Golf Variant 2007 ➤ , Jetta 2005 ➤ Running gear, axles, steering - Edition 07.2010 00 – Technical data 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.
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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‐...
Golf Variant 2007 ➤ , Jetta 2005 ➤ Running gear, axles, steering - Edition 07.2010 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 .
Golf Variant 2007 ➤ , Jetta 2005 ➤ Running gear, axles, steering - Edition 07.2010 40 – Front suspension Appraisal of accident vehicles A checklist for evaluating running gear of accident vehicles can be found under ⇒ page 1 Rep. gr.40 - Front suspension...
Golf Variant 2007 ➤ , Jetta 2005 ➤ Running gear, axles, steering - Edition 07.2010 Repairing front suspension Overview - front axle Note It is not permitted to carry out welding and straightening operations on load-bearing or wheel-guiding sus‐ ♦...
Golf Variant 2007 ➤ , Jetta 2005 ➤ Running gear, axles, steering - Edition 07.2010 The chapter „Removing and installing drive shafts“ can be found ⇒ page 72 The chapter „Repairing drive shaft“ can be found on ⇒ page 87...
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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- .
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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.
Golf Variant 2007 ➤ , Jetta 2005 ➤ Running gear, axles, steering - Edition 07.2010 Subframe, anti-roll bar, suspension links 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.
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Golf Variant 2007 ➤ , Jetta 2005 ➤ Running gear, axles, steering - Edition 07.2010 8 - Front left vehicle level sender -G78- ❑ Can be checked in guided fault finding of the vehicle diagnostic, testing and information system -VAS 5051B- .
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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 ❑...
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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 gearboxes. Identification ⇒ Rep. gr. 34 . Use a bolt with hardness class 10.9 for this and all...
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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 ❑...
Golf Variant 2007 ➤ , Jetta 2005 ➤ Running gear, axles, steering - Edition 07.2010 Assembly overview: front left vehicle level sender -G78- Note The front left vehicle level sender -G78/- is only available as a replacement part complete with coupling rod ♦...
Golf Variant 2007 ➤ , Jetta 2005 ➤ Running gear, axles, steering - Edition 07.2010 ♦ Torque wrench -V.A.G 1410- Removing Note To remove front left vehicle level sender -G78- , steering must be turned to right lock to ensure clearance between suspension link and anti-roll bar.
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 Fixing position of bracket The position of the front axle is now fixed.
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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 – Turn steering wheel to straight-ahead position and remove ig‐ nition key so that the steering lock engages.
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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.
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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.
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 ⇒...
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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‐...
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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 with brackets. – Place engine and gearbox jack -V.A.G 1383 A- under sub‐...
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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;...
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 ♦...
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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‐ ♦...
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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 ♦...
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 ♦...
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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 – Press out both bonded rubber bushes at the same time as illustrated.
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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. – Insert assembled bonded rubber bushes with bolt head down‐...
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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‐...
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.
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-. Note There should be no palpable or visible „play“ during both tests.
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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. The wheel bearing can be damaged by the weight of the vehi‐...
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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.
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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.
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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;...
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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.
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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.
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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...
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-...
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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 .
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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.
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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°...
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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‐...
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 with the ground when the drive shaft bolt is tightened;...
Golf Variant 2007 ➤ , Jetta 2005 ➤ Running gear, axles, steering - Edition 07.2010 – Tighten outer joint to 120 Nm. Loosening 12-point bolt – To avoid damage to wheel bearing, do not loosen 12-point bolt using 24 mm socket -T10361- further than 90° with vehicle still standing on its wheels.
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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: ♦...
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‐...
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Golf Variant 2007 ➤ , Jetta 2005 ➤ Running gear, axles, steering - Edition 07.2010 ♦ Multi-purpose tool -VW 771- ♦ Drive shaft puller -T10382- ♦ Torque wrench -V.A.G 1332- Removing – Loosen drive shaft bolt at wheel hub ⇒ page 71 Caution During this step, vehicle must not be standing on its wheels.
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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.
