Page 1 Service Workshop Manual Golf 2004 ➤ Golf Plus 2005 ➤ Running gear, axles, steering Edition 08.2009 Service Department. Technical Information...
Page 2 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 K0058991120...
Page 3: Table Of Contents
Golf 2004 ➤ , Golf Plus 2005 ➤ Running gear, axles, steering - Edition 08.2009 Contents 00 - Technical data ........... . Checklist for evaluating running gear of accident vehicles .
Page 4 Golf 2004 ➤ , Golf Plus 2005 ➤ Running gear, axles, steering - Edition 08.2009 Checking outer constant velocity joint ........103 Checking inner constant velocity joint .
Page 5 Golf 2004 ➤ , Golf Plus 2005 ➤ Running gear, axles, steering - Edition 08.2009 11.2 Renew vehicle level sender in vehicle ........215 11.3 Removing and installing upper transverse link .
Page 6 Golf 2004 ➤ , Golf Plus 2005 ➤ Running gear, axles, steering - Edition 08.2009 Notes on safety and conditions for removing and fitting tyres (wheels with tyre pressure monitoring) ............. . 290 Wheel change .
Page 7 Golf 2004 ➤ , Golf Plus 2005 ➤ Running gear, axles, steering - Edition 08.2009 General repair instructions ..........334 Steering box .
Page 8 Golf 2004 ➤ , Golf Plus 2005 ➤ Running gear, axles, steering - Edition 08.2009 Contents...
Page 9: Technical Data
♦ Exam all components shown in the assembly overviews for deformation, cracks and other damage. ♦ Renew damaged parts ♦ Align wheels on a VOLKSWAGEN AG-approved wheel align‐ ment stand. Visual and functional check of wheels and tyres ♦ Check for true running and imbalance ⇒ Wheels, tyres, wheel alignment;...
Page 10 Golf 2004 ➤ , Golf Plus 2005 ➤ Running gear, axles, steering - Edition 08.2009 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‐...
Page 11: General Information
Golf 2004 ➤ , Golf Plus 2005 ➤ Running gear, axles, steering - Edition 08.2009 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 . 2.
Page 12: Front Suspension
Golf 2004 ➤ , Golf Plus 2005 ➤ Running gear, axles, steering - Edition 08.2009 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...
Page 13: Repairing Front Suspension
Golf 2004 ➤ , Golf Plus 2005 ➤ Running gear, axles, steering - Edition 08.2009 Repairing front suspension Overview - front axle Note It is not permitted to weld or straighten load-bearing or wheel-guiding components of the suspension. ♦ Always renew self-locking nuts. ♦...
Page 14: Raising Wheel Suspension To Unladen Position, Golf
Golf 2004 ➤ , Golf Plus 2005 ➤ Running gear, axles, steering - Edition 08.2009 The chapter “Removing and installing drive shafts” can be found ⇒ page 77 The chapter “Repairing drive shaft” can be found on ⇒ page 94 Raising wheel suspension to unladen position, Golf Special tools and workshop equipment required...
Page 15 Golf 2004 ➤ , Golf Plus 2005 ➤ Running gear, axles, steering - Edition 08.2009 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 axle on one side is raised, both sides of the vehicle must be strapped to the lifting platform arms with tensioning straps -T10038- .
Page 16: Raising Wheel Suspension To Unladen Position, Golf Plus, Crossgolf
Golf 2004 ➤ , Golf Plus 2005 ➤ Running gear, axles, steering - Edition 08.2009 Raising wheel suspension to unladen position, Golf Plus, CrossGolf Special tools and workshop equipment required ♦ Engine and gearbox jack - V.A.G 1383 A- ♦ Tensioning strap -T10038- ♦...
Page 17 Golf 2004 ➤ , Golf Plus 2005 ➤ Running gear, axles, steering - Edition 08.2009 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!
Page 18: Subframe, Anti-Roll Bar, Suspension Link
Golf 2004 ➤ , Golf Plus 2005 ➤ Running gear, axles, steering - Edition 08.2009 Subframe, anti-roll bar, suspension link Assembly overview: subframe, anti-roll bar, suspension links Caution ♦ It is not permitted to weld or straighten load-bearing or wheel-guiding components of the suspension. ♦...
Page 19 Golf 2004 ➤ , Golf Plus 2005 ➤ Running gear, axles, steering - Edition 08.2009 8 - Front left vehicle level sender -G78- ❑ Removing and installing ⇒ page 15 ❑ Can be tested in guided fault finding using ⇒ Vehicle diagnosis, testing and information system VAS 5051 9 - Bolt ❑...
Page 20 Golf 2004 ➤ , Golf Plus 2005 ➤ Running gear, axles, steering - Edition 08.2009 ❑ 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 ❑...
Page 21 Golf 2004 ➤ , Golf Plus 2005 ➤ Running gear, axles, steering - Edition 08.2009 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 other gearboxes.
Page 22: Assembly Overview - Front Left Vehicle Level Sender G78
Golf 2004 ➤ , Golf Plus 2005 ➤ Running gear, axles, steering - Edition 08.2009 31 - Nut ❑ 65 Nm ❑ When tightening, counter hold on hexagon socket of joint stub. ❑ Self-locking ❑ Always renew after removing 32 - Anti-roll bar ❑...
Page 23: Removing And Installing Front Left Vehicle Level Sender G78
Golf 2004 ➤ , Golf Plus 2005 ➤ Running gear, axles, steering - Edition 08.2009 Removing and installing front left vehicle level sender -G78- Special tools and workshop equipment required ♦ 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.
Page 24: Repairing Thread In Longitudinal Member
Golf 2004 ➤ , Golf Plus 2005 ➤ Running gear, axles, steering - Edition 08.2009 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 .
Page 25: Lowering Subframe
Golf 2004 ➤ , Golf Plus 2005 ➤ Running gear, axles, steering - Edition 08.2009 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.
Page 26 Golf 2004 ➤ , Golf Plus 2005 ➤ Running gear, axles, steering - Edition 08.2009 ♦ 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. –...
Page 27 Golf 2004 ➤ , Golf Plus 2005 ➤ Running gear, axles, steering - Edition 08.2009 – Detach exhaust system bracket from subframe -arrows-. – Disconnect pendulum support from gearbox by removing bolts -14-. – Disconnect coupling rods from anti-roll bar. –...
Page 28 Golf 2004 ➤ , Golf Plus 2005 ➤ Running gear, axles, steering - Edition 08.2009 – 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.
Page 29: Removing And Installing Subframe Without Steering Box
Golf 2004 ➤ , Golf Plus 2005 ➤ Running gear, axles, steering - Edition 08.2009 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 ♦...
Page 30 Golf 2004 ➤ , Golf Plus 2005 ➤ Running gear, axles, steering - Edition 08.2009 – Remove bolts -arrows- on heat shield. – Remove heat shield from subframe. Continuation for all vehicles – Remove coupling rods from anti-roll bar. – Disconnect pendulum support from gearbox by removing bolts -14-.
Page 31: Removing And Installing Subframe With Steering Box
Golf 2004 ➤ , Golf Plus 2005 ➤ Running gear, axles, steering - Edition 08.2009 Component Specified torque Steering box to subframe 50 Nm + 90° ♦ Use new bolts ♦ Always renew clamp on 1st and 2nd generation steering boxes Exhaust system bracket to subframe ⇒...
Page 32 Golf 2004 ➤ , Golf Plus 2005 ➤ Running gear, axles, steering - Edition 08.2009 ♦ Torque wrench -V.A.G 1332- Removing – Remove battery and battery tray ⇒ Electrical system; Rep. Gr. 27 ; Battery; Removing and installing battery . –...
Page 33 Golf 2004 ➤ , Golf Plus 2005 ➤ Running gear, axles, steering - Edition 08.2009 – Remove footwell trim by removing nuts -arrows-. – Remove bolt -1- and pull universal joint -2- off steering box. – Remove front wheels. – Remove lower noise insulation ⇒ General body repairs, ex‐ terior;...
Page 34 Golf 2004 ➤ , Golf Plus 2005 ➤ Running gear, axles, steering - Edition 08.2009 – Disconnect pendulum support from gearbox by removing bolts -14-. – Fix position of subframe with brackets. ⇒ page 16 – Place engine and gearbox jack -V.A.G 1383 A- under sub‐ frame.
Page 35 Golf 2004 ➤ , Golf Plus 2005 ➤ Running gear, axles, steering - Edition 08.2009 – 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, specified torque ⇒ General body repairs, exterior;...
Page 36: Repairing Subframe (Front-Wheel Drive)
Golf 2004 ➤ , Golf Plus 2005 ➤ Running gear, axles, steering - Edition 08.2009 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 ♦...
Page 37 Golf 2004 ➤ , Golf Plus 2005 ➤ Running gear, axles, steering - Edition 08.2009 – 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- because otherwise insert may be damaged.
Page 38 Golf 2004 ➤ , Golf Plus 2005 ➤ Running gear, axles, steering - Edition 08.2009 – Press in bonded rubber bushes -1- until dimension -a- is ob‐ tained. Dimension -a- = 2 - 3 mm. – Align tube -T10214/2- with pressed-in bonded rubber bushes on subframe.
