edition 07.2010

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

fective rubber boot during this operation.
– Mark position of nut -3- on steering rack.
– Loosen nut -3- while counterholding w
on head
age ofolktrack
n AG. V rod -2-.
swagen AG
does
ks not
Vol gu
– Loosen spring-type clip -1- fromed boot using hose clip pliers -
by ara
nte
V.A.G 1275- and push ontothoristrack rod. eo
au ra
– Remove clamp and pull
ss boot from steering box housing. c

ce
le
un

pt
– Now turn track rod out of track rod ball joint.

an
d
itte

y li
erm

– Pull boot with spring-type clip off track rod.

ab
ility
ot p

wit
is n

h re
Note
ole,

spec
urposes, in part or in wh

♦ If the steering rack shows signs of corrosion, damage, wear or

t to the co
soiling, renew the complete steering box.
♦ Likewise, if there is no film of grease on the steering rack, the

rrectne
steering box must be renewed.

ss
Installing boot

o
cial p

f inform
mer

Caution

atio
om

n
c

Do not grease steering rack.

i
or

n thi
te

sd
iva

o
pr

cum
r

– Turn steering wheel to straight-ahead position.

fo

en
ng

t.
yi Co
– Thread new clamps and rubber boot onto track rod. Cop py
ht. rig
rig ht
– Screw in track rod to mark made during removal. py by
co Vo
by lksw
cted agen
Prote AG.
– Tighten lock nut -3- to specified torque while counterholding
track rod ball joint -2-.
– Lightly lubricate seal point 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 seal point between boot and steering box with
grease -G 052 168 A1- (from repair kit Fuchs Renolit JP1619).
– Push rubber boot onto steering box housing to stop.

362 Rep. gr.48 - Steering

 Golf Variant 2007 ➤ , Jetta 2005 ➤
Running gear, axles, steering - Edition 07.2010

– Install new clamp, as shown in figure, with locking pliers for

Phaeton steering box -VAS 6199- .
Continue installation in reverse order.
Specified torque for wheel bolts ⇒ page 241
Check wheel alignment after completing the installation.
– Check wheel alignment ⇒ page 261 .
– Adapt steering angle sender -G85- using ⇒ vehicle diagnostic,
testing and information system -VAS 5051B- , „Guided fault
finding“ .
– Then adapt steering using ⇒ vehicle diagnostic, testing and
information system -VAS 5051B- , „guided fault finding“w.agen AG. Volkswagen AG doe
ks s no
Vol t gu
d by ara
Specified torques ris
e nte
tho eo
au ra
Component ss Specified torque c

ce
e
nl

Track rod ball joint to track rod 50 Nm

pt
du

an
itte

y li
erm

ab
ility
ot p

wit
7.2 Removing and installing track rod
, is n

h re
hole

spec
es, in part or in w

Special tools and workshop

t to the co
equipment required
♦ Ball joint puller -3287 A-

rrectness of i
♦ Hose clip pliers -V.A.G
l purpos

1275-
♦ Torque wrench -V.A.G

nform
ercia

1332-
m

at
♦ Open-end insert, 38 mm -
om

ion
V.A.G 1923-
c

in t
or

his
te

♦ Locking pliers for Phaeton

a

do
riv

steering box -VAS 6199-

p

cum
for

en
ng

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

7. Repairing electromechanical 2nd and 3rd generation steering boxes 363

 Golf Variant 2007 ➤ , Jetta 2005 ➤
Running gear, axles, steering - Edition 07.2010

Removing track rod

– Turn steering wheel to straight-ahead position.
– Clean outside of steering box in vicinity of boots.
– Loosen nut -3-, counterholding on track rod ball joint -2-.
– Remove front wheel.
– Loosen nut on track rod ball joint but do not remove complete‐
ly.
Leave nut screwed on a few turns to protect thread on pin.

AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c
– Press track rod ball joint off wheel bearing housing using ball

ce
le
un

pt
joint puller -3287 A- and now remove nut.

an
d
itte

y li
– Loosen spring-type clip (item -1- in figure N44-10005
erm

ab
ility
⇒ page 364 ) on rubber boot using hose clip pliers -V.A.G
ot p

1275- and push onto track rod.

wit
is n

h re
ole,

– Remove clamp and pull boot from steering box housing.

spec
urposes, in part or in wh

t to the co
rrectness o

– Unscrew track rod from steering rack using open-end insert,

cial p

f in

38 mm -V.A.G 1923- .
form
mer

atio
om

Note
c

i
or

n thi
te

sd
va

♦ If the steering rack shows signs of corrosion, damage, wear or

i

o
pr

cum

soiling, renew the complete steering box.

r
fo

en
ng

t.
yi Co
♦ Likewise, if there is no film of grease on the steering rack, the Cop py
steering box must be renewed.
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted
Installing track rod
agen
Prote AG.

Note

Do not grease steering rack.

Caution

Under no circumstances may a different grease be used!

– Turn steering wheel to straight-ahead position.

– Thread new clamps and rubber boot onto track rod.

364 Rep. gr.48 - Steering

 Golf Variant 2007 ➤ , Jetta 2005 ➤
Running gear, axles, steering - Edition 07.2010

– Screw track rod into track rod ball joint until dimension -a- is
attained.
Dimension -a- = 371 ± 1 mm
– Turn track rod into steering rack and tighten to specified tor‐
que.
– Lightly lubricate seal point between boot and track rod with
grease -G 052 168 A1- (from repair kit Fuchs Renolit JP1619).

– Position boot -2- on track rod -1-.

– Secure spring-type clip on rubber boot using hose clip pliers -
V.A.G 1275- .
– Lightly lubricate seal point between boot and steering box with
olkswagen AG
grease -G 052 168 A1- (from repair kit Fuchs
wa en AG. V JP1619).
gRenolit does
ks ol not
yV gu
– Push rubber boot onto steering box
ise
d bhousing to stop. ara
nte
r
ho eo
aut ra
ss c

ce
le
un

pt
an
d
itte

y li
rm

ab
pe

ility
ot

wit
– Install new clamp, as shown in figure, with locking pliers for
, is n

h re
Phaeton steering box -VAS 6199- .
hole

spec
Continue installation in reverse order.
es, in part or in w

t to the co
Specified torque for wheel bolts ⇒ page 241
Check wheel alignment after completing the installation.

rrectness of i
– Check wheel alignment ⇒ page 261 .
l purpos

– Adapt steering angle sender -G85- using ⇒ vehicle diagnostic,

testing and information system -VAS 5051B- , „Guided fault
nform
ercia

finding“ .
m

– Then adapt steering using ⇒ vehicle diagnostic, testing and

com

tion in

information system -VAS 5051B- , „guided fault finding“ .

r
te o

thi
s
iva

do

Specified torques
r
rp

cum
fo

en
g

Component Specified torque

n

t.
yi Co
Cop py
Track rod to steering rack 100 Nm
t. rig
gh ht
pyri by
Track rod ball joint to track rod 50 Nm
co Vo
by lksw
cted agen
Prote
Track rod ball joint to wheel bearing housing 20 Nm + 90°
AG.

♦ Use new nut

7. Repairing electromechanical 2nd and 3rd generation steering boxes 365