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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- .
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...
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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.
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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.
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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- .
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Golf Variant 2007 ➤ , Jetta 2005 ➤ Running gear, axles, steering - Edition 07.2010 Pressing off inner constant velocity joint Assembling Installation position of dished spring at inner joint Dished spring Pressing on inner constant velocity joint Note Chamfer on internal circumference of ball hub (splines) must face contact shoulder on drive shaft.
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.
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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.
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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.
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.
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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.
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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- .
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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.
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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- .
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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- .
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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.
Page 134
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- .
Golf Variant 2007 ➤ , Jetta 2005 ➤ Running gear, axles, steering - Edition 07.2010 42 – Rear suspension Appraisal of accident vehicles A checklist for evaluating running gear of accident vehicles can be found under ⇒ page 1 1. Appraisal of accident vehicles...
Golf Variant 2007 ➤ , Jetta 2005 ➤ Running gear, axles, steering - Edition 07.2010 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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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! –...
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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.
Golf Variant 2007 ➤ , Jetta 2005 ➤ Running gear, axles, steering - Edition 07.2010 Removing and installing rear axle Special tools and workshop equipment required ♦ Torque wrench -V.A.G 1332- ♦ Engine and gearbox jack - V.A.G 1383/A - ♦...
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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-.
Page 144
Golf Variant 2007 ➤ , Jetta 2005 ➤ Running gear, axles, steering - Edition 07.2010 – Unclip speed sensor wire from retainer -1- -arrows-. – Pull out hose retainer -1- on both sides of vehicle. – Mark installation position of bearing bracket on body.
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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.
Page 146
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°...
Golf Variant 2007 ➤ , Jetta 2005 ➤ Running gear, axles, steering - Edition 07.2010 Vehicle level sender for vehicles with automatic headlight range control Note The vehicle level sender is available as a replacement part only complete with coupling rod and upper and ♦...
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.
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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 – Remove wheel. – Remove coil spring ⇒ page 165 – Remove nut -1- and pull coupling rod -2- out of anti-roll bar.
Page 153
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.
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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...
Golf Variant 2007 ➤ , Jetta 2005 ➤ Running gear, axles, steering - Edition 07.2010 A proper seal can be achieved only by installing a new grease cap. 15 - Bolt ❑ M16 x 1.5 x 70 ❑ 180 Nm + 180° further ❑...
Page 157
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-.
Page 158
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.
Page 159
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-.
Golf Variant 2007 ➤ , Jetta 2005 ➤ Running gear, axles, steering - Edition 07.2010 Removing and installing wheel bearing/wheel hub unit Special tools and workshop equipment required ♦ Hub grease cap puller -VW 637/2- ♦ Fitting sleeve -3241- ♦ Torque wrench -V.A.G 1332- ♦...
Page 164
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- . – Lever off grease cap.
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 ⇒...
Page 170
Golf Variant 2007 ➤ , Jetta 2005 ➤ Running gear, axles, steering - Edition 07.2010 – Set up tools as shown in figure. Tube -T10230/3- Thrust piece -T10230/10- Removal tool -3372- Thrust plate -VW 401- Thrust plate -VW 402- – Press out bonded rubber bush.
Page 171
Golf Variant 2007 ➤ , Jetta 2005 ➤ Running gear, axles, steering - Edition 07.2010 – Set up special tools as shown in figure. Tube -T10230/5- Thrust plate -T10230/12- (chamfer must face bonded rubber bush) Bonded rubber bush Removal tool -3372- Thrust plate -VW 402- –...
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.
Page 175
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“...
Golf Variant 2007 ➤ , Jetta 2005 ➤ Running gear, axles, steering - Edition 07.2010 Assembly overview: anti-roll bar The -arrow- points forwards. 1 - Anti-roll bar ❑ Note different running gear versions ⇒ page 275 ❑ Removing and installing ⇒...
Page 179
Golf Variant 2007 ➤ , Jetta 2005 ➤ Running gear, axles, steering - Edition 07.2010 ♦ Torque wrench -V.A.G 1331- Removing Note The following procedure is for the left side of the vehicle. The procedure for the right side of the vehicle is identical.