Page 39: Repairing Subframe (Four-Wheel Drive)
Golf 2004 ➤ , Golf Plus 2005 ➤ Running gear, axles, steering - Edition 08.2009 3.10 Repairing subframe (four-wheel drive) Special tools and workshop equipment required ♦ Assembly tool -T10214- ♦ Assembly tool -T10244- Pressing out bonded rubber bush – Remove subframe ⇒...
Page 40 Golf 2004 ➤ , Golf Plus 2005 ➤ Running gear, axles, steering - Edition 08.2009 – 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‐ wards into tube -T10214/2- .
Page 41: Checking Swivel Joint
Golf 2004 ➤ , Golf Plus 2005 ➤ Running gear, axles, steering - Edition 08.2009 – 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. •...
Page 42: Removing And Installing Swivel Joint
Golf 2004 ➤ , Golf Plus 2005 ➤ Running gear, axles, steering - Edition 08.2009 – 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. ♦...
Page 43 Golf 2004 ➤ , Golf Plus 2005 ➤ Running gear, axles, steering - Edition 08.2009 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‐ cle if the bolt is loosened.
Page 44: Removing And Installing Suspension Link With Mounting Bracket
Golf 2004 ➤ , Golf Plus 2005 ➤ Running gear, axles, steering - Edition 08.2009 – Tighten nuts -arrows-. Note Ensure boot is not damaged or twisted. – Install wheel and tighten ⇒ page 288 – Tighten drive shaft bolt at wheel hub: ♦...
Page 45 Golf 2004 ➤ , Golf Plus 2005 ➤ Running gear, axles, steering - Edition 08.2009 ♦ Locating pins -T10096- Removing – Remove wheel. – Remove lower noise insulation ⇒ Rep. Gr. 50 ; Assembly overview - noise insulation . – Remove nuts -arrows-. –...
Page 46 Golf 2004 ➤ , Golf Plus 2005 ➤ Running gear, axles, steering - Edition 08.2009 – Remove bolts -1-. – Remove suspension link with mounting bracket. Installing – Insert suspension link with mounting bracket into subframe. – Start bolts -10- and -17-, but do not yet tighten. –...
Page 47: Removing And Installing Suspension Link With Mounting Bracket (Left Side For Vehicles With Dsg Or Automatic Gearboxes)
Golf 2004 ➤ , Golf Plus 2005 ➤ Running gear, axles, steering - Edition 08.2009 – Bolt suspension link to bracket -10- and -17- in unladen state. Continue installation in reverse order. Note Ensure boot is not damaged or twisted. –...
Page 48 Golf 2004 ➤ , Golf Plus 2005 ➤ Running gear, axles, steering - Edition 08.2009 ♦ Locating pins -T10096- ♦ Engine and gearbox jack -V.A.G 1383 A- Removing – Remove left front wheel. – Remove lower noise insulation ⇒ General body repairs, ex‐ terior;...
Page 49 Golf 2004 ➤ , Golf Plus 2005 ➤ Running gear, axles, steering - Edition 08.2009 – Disconnect pendulum support from gearbox by removing bolts -14-. – If present, detach coupling rod of front left vehicle level sender -G78- from suspension link. –...
Page 50 Golf 2004 ➤ , Golf Plus 2005 ➤ Running gear, axles, steering - Edition 08.2009 – 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. –...
Page 51: Removing And Installing Suspension Link With Mounting Bracket (Right Side For Vehicles With 6-Cylinder Engines)
Golf 2004 ➤ , Golf Plus 2005 ➤ Running gear, axles, steering - Edition 08.2009 Component Specified torque Shield to subframe 6 Nm ♦ Bolt M6 is self-locking Steering box to subframe 50 Nm + 90° ♦ Use new bolts ♦...
Page 52 Golf 2004 ➤ , Golf Plus 2005 ➤ Running gear, axles, steering - Edition 08.2009 ♦ Torque wrench -V.A.G 1332- ♦ Locating pins -T10096- Removing – Remove wheel. – Remove lower noise insulation ⇒ Rep. Gr. 50 ; Assembly overview - noise insulation . –...
Page 53 Golf 2004 ➤ , Golf Plus 2005 ➤ Running gear, axles, steering - Edition 08.2009 – Loosen bolt -10-. – Fix position of subframe ⇒ page 16 – Remove coupling rods from anti-roll bar. – Now unscrew bolts for: ♦ steering box -3- and -6- ♦...
Page 54 Golf 2004 ➤ , Golf Plus 2005 ➤ Running gear, axles, steering - Edition 08.2009 – Bolt suspension link to swivel joint and tighten -arrows-. – Bolt suspension link to bracket in unladen state -10-. – Bolt coupling rods to anti-roll bar. –...
Page 55: Renewing Bonded Rubber Bush For Suspension Link
Golf 2004 ➤ , Golf Plus 2005 ➤ Running gear, axles, steering - Edition 08.2009 Component Specified torque Suspension link to bracket 70 Nm +180° ♦ Use new bolt ♦ Tighten bolt in unladen state Steering box to subframe 50 Nm + 90° ♦...
Page 56 Golf 2004 ➤ , Golf Plus 2005 ➤ Running gear, axles, steering - Edition 08.2009 Pressing out bonded rubber bush – Press out bonded rubber bush as illustrated. Press tool -VW 411- Tube -T10219/1- Thrust plate -VW 402- Pressing in bonded rubber bush Apply the bonded rubber bush at an angle to prevent damage when pressing in.
Page 57: Renewing Mounting Bracket With Suspension Link Bush
Golf 2004 ➤ , Golf Plus 2005 ➤ Running gear, axles, steering - Edition 08.2009 The dimensions -a- and -b- must be the same. 3.17 Renewing mounting bracket with suspension link bush Special tools and workshop equipment required ♦ Guide -VW 439- ♦...
Page 58 Golf 2004 ➤ , Golf Plus 2005 ➤ Running gear, axles, steering - Edition 08.2009 ♦ 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. –...
Page 59: Removing And Installing Anti-Roll Bar
Golf 2004 ➤ , Golf Plus 2005 ➤ Running gear, axles, steering - Edition 08.2009 3.18 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- ♦...
Page 60 Golf 2004 ➤ , Golf Plus 2005 ➤ Running gear, axles, steering - Edition 08.2009 – Remove bolt -1- and pull universal joint -2- off steering box. – Remove lower noise insulation ⇒ Rep. Gr. 50 ; Assembly overview - noise insulation . –...
Page 61 Golf 2004 ➤ , Golf Plus 2005 ➤ Running gear, axles, steering - Edition 08.2009 – Place 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. –...
Page 62 Golf 2004 ➤ , Golf Plus 2005 ➤ Running gear, axles, steering - Edition 08.2009 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°...
Page 63 Golf 2004 ➤ , Golf Plus 2005 ➤ Running gear, axles, steering - Edition 08.2009 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- ⇒...
Page 64: Assembly Overview - Wheel Bearing
Golf 2004 ➤ , Golf Plus 2005 ➤ Running gear, axles, steering - Edition 08.2009 Assembly overview - wheel bearing 1 - Wheel bearing housing (3- point mounting) - FS III brakes ❑ Removing and installing ⇒ page 60 ❑ With integrated brake carrier.
Page 65: Removing And Installing Wheel Bearing Housing (3-Point Mounting)
Golf 2004 ➤ , Golf Plus 2005 ➤ Running gear, axles, steering - Edition 08.2009 12 - Ventilated brake disc 13 - Bolt ❑ M16 x 1.5 x 80 ❑ Hexagon bolt, 200 Nm and turn +180° further ❑ 12-point bolt, 70 Nm + 90° further ❑...
Page 66: Removing And Installing Wheel Bearing Housing (4-Point Mounting)
Golf 2004 ➤ , Golf Plus 2005 ➤ Running gear, axles, steering - Edition 08.2009 Removing – Loosen drive shaft bolt at wheel hub: ♦ Hexagon bolt ⇒ page 77 ♦ Twelve-point bolt ⇒ page 78 Note During this step, vehicle must not be standing on its wheels or wheel bearing will be damaged.
Page 67 Golf 2004 ➤ , Golf Plus 2005 ➤ Running gear, axles, steering - Edition 08.2009 ♦ Torque wrench -V.A.G 1332- Removing – Loosen drive shaft bolt at wheel hub: ♦ Hexagon bolt ⇒ page 77 ♦ Twelve-point bolt ⇒ page 78 Note During this step, vehicle must not be standing on its wheels or wheel bearing will be damaged.
Page 68: Removing And Installing Wheel Bearing Housing
Golf 2004 ➤ , Golf Plus 2005 ➤ Running gear, axles, steering - Edition 08.2009 Specified torques Component Specified torque Drive shaft to wheel hub “hexagon bolt” 200 Nm +180° ♦ Use new bolt Drive shaft to wheel hub “12-point bolt” 70 Nm + 90°...
Page 69 Golf 2004 ➤ , Golf Plus 2005 ➤ Running gear, axles, steering - Edition 08.2009 ♦ Spreader -3424- Removing – Loosen drive shaft bolt at wheel hub: ♦ Hexagon bolt ⇒ page 77 ♦ Twelve-point bolt ⇒ page 78 Note During this step, vehicle must not be standing on its wheels or wheel bearing will be damaged.
Page 70 Golf 2004 ➤ , Golf Plus 2005 ➤ Running gear, axles, steering - Edition 08.2009 – Remove threaded connection between wheel bearing housing and suspension strut -arrow-. – Insert spreader -3424- into slot of wheel bearing housing. – Turn ratchet handle through 90° and detach from spreader -3424- .
Page 71 Golf 2004 ➤ , Golf Plus 2005 ➤ Running gear, axles, steering - Edition 08.2009 Specified torques Component Specified torque Suspension strut to wheel bearing housing 70 Nm + 90° ♦ Use new nut Swivel joint to cast steel suspension link 60 Nm ♦...
Page 72: Assembly Overview: Suspension Strut
Golf 2004 ➤ , Golf Plus 2005 ➤ Running gear, axles, steering - Edition 08.2009 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 ❑...
Page 73: Removing And Installing Suspension Strut, Golf
Golf 2004 ➤ , Golf Plus 2005 ➤ Running gear, axles, steering - Edition 08.2009 Removing and installing suspension strut, Golf Special tools and workshop equipment required ♦ Torque wrench -V.A.G 1332- ♦ Spreader -3424- ♦ Engine and gearbox jack - V.A.G 1383 A- ♦...
Page 74 Golf 2004 ➤ , Golf Plus 2005 ➤ Running gear, axles, steering - Edition 08.2009 – 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.
Page 75 Golf 2004 ➤ , Golf Plus 2005 ➤ Running gear, axles, steering - Edition 08.2009 – Insert spreader -3424- into slot of 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.
Page 76 Golf 2004 ➤ , Golf Plus 2005 ➤ Running gear, axles, steering - Edition 08.2009 Tighten hexagon bolts -arrows- for upper shock absorber mount‐ ing. – Install plenum chamber cover. – Install wiper arms ⇒ Rep. Gr. 92 ; Wiper system; Removing and installing wiper arms .
Page 77 Golf 2004 ➤ , Golf Plus 2005 ➤ Running gear, axles, steering - Edition 08.2009 – 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 boot is not damaged or twisted.
Page 78: Removing And Installing Suspension Strut, Golf Plus, Crossgolf
Golf 2004 ➤ , Golf Plus 2005 ➤ Running gear, axles, steering - Edition 08.2009 Removing and installing suspension strut, Golf Plus, CrossGolf Special tools and workshop equipment required ♦ Torque wrench -V.A.G 1332- ♦ Spreader -3424- ♦ Engine and gearbox jack - V.A.G 1383 A- ♦...
Page 79 Golf 2004 ➤ , Golf Plus 2005 ➤ Running gear, axles, steering - Edition 08.2009 – Unscrew hexagon nut for coupling rod -arrow- from suspen‐ sion strut. – Unhook speed sensor wiring at suspension strut. – Remove nuts -arrows-. – Pull wheel bearing housing with swivel joint out of suspension link.
Page 80 Golf 2004 ➤ , Golf Plus 2005 ➤ Running gear, axles, steering - Edition 08.2009 – Insert spreader -3424- into slot of wheel bearing housing. – Turn ratchet handle through 90° and detach from spreader -3424- . – Press brake disc towards suspension strut by hand. Note Otherwise the shock absorber tube can cant in the bore of the wheel bearing housing.
Page 81 Golf 2004 ➤ , Golf Plus 2005 ➤ Running gear, axles, steering - Edition 08.2009 Installation position of spring plate – Insert suspension strut with one of the two markings -arrows- pointing forwards. Tighten hexagon bolts -arrows- for upper shock absorber mount‐ ing.
Page 82 Golf 2004 ➤ , Golf Plus 2005 ➤ Running gear, axles, steering - Edition 08.2009 – Tighten threaded connection between wheel bearing housing and suspension strut -arrow- WARNING ♦ Do not leave the engine and gearbox jack -V.A.G 1383 A- under the vehicle for longer than necessary.
Page 83: Repairing Suspension Strut
Golf 2004 ➤ , Golf Plus 2005 ➤ Running gear, axles, steering - Edition 08.2009 Component Specified torque Drive shaft to wheel hub “12-point bolt” 70 Nm + 90° ♦ Use new bolt Repairing suspension strut Special tools and workshop equipment required ♦...
Page 84 Golf 2004 ➤ , Golf Plus 2005 ➤ Running gear, axles, steering - Edition 08.2009 Removing coil spring – Compress coil spring with spring compressor -V.A.G 1752/1- until deep groove ball thrust bearing is free at top. Spring compressor -V.A.G 1752/1- Torque wrench -V.A.G 1332- Tool insert -T10001/8- Ratchet handle -T10001/11-...
Page 85: Removing And Installing Drive Shafts
Golf 2004 ➤ , Golf Plus 2005 ➤ Running gear, axles, steering - Edition 08.2009 Removing and installing drive shafts Removing and installing drive shaft with constant velocity joint ⇒ page 79 Removing and installing left drive shaft with (push-on) constant velocity slip joint ⇒...
Page 86: Loosening And Tightening 12-Point Flange Bolt Securing Drive Shaft
Golf 2004 ➤ , Golf Plus 2005 ➤ Running gear, axles, steering - Edition 08.2009 – 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;...
Page 87: Removing And Installing Drive Shaft With Constant Velocity Joint
Golf 2004 ➤ , Golf Plus 2005 ➤ Running gear, axles, steering - Edition 08.2009 – 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.
Page 88 Golf 2004 ➤ , Golf Plus 2005 ➤ Running gear, axles, steering - Edition 08.2009 Removing – Loosen drive shaft bolt at wheel hub: ♦ Hexagon bolt ⇒ page 77 ♦ Twelve-point bolt ⇒ page 78 Caution During this step, vehicle must not be standing on its wheels. The wheel bearing can be damaged by the weight of the vehi‐...
Page 89: Removing And Installing Left Drive Shaft With (Push-On) Constant Velocity Slip Joint
Golf 2004 ➤ , Golf Plus 2005 ➤ Running gear, axles, steering - Edition 08.2009 – Bolt swivel joint to suspension link -arrows-. Note Ensure boot is not damaged or twisted. – Place inner joint of drive shaft in position and tighten bolts di‐ agonally to 10 Nm.
Page 90 Golf 2004 ➤ , Golf Plus 2005 ➤ Running gear, axles, steering - Edition 08.2009 ♦ Multi-purpose tool -VW 771- ♦ Drive shaft puller -T10382- ♦ Torque wrench -V.A.G 1332- Removing – Loosen drive shaft bolt at wheel hub ⇒ page 78 Caution During this step, vehicle must not be standing on its wheels.
Page 91 Golf 2004 ➤ , Golf Plus 2005 ➤ Running gear, axles, steering - Edition 08.2009 – 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. –...
Page 92 Golf 2004 ➤ , Golf Plus 2005 ➤ Running gear, axles, steering - Edition 08.2009 – 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- .
Page 93: Removing And Installing Right Drive Shaft With (Push-On) Constant Velocity Slip Joint
Golf 2004 ➤ , Golf Plus 2005 ➤ Running gear, axles, steering - Edition 08.2009 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 ♦...
Page 94 Golf 2004 ➤ , Golf Plus 2005 ➤ Running gear, axles, steering - Edition 08.2009 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.
Page 95 Golf 2004 ➤ , Golf Plus 2005 ➤ Running gear, axles, steering - Edition 08.2009 – 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.
Page 96: Removing And Installing Drive Shafts With Triple Roller Joint Aar2600I
Golf 2004 ➤ , Golf Plus 2005 ➤ Running gear, axles, steering - Edition 08.2009 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°...
Page 97 Golf 2004 ➤ , Golf Plus 2005 ➤ Running gear, axles, steering - Edition 08.2009 – Remove nuts -arrows-. – Pull wheel bearing housing with swivel joint out of suspension link. – Pull drive shaft out of wheel hub and tie up to body. –...
Page 98: Removing And Installing Drive Shafts With Triple Roller Joint Aar3300I
Golf 2004 ➤ , Golf Plus 2005 ➤ Running gear, axles, steering - Edition 08.2009 – Bolt swivel joint to suspension link -arrows-. Note Ensure boot is not damaged or twisted. – Tighten drive shaft bolt at wheel hub: ♦ Hexagon bolt ⇒...
Page 99 Golf 2004 ➤ , Golf Plus 2005 ➤ Running gear, axles, steering - Edition 08.2009 – Remove wheel. – Remove lower noise insulation ⇒ Rep. Gr. 50 ; Assembly overview - noise insulation . – Unbolt drive shaft from gearbox flange shaft. –...
Page 100: Removing And Installing Intermediate Shaft
Golf 2004 ➤ , Golf Plus 2005 ➤ Running gear, axles, steering - Edition 08.2009 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”...
Page 101 Golf 2004 ➤ , Golf Plus 2005 ➤ Running gear, axles, steering - Edition 08.2009 – Now push intermediate shaft onto stub shaft of gearbox until bearing -2- contacts bearing bracket -1- without “gap” -arrow-. – Tighten bolts -arrows- to prescribed torque. –...
Page 102: Repairing Drive Shaft - Overview Of Drive Shafts
Golf 2004 ➤ , Golf Plus 2005 ➤ Running gear, axles, steering - Edition 08.2009 Repairing drive shaft - overview of drive shafts I - Assembly overview - drive shaft with VL90 or VL100 con‐ stant velocity joint ⇒ page 97 II - Assembly overview - drive shaft with VL107 constant ve‐...