Page 180
Golf Variant 2007 ➤ , Jetta 2005 ➤ Running gear, axles, steering - Edition 07.2010 – Connect coupling rod -2- to anti-roll bar and tighten nut -1-. Specified torques Component Specified torque Anti-roll bar to subframe 25 Nm + 45°...
Golf Variant 2007 ➤ , Jetta 2005 ➤ Running gear, axles, steering - Edition 07.2010 Removing and installing shield Removing – Remove nuts -1-. – Pull shield -2- downwards off the subframe and detach above at the same time -arrow-.
Page 183
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 Shield to subframe 2 Nm 7.
Golf Variant 2007 ➤ , Jetta 2005 ➤ Running gear, axles, steering - Edition 07.2010 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-...
Page 187
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- .
Golf Variant 2007 ➤ , Jetta 2005 ➤ Running gear, axles, steering - Edition 07.2010 Assembly overview: subframe, final drive (four-wheel drive) -Arrow- indicates direction of travel. 1 - Subframe 2 - Rear bonded rubber bush ❑ Renewing ⇒ page 186 3 - Front bonded rubber bush ❑...
Page 189
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.
Page 190
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-.
Page 191
Golf Variant 2007 ➤ , Jetta 2005 ➤ Running gear, axles, steering - Edition 07.2010 – Unscrew centre bearing bolts -arrows- two turns. – Support propshaft -A- on tunnel support -1- using a wooden block. – Push rear propshaft tube towards gearbox as far as possible.
Page 192
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.
Page 193
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.
Page 195
Golf Variant 2007 ➤ , Jetta 2005 ➤ Running gear, axles, steering - Edition 07.2010 – Remove clip -1-. Note Do not open brake line. – Now strap vehicle to lifting platform arms on both sides of ve‐ hicle using tensioning straps -T10038- .
Page 196
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;...
Page 197
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 ⇒...
Page 198
Golf Variant 2007 ➤ , Jetta 2005 ➤ Running gear, axles, steering - Edition 07.2010 – Remove clip -1-. Note Do not open brake line. – Now strap vehicle to lifting platform arms on both sides of ve‐ hicle using tensioning straps -T10038- .
Page 199
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‐...
Page 200
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 ⇒...
Golf Variant 2007 ➤ , Jetta 2005 ➤ Running gear, axles, steering - Edition 07.2010 10.1 Overview - rear left vehicle level sender -G76- Note ♦ The vehicle level sender is available as a replacement part only complete with coupling rod and upper and lower retaining plates.
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.
Page 208
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.
Page 210
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! –...
Page 211
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.
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.
Page 214
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.
Page 215
Golf Variant 2007 ➤ , Jetta 2005 ➤ Running gear, axles, steering - Edition 07.2010 Position: threaded connection between trailing arm and wheel bearing housing 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.
Page 221
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. 1 - Mounting bracket 2 - Trailing arm – Tighten bolt when dimension -a- is set.
Page 222
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.
Golf Variant 2007 ➤ , Jetta 2005 ➤ Running gear, axles, steering - Edition 07.2010 End of spring -arrow- must lie against stop on bottom spring seat. – Install spring together with spring seat. – The bottom spring seat has a pin.
Page 229
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“...
Golf Variant 2007 ➤ , Jetta 2005 ➤ Running gear, axles, steering - Edition 07.2010 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.
Page 234
Golf Variant 2007 ➤ , Jetta 2005 ➤ Running gear, axles, steering - Edition 07.2010 Removing – Remove rear wheels. Note The following procedure is for the left side of the vehicle. The procedure for the right side of the vehicle is identical.
Page 235
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.
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.
Page 239
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 inner splines.
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.
Page 246
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.
Page 247
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.
Golf Variant 2007 ➤ , Jetta 2005 ➤ Running gear, axles, steering - Edition 07.2010 Fitting wheel and tyre 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‐...