Page 103 Golf 2004 ➤ , Golf Plus 2005 ➤ Running gear, axles, steering - Edition 08.2009 IV - Assembly overview - drive shaft with triple roller joint AAR2600i ⇒ page 121 V - Assembly overview - drive shaft with triple roller joint AAR3300i ⇒...
Page 104: Heat Shields For Drive Shafts
Golf 2004 ➤ , Golf Plus 2005 ➤ Running gear, axles, steering - Edition 08.2009 Heat shields for drive shafts Front-wheel drive Component Specified torque Hexagon bolt -1- 25 Nm Four-wheel drive: Component Specified torque Nuts -1- 20 Nm ♦ Initially tighten all nuts to 10 Nm Four-wheel drive: Component...
Page 105: Assembly Overview - Drive Shaft With Vl90 Or Vl100 Constant Velocity Joint
Golf 2004 ➤ , Golf Plus 2005 ➤ Running gear, axles, steering - Edition 08.2009 Assembly overview - drive shaft with VL90 or VL100 constant velocity joint 1 - Outer constant velocity joint ❑ Renew only as com‐ plete unit ❑...
Page 106 Golf 2004 ➤ , Golf Plus 2005 ➤ Running gear, axles, steering - Edition 08.2009 11 - Hose clip ❑ Always renew after removing ❑ Tightening ⇒ page 103 12 - Left drive shaft 13 - Locking plate ❑ Renew each time after removing 14 - Multi-point socket head bolt ❑...
Page 107: Dismantling And Assembling Drive Shaft With Vl90 Or Vl100 Constant Velocity Joint
Golf 2004 ➤ , Golf Plus 2005 ➤ Running gear, axles, steering - Edition 08.2009 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- ♦...
Page 108 Golf 2004 ➤ , Golf Plus 2005 ➤ Running gear, axles, steering - Edition 08.2009 ♦ Circlip pliers -VW 161 A- ♦ Torque wrench -V.A.G 1331- ♦ Torque wrench -V.A.G 1332- ♦ Special pliers -V.A.G 1682- ♦ Assembly tool -T10065- ♦...
Page 109 Golf 2004 ➤ , Golf Plus 2005 ➤ Running gear, axles, steering - Edition 08.2009 ♦ 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- .
Page 110 Golf 2004 ➤ , Golf Plus 2005 ➤ Running gear, axles, steering - Edition 08.2009 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.
Page 111: Checking Outer Constant Velocity Joint
Golf 2004 ➤ , Golf Plus 2005 ➤ Running gear, axles, steering - Edition 08.2009 Tighten hose clip on outer joint – Apply special pliers -V.A.G 1682- as shown in diagram. En‐ sure that the jaws of the pliers seat in the ends of the hose clip -arrows B-.
Page 112: Checking Inner Constant Velocity Joint
Golf 2004 ➤ , Golf Plus 2005 ➤ Running gear, axles, steering - Edition 08.2009 – 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 113 Golf 2004 ➤ , Golf Plus 2005 ➤ Running gear, axles, steering - Edition 08.2009 – 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 114 Golf 2004 ➤ , Golf Plus 2005 ➤ Running gear, axles, steering - Edition 08.2009 – 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.
Page 115: Assembly Overview - Drive Shaft With Vl107 Constant Velocity Joint (Bolt-On)
Golf 2004 ➤ , Golf Plus 2005 ➤ Running gear, axles, steering - Edition 08.2009 Assembly overview - drive shaft with VL107 constant velocity joint (bolt-on) 1 - Outer constant velocity joint ❑ Renew only as com‐ plete unit ❑ Removing ⇒...
Page 116 Golf 2004 ➤ , Golf Plus 2005 ➤ Running gear, axles, steering - Edition 08.2009 11 - Hose clip ❑ Always renew after removing ❑ Tightening ⇒ page 113 12 - Drive shaft 13 - Intermediate shaft ❑ For Golf only ❑...
Page 117: Dismantling And Assembling Drive Shaft With Vl107 Constant Velocity Joint
Golf 2004 ➤ , Golf Plus 2005 ➤ Running gear, axles, steering - Edition 08.2009 25 - Bearing ❑ For Golf only ❑ Pressing off on ⇒ page 114 Dismantling and assembling drive shaft with VL107 constant velocity joint Special tools and workshop equipment required ♦...
Page 118 Golf 2004 ➤ , Golf Plus 2005 ➤ Running gear, axles, steering - Edition 08.2009 ♦ Multi-purpose tool -VW 771- ♦ Puller -T10382- Removing outer constant velocity joint – Clamp drive shaft in vice using protective jaw covers. – Fold back boot. –...
Page 119 Golf 2004 ➤ , Golf Plus 2005 ➤ Running gear, axles, steering - Edition 08.2009 Installation position of dished spring and thrust washer on outer joint Dished spring Thrust washer – Knock onto shaft with plastic hammer until circlip engages. Driving off cover for inner joint –...
Page 120 Golf 2004 ➤ , Golf Plus 2005 ➤ Running gear, axles, steering - Edition 08.2009 Pressing on inner constant velocity joint – Press joint on to stop. – Install retaining ring. – Coat sealing surface of cover with -D 454 300 A2- . –...
Page 121 Golf 2004 ➤ , Golf Plus 2005 ➤ Running gear, axles, steering - Edition 08.2009 Tighten hose clip on outer joint – Apply special pliers -V.A.G 1682- as shown in diagram. En‐ sure that the jaws of the pliers seat in the ends of the hose clip -arrows B-.
Page 122: Repairing Intermediate Shaft
Golf 2004 ➤ , Golf Plus 2005 ➤ Running gear, axles, steering - Edition 08.2009 Repairing intermediate shaft Special tools and workshop equipment required ♦ Thrust plate -VW 401- ♦ Thrust plate -VW 402- ♦ Thrust piece -T10032- ♦ Thrust piece -3118- ♦...
Page 123 Golf 2004 ➤ , Golf Plus 2005 ➤ Running gear, axles, steering - Edition 08.2009 Pressing on bearing – Press bearing to stop on intermediate shaft as shown in figure. Thrust piece -T10032- Intermediate shaft Bearing Thrust piece -3118- Thrust plate -VW 401- Separating device Kukko -15-2- Thrust plate -VW 402- Shoulder -arrow- of press tool -3118- must be facing bearing.
Page 124: Assembly Overview - Drive Shaft With Vl107 Constant Velocity Slip Joint (Push-On)
Golf 2004 ➤ , Golf Plus 2005 ➤ Running gear, axles, steering - Edition 08.2009 Assembly overview - drive shaft with VL107 constant velocity slip joint (push-on) 1 - Outer constant velocity joint ❑ Renew only complete ❑ Removing ⇒ page 117 ❑...
Page 125: Dismantling And Assembling Drive Shaft With Vl107 (Push-On) Constant Velocity Slip Joint
Golf 2004 ➤ , Golf Plus 2005 ➤ Running gear, axles, steering - Edition 08.2009 13 - Clamp ❑ Always renew after removing ❑ Tightening ⇒ page 119 14 - Constant velocity slip joint ❑ Renew only complete ❑ Removing ⇒...
Page 126 Golf 2004 ➤ , Golf Plus 2005 ➤ Running gear, axles, steering - Edition 08.2009 – Pull constant velocity joint from drive shaft with puller -T10382- and multi-purpose tool -VW 771- . Puller plate -T10382/1- Spindles -T10382/2- Driving on outer constant velocity joint Installation position of dished spring 1 and thrust washer 2 on outer joint Dished spring...
Page 127: Checking Outer Constant Velocity Joint
Golf 2004 ➤ , Golf Plus 2005 ➤ Running gear, axles, steering - Edition 08.2009 Tighten hose clip on outer joint – Apply special pliers -V.A.G 1682- as shown in diagram. En‐ sure jaws of tool contact corners -arrows B- of hose clamp. –...
Page 128 Golf 2004 ➤ , Golf Plus 2005 ➤ Running gear, axles, steering - Edition 08.2009 – 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 129: Assembly Overview - Drive Shaft With Triple Roller Joint Aar2600I
Golf 2004 ➤ , Golf Plus 2005 ➤ Running gear, axles, steering - Edition 08.2009 Assembly overview - drive shaft with triple roller joint AAR2600i 1 - Outer constant velocity joint ❑ Renew only as com‐ plete unit ❑ Removing ⇒...
Page 130: Dismantling And Assembling Drive Shaft With Triple Roller Joint Aar2600I
Golf 2004 ➤ , Golf Plus 2005 ➤ Running gear, axles, steering - Edition 08.2009 13 - Hose clip ❑ Always renew after removing ❑ Tighten hose clip with hose clip pliers -V.A.G 1275- 14 - Retaining ring ❑ Always renew after removing 15 - Joint body 16 - Retaining ring ❑...
Page 131 Golf 2004 ➤ , Golf Plus 2005 ➤ Running gear, axles, steering - Edition 08.2009 ♦ 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- ♦...
Page 132 Golf 2004 ➤ , Golf Plus 2005 ➤ Running gear, axles, steering - Edition 08.2009 ♦ 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- .
Page 133 Golf 2004 ➤ , Golf Plus 2005 ➤ Running gear, axles, steering - Edition 08.2009 – Remove retaining ring. 1 - Pliers (commercially available) - or -VW 161 A- – Set drive shaft into press. – Press triple roller spider off drive shaft. –...
Page 134 Golf 2004 ➤ , Golf Plus 2005 ➤ Running gear, axles, steering - Edition 08.2009 – Fit triple roller spider onto shaft and press on to stop. – Ensure that pressure does not exceed 3.0 t. – If necessary, coat splines of drive shaft and triple roller spider with lubricant paste G 052 142 A2.
Page 135: Assembly Overview - Drive Shaft With Triple Roller Joint Aar3300I
Golf 2004 ➤ , Golf Plus 2005 ➤ Running gear, axles, steering - Edition 08.2009 Assembly overview - drive shaft with triple roller joint AAR3300i 1 - Outer constant velocity joint ❑ Renew only as com‐ plete unit ❑ Removing ⇒...
Page 136 Golf 2004 ➤ , Golf Plus 2005 ➤ Running gear, axles, steering - Edition 08.2009 ❑ Tighten hose clip with hose clip pliers -V.A.G 1275- 12 - Boot for triple roller joint ❑ Check for splits and chafing 13 - Hose clip ❑...
Page 137: Dismantling And Assembling Drive Shaft With Triple Roller Joint Aar3300I
Golf 2004 ➤ , Golf Plus 2005 ➤ Running gear, axles, steering - Edition 08.2009 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- ♦...
Page 138 Golf 2004 ➤ , Golf Plus 2005 ➤ Running gear, axles, steering - Edition 08.2009 ♦ 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- ♦...
Page 139 Golf 2004 ➤ , Golf Plus 2005 ➤ Running gear, axles, steering - Edition 08.2009 ♦ 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- .
Page 140 Golf 2004 ➤ , Golf Plus 2005 ➤ Running gear, axles, steering - Edition 08.2009 – Remove retaining ring. 1 - Pliers (commercially available) - or -VW 161 A- – Set drive shaft into press. – Press triple roller spider off drive shaft. –...
Page 141 Golf 2004 ➤ , Golf Plus 2005 ➤ Running gear, axles, steering - Edition 08.2009 – Fit triple roller spider 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- .
Page 142: Rear Suspension
Golf 2004 ➤ , Golf Plus 2005 ➤ Running gear, axles, steering - Edition 08.2009 42 – Rear suspension Appraisal of accident vehicles A checklist for evaluating running gear of accident vehicles can be found under ⇒ page 1 Rep. Gr.42 - Rear suspension...
Page 143: Repairing Rear Suspension (Front-Wheel Drive)
Golf 2004 ➤ , Golf Plus 2005 ➤ Running gear, axles, steering - Edition 08.2009 Repairing rear suspension (front- wheel drive) Overview - rear axle I - Assembly overview: sub‐ frame, transverse link, track rod (front-wheel drive) ⇒ page 140 II - Assembly overview: wheel bearing housing, trailing arm (front-wheel drive)
Page 144: Rear Axle In Unladen Position, Golf
Golf 2004 ➤ , Golf Plus 2005 ➤ Running gear, axles, steering - Edition 08.2009 Rear axle in unladen position, Golf Special tools and workshop equipment required ♦ Engine and gearbox jack - V.A.G 1383 A- ♦ Tensioning strap -T10038- ♦...
Page 145 Golf 2004 ➤ , Golf Plus 2005 ➤ Running gear, axles, steering - Edition 08.2009 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!
Page 146: Rear Axle In Unladen Position, Golf Plus, Crossgolf
Golf 2004 ➤ , Golf Plus 2005 ➤ Running gear, axles, steering - Edition 08.2009 Rear axle in unladen position, Golf Plus, CrossGolf Special tools and workshop equipment required ♦ Engine and gearbox jack - V.A.G 1383 A- ♦ Tensioning strap -T10038- ♦...
Page 147 Golf 2004 ➤ , Golf Plus 2005 ➤ Running gear, axles, steering - Edition 08.2009 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!
Page 148: Assembly Overview: Subframe, Transverse Link, Track Rod (Front-Wheel Drive)
Golf 2004 ➤ , Golf Plus 2005 ➤ Running gear, axles, steering - Edition 08.2009 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 149 Golf 2004 ➤ , Golf Plus 2005 ➤ Running gear, axles, steering - Edition 08.2009 10 - Nut ❑ M12 x 1.5 x 75 ❑ 90 Nm + 90° further ❑ Self-locking ❑ Always renew after removing ❑ Always tighten threaded connections in unladen position: Golf ⇒...
Page 150 Golf 2004 ➤ , Golf Plus 2005 ➤ Running gear, axles, steering - Edition 08.2009 22 - Washer 23 - Bolt ❑ Always renew after removing ❑ Always tighten threaded connections in unladen position: Golf ⇒ page 136 Golf Plus, CrossGolf ⇒...
Page 151: Removing And Installing Rear Axle
Golf 2004 ➤ , Golf Plus 2005 ➤ Running gear, axles, steering - Edition 08.2009 Removing and installing rear axle Special tools and workshop equipment required ♦ Torque wrench -V.A.G 1332- ♦ Engine/gearbox jack - V.A.G 1383/A - ♦ Tensioning strap -T10038- ♦...
Page 152 Golf 2004 ➤ , Golf Plus 2005 ➤ Running gear, axles, steering - Edition 08.2009 – Remove screw -arrow-. – Lever off spring clip -1- for handbrake cable. – Push lever -2- in -direction of arrow- and unhook brake cable -3-.
Page 153 Golf 2004 ➤ , Golf Plus 2005 ➤ Running gear, axles, steering - Edition 08.2009 – 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. –...
Page 154 Golf 2004 ➤ , Golf Plus 2005 ➤ Running gear, axles, steering - Edition 08.2009 – 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 vehicle side is shown to improve clarity.
Page 155 Golf 2004 ➤ , Golf Plus 2005 ➤ Running gear, axles, steering - Edition 08.2009 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°...
Page 156: Vehicle Level Sender For Vehicles With Automatic Headlight Range Control
Golf 2004 ➤ , Golf Plus 2005 ➤ Running gear, axles, steering - Edition 08.2009 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 ♦...
Page 157: Removing And Installing Upper Transverse Link
Golf 2004 ➤ , Golf Plus 2005 ➤ Running gear, axles, steering - Edition 08.2009 ♦ 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.
Page 158 Golf 2004 ➤ , Golf Plus 2005 ➤ Running gear, axles, steering - Edition 08.2009 – Unhook speed sensor line -arrow A- from upper transverse link. – Remove bolt -1-. – Mark position of eccentric bolt -arrow- relative to subframe us‐ ing e.g.
Page 159: Removing And Installing Lower Transverse Link
Golf 2004 ➤ , Golf Plus 2005 ➤ Running gear, axles, steering - Edition 08.2009 Specified torques Component Specified torque Upper transverse link to wheel bearing housing 130 Nm + 90° ♦ Use new nuts and bolts ♦ Tighten threaded connections only when vehicle is in the normal running position.
Page 160: Removing And Installing Track Rod
Golf 2004 ➤ , Golf Plus 2005 ➤ Running gear, axles, steering - Edition 08.2009 – 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 161 Golf 2004 ➤ , Golf Plus 2005 ➤ Running gear, axles, steering - Edition 08.2009 ♦ Torque wrench -V.A.G 1331- ♦ Torque wrench -V.A.G 1332- Removing – Remove wheel. – Remove coil spring ⇒ page 174 – Remove nut -1- and pull coupling rod -2- out of anti-roll bar. –...
Page 162 Golf 2004 ➤ , Golf Plus 2005 ➤ Running gear, axles, steering - Edition 08.2009 – 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 closed.
Page 163 Golf 2004 ➤ , Golf Plus 2005 ➤ Running gear, axles, steering - Edition 08.2009 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°...
Page 164: Assembly Overview: Wheel Bearing Housing, Trailing Arm (Front-Wheel Drive)
Golf 2004 ➤ , Golf Plus 2005 ➤ Running gear, axles, steering - Edition 08.2009 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 ❑...
Page 165: Removing And Installing Wheel Bearing Housing
Golf 2004 ➤ , Golf Plus 2005 ➤ Running gear, axles, steering - Edition 08.2009 12 - Bolt ❑ 4 Nm 13 - Brake disc 14 - Grease cap ❑ Always renew after removing ❑ Pressing off and driving in ⇒...
Page 166 Golf 2004 ➤ , Golf Plus 2005 ➤ Running gear, axles, steering - Edition 08.2009 – Remove bolt -arrow-. – Remove bolt for track rod -1-, upper transverse link -2- and lower transverse link -3- from wheel housing -4-. – Remove coupling rod -arrow- from wheel bearing housing. –...
Page 167 Golf 2004 ➤ , Golf Plus 2005 ➤ Running gear, axles, steering - Edition 08.2009 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 168 Golf 2004 ➤ , Golf Plus 2005 ➤ Running gear, axles, steering - Edition 08.2009 – Tighten bolt -1- for upper transverse link. Note The washer -2- must be installed so that there is a gap -arrow B- between the washer and the backplate -3-. –...
Page 169: Renewing Bonded Rubber Bush For Wheel Bearing Housing
Golf 2004 ➤ , Golf Plus 2005 ➤ Running gear, axles, steering - Edition 08.2009 Renewing bonded rubber bush for wheel bearing housing Special tools and workshop equipment required ♦ Press tool -30 - 506 B- ♦ Drift sleeve -41-501- ♦...