Page 251
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.
Golf Variant 2007 ➤ , Jetta 2005 ➤ Running gear, axles, steering - Edition 07.2010 Removing and fitting tyres (wheels with tyre pressure monitoring) Notes on safety and conditions for re‐ moving and fitting tyres (wheels with tyre pressure monitoring) •...
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 monitored with the TPM system.
Golf Variant 2007 ➤ , Jetta 2005 ➤ Running gear, axles, steering - Edition 07.2010 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 .
Page 255
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.
Golf Variant 2007 ➤ , Jetta 2005 ➤ Running gear, axles, steering - Edition 07.2010 Removing and fitting tyres with run- flat properties to wheel rims Notes on safety • Only specially trained mechanics may remove or install tyres with run-flat properties.
Page 257
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.
Golf Variant 2007 ➤ , Jetta 2005 ➤ Running gear, axles, steering - Edition 07.2010 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‐...
Page 259
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-.
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.
Page 261
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.
Golf Variant 2007 ➤ , Jetta 2005 ➤ Running gear, axles, steering - Edition 07.2010 Tyre pressure monitor display General The tyre pressure monitor system is part of the software in the ABS control unit -J104- . The system is used to detect slow tyre pressure loss from a wheel.
Golf Variant 2007 ➤ , Jetta 2005 ➤ Running gear, axles, steering - Edition 07.2010 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...
Page 264
Golf Variant 2007 ➤ , Jetta 2005 ➤ Running gear, axles, steering - Edition 07.2010 Vehicles as of model year 2010 – Push button in glove compartment until an audible signal sounds. The audible signal confirms basic setting. Rep. gr.44 - Wheels, tyres, vehicle geometry...
Golf Variant 2007 ➤ , Jetta 2005 ➤ Running gear, axles, steering - Edition 07.2010 Tyre pressure monitor For detailed information on the tyre pressure monitor (TPM), refer to ⇒ Self-study programme No. 347 ; Tyre Pressure Monitoring Systems .
Page 266
Golf Variant 2007 ➤ , Jetta 2005 ➤ Running gear, axles, steering - Edition 07.2010 Time for which the button is pressed Up to 2 seconds 3-7 seconds 8-10 seconds 11-15 seconds State or action Actual state Switch Confirm Deactivation...
Page 268
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-.
Golf Variant 2007 ➤ , Jetta 2005 ➤ Running gear, axles, steering - Edition 07.2010 Prerequisite: the positions of the subframe and brackets were fixed before the parts were removed ⇒ page 16 Test prerequisites • Check suspension, wheel bearing, steering and steering link‐...
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...
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-.
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...
Golf Variant 2007 ➤ , Jetta 2005 ➤ Running gear, axles, steering - Edition 07.2010 There must be a clearance of 5 mm all round between universal joint -2- and recess in bulkhead. Specified torques Component Specified torque Subframe to body 70 Nm + 90°...
Page 280
Golf Variant 2007 ➤ , Jetta 2005 ➤ Running gear, axles, steering - Edition 07.2010 – Loosen upper transverse link nut -A- on subframe. – Adjust camber by turning eccentric bolt -B- with 18 mm socket -T10001- -1-. Note The maximum adjustment range is 90° to the left or right of centre.
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.
Golf Variant 2007 ➤ , Jetta 2005 ➤ Running gear, axles, steering - Edition 07.2010 Wheels, tyres 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.
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.
Page 286
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 ❑...
Golf Variant 2007 ➤ , Jetta 2005 ➤ Running gear, axles, steering - Edition 07.2010 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.
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-.
Golf Variant 2007 ➤ , Jetta 2005 ➤ Running gear, axles, steering - Edition 07.2010 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.
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.
Page 292
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 ♦...
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.
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.
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.
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...
Page 298
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.
Golf Variant 2007 ➤ , Jetta 2005 ➤ Running gear, axles, steering - Edition 07.2010 48 – Steering Appraisal of accident vehicles A checklist for evaluating running gear of accident vehicles can be found under ⇒ page 1 1. Appraisal of accident vehicles...