Page 170 Golf 2004 ➤ , Golf Plus 2005 ➤ Running gear, axles, steering - Edition 08.2009 – Remove backplate. – Remove bolt -arrow- for lower transverse link -1-. Pressing out bonded rubber bush – Attach tools as shown in figure. Nut -3346/3- Thrust piece -3301- Tube -3301/3- Drift sleeve -41 - 501-...
Page 171 Golf 2004 ➤ , Golf Plus 2005 ➤ Running gear, axles, steering - Edition 08.2009 – Tighten bolt -arrow- for lower transverse link -1-. – Install coil spring ⇒ page 173 – Install brake disc. – Attach brake carrier with brake caliper ⇒ Brake systems; Rep. Gr.
Page 172: Removing And Installing Wheel Bearing/Wheel Hub Unit
Golf 2004 ➤ , Golf Plus 2005 ➤ Running gear, axles, steering - Edition 08.2009 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 173 Golf 2004 ➤ , Golf Plus 2005 ➤ Running gear, axles, steering - Edition 08.2009 Loosen grease cap from seat by tapping lightly on the claw of hub grease cap puller -VW 637/2-. – Lever off grease cap. – Remove brake carrier with brake caliper and hang from body with wire ⇒...
Page 174: Removing And Installing Trailing Arm With Mounting Bracket
Golf 2004 ➤ , Golf Plus 2005 ➤ Running gear, axles, steering - Edition 08.2009 – Drive on grease cap with fitting sleeve -3241/4-. Note Always renew removed grease caps. ♦ Damaged grease caps may allow moisture to enter the bear‐ ♦...
Page 175 Golf 2004 ➤ , Golf Plus 2005 ➤ Running gear, axles, steering - Edition 08.2009 – Remove bolt -arrow- securing handbrake cable -1- to trailing arm -2-. Vehicles with retainer for handbrake cable – Remove retainer -1- by pushing out inner pin of rivet -arrow-. Continuation for all vehicles –...
Page 176 Golf 2004 ➤ , Golf Plus 2005 ➤ Running gear, axles, steering - Edition 08.2009 Dimension -a- is 34 ± 1 mm. Mounting bracket Trailing arm – Tighten bolt when dimension -a- is set. Installing Threaded connection for trailing arm and wheel bearing housing may be tightened only after all other components (particularly the spring and shock absorber) of respective wheel suspension have been installed.
Page 177 Golf 2004 ➤ , Golf Plus 2005 ➤ Running gear, axles, steering - Edition 08.2009 – Tighten bolts -2- for trailing arm to specified torque, observing the required component position ⇒ page 168 – Bolt coupling rod -1- to wheel bearing housing and anti-roll bar. –...
Page 178: Repairing Trailing Arm
Golf 2004 ➤ , Golf Plus 2005 ➤ Running gear, axles, steering - Edition 08.2009 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 179 Golf 2004 ➤ , Golf Plus 2005 ➤ Running gear, axles, steering - Edition 08.2009 – 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. Pressing in bonded rubber bush –...
Page 180 Golf 2004 ➤ , Golf Plus 2005 ➤ Running gear, axles, steering - Edition 08.2009 – Set up 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- –...
Page 181: Assembly Overview: Shock Absorber, Coil Spring (Front-Wheel Drive)
Golf 2004 ➤ , Golf Plus 2005 ➤ Running gear, axles, steering - Edition 08.2009 Assembly overview: shock absorber, coil spring (front-wheel drive) 1 - Upper spring seat 2 - Coil spring ❑ Note various versions of running gear ⇒ page 317 ❑...
Page 182 Golf 2004 ➤ , Golf Plus 2005 ➤ Running gear, axles, steering - Edition 08.2009 ♦ Spring retainer -V.A.G 1752/4- ♦ 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 1752/4- -2- (accident risk).
Page 183: Removing And Installing Shock Absorbers
Golf 2004 ➤ , Golf Plus 2005 ➤ Running gear, axles, steering - Edition 08.2009 – 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 184 Golf 2004 ➤ , Golf Plus 2005 ➤ Running gear, axles, steering - Edition 08.2009 – 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”...
Page 185: Repairing Shock Absorber
Golf 2004 ➤ , Golf Plus 2005 ➤ Running gear, axles, steering - Edition 08.2009 Repairing shock absorber 1 - Shock absorber ❑ Removing and installing ⇒ page 175 ❑ Note different versions of running gear ⇒ page 317 , vehicle data plate 2 - Protective cap 3 - Protective tube...
Page 186 Golf 2004 ➤ , Golf Plus 2005 ➤ Running gear, axles, steering - Edition 08.2009 ♦ Torque wrench -V.A.G 1332- ♦ Shock absorber set -T10001- Dismantling and assembling Loosening and tightening threaded connection for shock absorb‐ er mounting Commercially available ratchet handle Socket -T10001/9- Ratchet handle -T10001/11- Socket -T10001/1-...
Page 187: Assembly Overview: Anti-Roll Bar (Front-Wheel Drive)
Golf 2004 ➤ , Golf Plus 2005 ➤ Running gear, axles, steering - Edition 08.2009 Assembly overview: anti-roll bar (front-wheel drive) 1 - Anti-roll bar ❑ Note different versions of running gear ⇒ page 317 , vehicle data plate ❑ Removing and installing ⇒...
Page 188 Golf 2004 ➤ , Golf Plus 2005 ➤ Running gear, axles, steering - Edition 08.2009 ♦ 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 189 Golf 2004 ➤ , Golf Plus 2005 ➤ Running gear, axles, steering - Edition 08.2009 – 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° ♦...
Page 190: Assembly Overview - Attachment Parts For Subframe Golf Bluemotion, Golf Plus Bluemotion (Front-Wheel Drive)
Golf 2004 ➤ , Golf Plus 2005 ➤ Running gear, axles, steering - Edition 08.2009 Assembly overview - attachment parts for subframe Golf BlueMotion, Golf Plus BlueMotion (front-wheel drive) 1 - Subframe 2 - Bolt 3 - Angle piece 4 - Nut ❑...
Page 191: Repairing Rear Suspension (Four-Wheel Drive)
Golf 2004 ➤ , Golf Plus 2005 ➤ Running gear, axles, steering - Edition 08.2009 Repairing rear suspension (four- wheel drive) Overview of rear axle (aluminium) Note It is not permitted to weld or straighten load-bearing or wheel-guiding components of the suspension. ♦...
Page 192 Golf 2004 ➤ , Golf Plus 2005 ➤ Running gear, axles, steering - Edition 08.2009 III - Wheel bearing housing, trailing link (four-wheel drive, subframe made from alumini‐ um and wheel bearing housing made from cast steel) ⇒ page 234 IV - Shock absorber, coil spring (four-wheel drive, subframe made from aluminium and...
Page 193: Overview Of Rear Axle (Steel)
Golf 2004 ➤ , Golf Plus 2005 ➤ Running gear, axles, steering - Edition 08.2009 Overview of rear axle (steel) Note It is not permitted to weld or straighten load-bearing or wheel-guiding components of the suspension. ♦ Always renew self-locking nuts. ♦...
Page 194 Golf 2004 ➤ , Golf Plus 2005 ➤ Running gear, axles, steering - Edition 08.2009 III - Wheel bearing housing, trailing link (four-wheel drive, subframe made from steel and wheel bearing housing made from aluminium) ⇒ page 251 IV - Shock absorber, coil spring (four-wheel drive, subframe made from steel and wheel bearing housing made from...
Page 195: Rear Axle In Unladen State (Aluminium And Steel)
Golf 2004 ➤ , Golf Plus 2005 ➤ Running gear, axles, steering - Edition 08.2009 Rear axle in unladen state (aluminium and steel) Special tools and workshop equipment required ♦ Engine and gearbox jack - V.A.G 1383 A- ♦ Tensioning strap -T10038- ♦...
Page 196 Golf 2004 ➤ , Golf Plus 2005 ➤ Running gear, axles, steering - Edition 08.2009 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!
Page 197: Assembly Overview - Subframe Made From Aluminium, Final Drive (Four-Wheel Drive)
Golf 2004 ➤ , Golf Plus 2005 ➤ Running gear, axles, steering - Edition 08.2009 Assembly overview - subframe made from aluminium, final drive (four- wheel drive) -Arrow- indicates direction of travel. 1 - Subframe Note 2 - Nut ❑ 50 Nm +180° further ❑...
Page 198 Golf 2004 ➤ , Golf Plus 2005 ➤ Running gear, axles, steering - Edition 08.2009 ♦ Engine and gearbox jack -V.A.G 1383 A- Removing subframe with attachments Note Please note that subsequent assembly work for which the hexa‐ gon or twelve-point bolt of the drive shaft has to be loosened requires that the vehicle is stood on its wheels.
Page 199 Golf 2004 ➤ , Golf Plus 2005 ➤ Running gear, axles, steering - Edition 08.2009 – Unscrew hexagon bolt -1- and detach handbrake cable -2- from brake cable bracket. Vehicles with retainer for handbrake cable – Remove retainer -1- by pushing out inner pin of rivet -arrow-. Continuation for all vehicles –...
Page 200 Golf 2004 ➤ , Golf Plus 2005 ➤ Running gear, axles, steering - Edition 08.2009 – Mark installation position of mounting bracket on body. – Remove bolts -arrows-. – 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-.