Golf Variant 2007 ➤ , Jetta 2005 ➤ Running gear, axles, steering - Edition 07.2010 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.
Golf Variant 2007 ➤ , Jetta 2005 ➤ Running gear, axles, steering - Edition 07.2010 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‐...
Golf Variant 2007 ➤ , Jetta 2005 ➤ Running gear, axles, steering - Edition 07.2010 Steering wheel, steering column 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‐...
Page 303
Golf Variant 2007 ➤ , Jetta 2005 ➤ Running gear, axles, steering - Edition 07.2010 – 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.
Page 304
Golf Variant 2007 ➤ , Jetta 2005 ➤ Running gear, axles, steering - Edition 07.2010 – Guide connector for steering angle sender -G85- into intended opening in the base of steering wheel. – Join connector -1- with the connector -2- of the steering angle sender -G85- .
Golf Variant 2007 ➤ , Jetta 2005 ➤ Running gear, axles, steering - Edition 07.2010 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.
Page 306
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.
Page 307
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 .
Page 308
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‐...
Golf Variant 2007 ➤ , Jetta 2005 ➤ Running gear, axles, steering - Edition 07.2010 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.
Page 320
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.
Page 327
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.
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.
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 joint bushes and lower steering column bearing: ♦ Transporting steering column with one hand on jointed shaft.
Page 330
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-.
Page 331
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-.
Golf Variant 2007 ➤ , Jetta 2005 ➤ Running gear, axles, steering - Edition 07.2010 Electromechanical steering box up to model year 2008 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.
Golf Variant 2007 ➤ , Jetta 2005 ➤ Running gear, axles, steering - Edition 07.2010 Assembly overview - electromechanical steering box, right-hand drive ve‐ hicle (2nd generation) up to model year 2008 Note There are no 2nd generation steering boxes available as spare parts.
Page 337
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 ♦...
Page 338
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‐...
Page 339
Golf Variant 2007 ➤ , Jetta 2005 ➤ Running gear, axles, steering - Edition 07.2010 – Now remove bolts -3-, -6-, -11- and -16- for steering box and anti-roll bar. – Fix subframe and brackets in place ⇒ page 16 –...
Page 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 steering box Install in reverse order. Threaded sleeves of steering box must seat in holes in brackets.
Page 342
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 con‐ ♦ trol unit -J500- must be recoded following the installation of a new steering box⇒...
Page 343
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 ⇒...
Golf Variant 2007 ➤ , Jetta 2005 ➤ Running gear, axles, steering - Edition 07.2010 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- ♦...
Page 345
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 ♦...
Page 346
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 .
Page 347
Golf Variant 2007 ➤ , Jetta 2005 ➤ Running gear, axles, steering - Edition 07.2010 – Remove bolts -arrows- from heat shield. – Remove heat shield from subframe. – Remove bolts -5- and -6- for steering box. – Remove bolts -7- and -8- for anti-roll bar.
Page 348
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.
Page 349
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. 4. Electromechanical steering box up to model year 2008...
Page 350
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.
Page 351
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.
Page 352
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 ♦...
Page 359
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‐...
Page 360
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°...
Golf Variant 2007 ➤ , Jetta 2005 ➤ Running gear, axles, steering - Edition 07.2010 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- ♦...
Page 362
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‐...
Page 363
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.
Page 364
Golf Variant 2007 ➤ , Jetta 2005 ➤ Running gear, axles, steering - Edition 07.2010 – Remove bolts -11- and -16- for anti-roll bar. – Fix position of subframe ⇒ page 16 – Separate connector for extended service intervals on oil sump.
Page 366
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.
Page 367
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.
Golf Variant 2007 ➤ , Jetta 2005 ➤ Running gear, axles, steering - Edition 07.2010 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.
Golf Variant 2007 ➤ , Jetta 2005 ➤ Running gear, axles, steering - Edition 07.2010 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.
Page 370
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.
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 372
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-.
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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‐...
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