Page 201 Golf 2004 ➤ , Golf Plus 2005 ➤ Running gear, axles, steering - Edition 08.2009 – Support propshaft on tunnel support using a wooden block. – Push rear propshaft tube towards gearbox as far as possible. – Now secure vehicle to lifting platform on both sides using ten‐ sioning straps -T10038-.
Page 202 Golf 2004 ➤ , Golf Plus 2005 ➤ Running gear, axles, steering - Edition 08.2009 – Secure position of subframe using 2 locking devices -T10096- and tighten to 20 Nm. – Unscrew remaining 2 bolts from subframe. – Carefully lower subframe with attachments. Note When lowering, ensure sufficient clearance of brake lines, elec‐...
Page 203: Repairing Subframe
Golf 2004 ➤ , Golf Plus 2005 ➤ Running gear, axles, steering - Edition 08.2009 Repairing subframe Special tools and workshop equipment required ♦ Hydraulic press -VAS 6178- ♦ Engine and gearbox jack - V.A.G 1383 A- ♦ Assembly tool -T10263- ♦...
Page 204 Golf 2004 ➤ , Golf Plus 2005 ➤ Running gear, axles, steering - Edition 08.2009 – Now secure vehicle to lifting platform on both sides using ten‐ sioning 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 205 Golf 2004 ➤ , Golf Plus 2005 ➤ Running gear, axles, steering - Edition 08.2009 – Set up special tools as shown in figure. 1 - Nut -T10263/5- 2 - Washer (commercial type) 3 - Subframe 4 - Tube -T10263/1- 5 - Hydraulic press -VAS 6178- 6 - Washer (commercial type) 7 - Nut -T10263/5-...
Page 206 Golf 2004 ➤ , Golf Plus 2005 ➤ Running gear, axles, steering - Edition 08.2009 Specified torques Component Specified torque Subframe to body 90 Nm + 90° ♦ Use new bolts Track rod to subframe 90 Nm + 90° ♦ Use new nuts and bolts ♦...
Page 207: Assembly Overview - Subframe Made From Steel, Final Drive (Four-Wheel Drive)
Golf 2004 ➤ , Golf Plus 2005 ➤ Running gear, axles, steering - Edition 08.2009 Assembly overview - subframe made from steel, final drive (four-wheel drive) -Arrow- indicates direction of travel. 1 - Subframe 2 - Rear bonded rubber bush ❑...
Page 208 Golf 2004 ➤ , Golf Plus 2005 ➤ Running gear, axles, steering - Edition 08.2009 ♦ Engine/gearbox jack -V.A.G 1383 A- Removing subframe with attachments Note Please note that subsequent assembly work for which the hexa‐ gon or twelve-point bolt of the drive shaft has to be loosened requires that the vehicle is stood on its wheels.
Page 209 Golf 2004 ➤ , Golf Plus 2005 ➤ Running gear, axles, steering - Edition 08.2009 – Remove retainer -1- by pushing out inner pin of rivet -arrow-. – Mark installation position of mounting bracket on body. – Remove bolts -arrows-. –...
Page 210 Golf 2004 ➤ , Golf Plus 2005 ➤ Running gear, axles, steering - Edition 08.2009 – 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 211 Golf 2004 ➤ , Golf Plus 2005 ➤ Running gear, axles, steering - Edition 08.2009 To secure the subframe in place, ensure that at positions -1- and -2- the locating pins -T10096- are screwed in one after the other on both sides of vehicle. –...
Page 212 Golf 2004 ➤ , Golf Plus 2005 ➤ Running gear, axles, steering - Edition 08.2009 – 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 between brake lines, electrical cables and centring pin and the propshaft.
Page 213: Repairing Subframe
Golf 2004 ➤ , Golf Plus 2005 ➤ Running gear, axles, steering - Edition 08.2009 10.2 Repairing subframe Special tools and workshop equipment required ♦ Tensioning strap -T10038- ♦ Locating pins -T10096- ♦ Assembly tool -T10263- ♦ Engine and gearbox jack - V.A.G 1383 A- ♦...
Page 214 Golf 2004 ➤ , Golf Plus 2005 ➤ Running gear, axles, steering - Edition 08.2009 – Remove clip -1-. Note Do not open brake line. – Now strap vehicle to the lifting platform arms on both sides of the vehicle 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 215 Golf 2004 ➤ , Golf Plus 2005 ➤ Running gear, axles, steering - Edition 08.2009 – Secure position of subframe using 2 locking devices -T10096- and tighten to 20 Nm. Note The locating devices -T10096- must only be tightened to a max‐ imum of 20 Nm;...
Page 216 Golf 2004 ➤ , Golf Plus 2005 ➤ Running gear, axles, steering - Edition 08.2009 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 217 Golf 2004 ➤ , Golf Plus 2005 ➤ Running gear, axles, steering - Edition 08.2009 – Remove clip -1-. Note Do not open brake line. – Now strap vehicle to the lifting platform arms on both sides of the vehicle 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 218 Golf 2004 ➤ , Golf Plus 2005 ➤ Running gear, axles, steering - Edition 08.2009 – Fix position of subframe using locating pins -T10096- . Note The locating devices -T10096- must only be tightened to a max‐ imum of 20 Nm; otherwise the threads of the locating pins may be damaged.
Page 219 Golf 2004 ➤ , Golf Plus 2005 ➤ Running gear, axles, steering - Edition 08.2009 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 220: Assembly Overview - Control Arm, Track Rod (Four-Wheel Drive, Subframe Made From Aluminium And Wheel Bearing Housing Made From Cast Steel)
Golf 2004 ➤ , Golf Plus 2005 ➤ Running gear, axles, steering - Edition 08.2009 Assembly overview - control arm, track rod (four-wheel drive, sub‐ frame made from aluminium and wheel bearing housing made from cast steel) -Arrow- indicates direction of travel. 1 - Eccentric bolt ❑...
Page 221 Golf 2004 ➤ , Golf Plus 2005 ➤ Running gear, axles, steering - Edition 08.2009 9 - Lower transverse link ❑ Removing and installing ⇒ page 217 10 - Nut ❑ M12 x 1.5 ❑ 90 Nm + 90° further ❑...
Page 222: Overview - Rear Left Vehicle Level Sender G76
Golf 2004 ➤ , Golf Plus 2005 ➤ Running gear, axles, steering - Edition 08.2009 ❑ Always tighten threaded connections in unladen position ⇒ page 187 26 - Nut ❑ M12 x 1.5 ❑ 90 Nm + 90° further ❑ Self-locking ❑...
Page 223: Renew Vehicle Level Sender In Vehicle
Golf 2004 ➤ , Golf Plus 2005 ➤ Running gear, axles, steering - Edition 08.2009 11.2 Renew vehicle level sender in vehicle Special tools and workshop equipment required ♦ Torque wrench -V.A.G 1331- Removing – Separate connection -1-. – Remove bolts -2- and -3-. –...
Page 224 Golf 2004 ➤ , Golf Plus 2005 ➤ Running gear, axles, steering - Edition 08.2009 – Unhook speed sensor line -arrow A- from upper transverse link. – Remove bolt -1-. – Mark position of eccentric bolt -arrow- relative to subframe us‐ ing e.g.
Page 225: Removing And Installing Lower Transverse Link
Golf 2004 ➤ , Golf Plus 2005 ➤ Running gear, axles, steering - Edition 08.2009 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 226 Golf 2004 ➤ , Golf Plus 2005 ➤ Running gear, axles, steering - Edition 08.2009 – 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 227: Removing And Installing Track Rod
Golf 2004 ➤ , Golf Plus 2005 ➤ Running gear, axles, steering - Edition 08.2009 11.5 Removing and installing track rod Special tools and workshop equipment required ♦ Torque wrench -V.A.G 1331- ♦ Torque wrench -V.A.G 1332- Removing – Measure distance from centre of wheel to lower edge of wheel housing ⇒...
Page 228 Golf 2004 ➤ , Golf Plus 2005 ➤ Running gear, axles, steering - Edition 08.2009 – Remove bolts -arrows- for anti-roll bar clamp. If the upper bolt of the anti-roll bar clamp on the right side of the vehicle cannot be removed, then additional work must be per‐ formed ⇒...
Page 229 Golf 2004 ➤ , Golf Plus 2005 ➤ Running gear, axles, steering - Edition 08.2009 – Bolt track rod -1- to subframe and tighten new nut -arrow- to prescribed torque. – Tighten bolts -arrows- for anti-roll bar clamp. For the right side of the vehicle only (depending on equipment) –...
Page 230 Golf 2004 ➤ , Golf Plus 2005 ➤ Running gear, axles, steering - Edition 08.2009 Component Specified torque Anti-roll bar to coupling rod 45 Nm ♦ Use new nut Rep. Gr.42 - Rear suspension...
Page 231: Assembly Overview - Control Arm, Track Rod (Four-Wheel Drive, Subframe Made From Steel And Wheel Bearing Housing Made From Aluminium)
Golf 2004 ➤ , Golf Plus 2005 ➤ Running gear, axles, steering - Edition 08.2009 Assembly overview - control arm, track rod (four-wheel drive, sub‐ frame made from steel and wheel bearing housing made from alumi‐ nium) -Arrow- indicates direction of travel. 1 - Eccentric bolt ❑...
Page 232 Golf 2004 ➤ , Golf Plus 2005 ➤ Running gear, axles, steering - Edition 08.2009 7 - Subframe 8 - Bolt ❑ M12 x 1.5 x 125 ❑ 90 Nm + 90° further ❑ Renew each time after removing 9 - Lower transverse link ❑...
Page 233 Golf 2004 ➤ , Golf Plus 2005 ➤ Running gear, axles, steering - Edition 08.2009 ❑ 130 Nm + 90° further ❑ Renew each time after removing ❑ Always tighten threaded connections in unladen position ⇒ page 187 26 - Track rod ❑...
Page 234: Overview - Rear Left Vehicle Level Sender G76
Golf 2004 ➤ , Golf Plus 2005 ➤ Running gear, axles, steering - Edition 08.2009 12.1 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 ♦...
Page 235: Removing And Installing Upper Transverse Link
Golf 2004 ➤ , Golf Plus 2005 ➤ Running gear, axles, steering - Edition 08.2009 ♦ Torque wrench -V.A.G 1331- 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.
Page 236 Golf 2004 ➤ , Golf Plus 2005 ➤ Running gear, axles, steering - Edition 08.2009 – Unhook speed sensor line -arrow A- from upper transverse link. – Remove bolt -1-. – Mark position of eccentric bolt -arrow- relative to subframe us‐ ing e.g.
Page 237: Removing And Installing Lower Transverse Link
Golf 2004 ➤ , Golf Plus 2005 ➤ Running gear, axles, steering - Edition 08.2009 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 238 Golf 2004 ➤ , Golf Plus 2005 ➤ Running gear, axles, steering - Edition 08.2009 – 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 239: Removing And Installing Track Rod
Golf 2004 ➤ , Golf Plus 2005 ➤ Running gear, axles, steering - Edition 08.2009 12.5 Removing and installing track rod Special tools and workshop equipment required ♦ Torque wrench -V.A.G 1331- ♦ Torque wrench -V.A.G 1332- Removing – Remove wheel. –...
Page 240 Golf 2004 ➤ , Golf Plus 2005 ➤ Running gear, axles, steering - Edition 08.2009 – Now strap vehicle to the lifting platform arms on both sides of the vehicle 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 241 Golf 2004 ➤ , Golf Plus 2005 ➤ Running gear, axles, steering - Edition 08.2009 – 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.
Page 242: Assembly Overview - Wheel Bearing Housing, Trailing Link (Four-Wheel Drive, Subframe Made From Aluminium And Wheel Bearing Housing Made From Cast Steel)
Golf 2004 ➤ , Golf Plus 2005 ➤ Running gear, axles, steering - Edition 08.2009 Assembly overview - wheel bearing housing, trailing link (four-wheel drive, subframe made from aluminium and wheel bearing housing made from cast steel) -Arrow- indicates direction of travel. 1 - Bolt ❑...
Page 243: Changing From Wheel Housing Bearing Made From Cast Steel To Wheel Bearing Housing Made From Aluminium
Golf 2004 ➤ , Golf Plus 2005 ➤ Running gear, axles, steering - Edition 08.2009 12 - Bonded rubber bush ❑ Renewing ⇒ page 240 13 - Nut ❑ 45 Nm ❑ Self-locking ❑ Always renew after removing 14 - Cross-head screw ❑...
Page 244: Removing And Installing Wheel Bearing Housing
Golf 2004 ➤ , Golf Plus 2005 ➤ Running gear, axles, steering - Edition 08.2009 ♦ Bolt and washer for shock absorber to wheel bearing housing ♦ Bolts (qty. 2) for trailing link to wheel bearing housing ♦ Cover plate with bolts (qty. 4) to wheel bearing housing Caution The additional washers that have to be installed must always be placed between the component and the wheel bearing...
Page 245 Golf 2004 ➤ , Golf Plus 2005 ➤ Running gear, axles, steering - Edition 08.2009 – Remove bolt -arrow-. – Remove bolt for track rod -1-, upper transverse link -2- and lower transverse link -3- from wheel housing -4-. – Unbolt coupling rod from wheel bearing housing -arrow-. –...
Page 246 Golf 2004 ➤ , Golf Plus 2005 ➤ Running gear, axles, steering - Edition 08.2009 – Position trailing arm 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.
Page 247 Golf 2004 ➤ , Golf Plus 2005 ➤ Running gear, axles, steering - Edition 08.2009 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.
Page 248: Renewing Bonded Rubber Bush For Wheel Bearing Housing
Golf 2004 ➤ , Golf Plus 2005 ➤ Running gear, axles, steering - Edition 08.2009 13.3 Renewing bonded rubber bush for wheel bearing housing Special tools and workshop equipment required ♦ Press tool -30 - 506 B- ♦ Drift sleeve -41 - 501- ♦...
Page 249 Golf 2004 ➤ , Golf Plus 2005 ➤ Running gear, axles, steering - Edition 08.2009 Note Hang brake caliper from body. – Remove cross-head screw for brake disc and remove brake disc. – Remove backplate. – Remove bolt -arrow- for lower transverse link -1-. Pressing out bonded rubber bush –...
Page 250: Removing And Installing Wheel Bearing/Wheel Hub Unit
Golf 2004 ➤ , Golf Plus 2005 ➤ Running gear, axles, steering - Edition 08.2009 – 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- –...
Page 251: Removing And Installing Trailing Arm With Mounting Bracket
Golf 2004 ➤ , Golf Plus 2005 ➤ Running gear, axles, steering - Edition 08.2009 ♦ Torque wrench -V.A.G 1410- Removing – Remove coil spring ⇒ page 257 – Remove drive shaft ⇒ page 276 – Remove brake carrier with brake caliper and tie to body with wire ⇒...
Page 252 Golf 2004 ➤ , Golf Plus 2005 ➤ Running gear, axles, steering - Edition 08.2009 ♦ Torque wrench -V.A.G 1332- Removing – Remove wheel. – Remove coil spring ⇒ page 257 – Remove bolt -arrow- securing handbrake cable -1- to trailing arm -2-.
Page 253 Golf 2004 ➤ , Golf Plus 2005 ➤ Running gear, axles, steering - Edition 08.2009 – 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 longitudinal member. The position of the mounting bracket must then be adjusted in relation to the trailing arm.
Page 254 Golf 2004 ➤ , Golf Plus 2005 ➤ Running gear, axles, steering - Edition 08.2009 – 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. –...
Page 255 Golf 2004 ➤ , Golf Plus 2005 ➤ Running gear, axles, steering - Edition 08.2009 Vehicles with retainer for handbrake cable – Attach retainer -1- by pushing in inner pin of rivet -arrow-. Continuation for all vehicles After installation, toe setting must be checked on wheel alignment unit.
Page 256: Repairing Trailing Arm
Golf 2004 ➤ , Golf Plus 2005 ➤ Running gear, axles, steering - Edition 08.2009 13.6 Repairing trailing arm Special tools and workshop equipment required ♦ Assembly tool -T10230- ♦ Removal tool -3372- ♦ Thrust plate -VW 401- ♦ Thrust plate -VW 402- Pressing out bonded rubber bush –...
Page 257 Golf 2004 ➤ , Golf Plus 2005 ➤ Running gear, axles, steering - Edition 08.2009 – 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. Pressing in bonded rubber bush –...
Page 258 Golf 2004 ➤ , Golf Plus 2005 ➤ Running gear, axles, steering - Edition 08.2009 – Set up 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- –...
Page 259: Assembly Overview - Wheel Bearing Housing, Trailing Link (Four-Wheel Drive, Subframe Made From Steel And Wheel Bearing Housing Made From Aluminium)
Golf 2004 ➤ , Golf Plus 2005 ➤ Running gear, axles, steering - Edition 08.2009 Assembly overview - wheel bearing housing, trailing link (four-wheel drive, subframe made from steel and wheel bearing housing made from aluminium) -Arrow- indicates direction of travel. 1 - Mounting bracket 2 - Cover 3 - Bolt...
Page 260: Removing And Installing Wheel Bearing Housing
Golf 2004 ➤ , Golf Plus 2005 ➤ Running gear, axles, steering - Edition 08.2009 12 - Bonded rubber bush ❑ Renewing ⇒ page 240 13 - Nut ❑ M12 x 25 ❑ 45 Nm ❑ Self-locking ❑ Renew each time after removing 14 - Bolt ❑...
Page 261 Golf 2004 ➤ , Golf Plus 2005 ➤ Running gear, axles, steering - Edition 08.2009 Removing – Remove coil spring ⇒ page 257 – Loosen the outer drive shaft threaded connection ⇒ page 274 – Remove wheel. – Remove brake carrier with brake caliper and tie to body with wire ⇒...
Page 262 Golf 2004 ➤ , Golf Plus 2005 ➤ Running gear, axles, steering - Edition 08.2009 – 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‐...
Page 263: Renewing Bonded Rubber Bush For Wheel Bearing Housing
Golf 2004 ➤ , Golf Plus 2005 ➤ Running gear, axles, steering - Edition 08.2009 Component Specified torque 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°...
Page 264 Golf 2004 ➤ , Golf Plus 2005 ➤ Running gear, axles, steering - Edition 08.2009 ♦ Torque wrench -V.A.G 1410- Removing – Remove coil spring ⇒ page 257 – Remove drive shaft ⇒ page 276 – Remove brake carrier with brake caliper and tie to body with wire ⇒...
Page 265: Assembly Overview - Shock Absorber, Coil Spring (Four-Wheel Drive, Subframe Made From Aluminium And Wheel Bearing Housing Made From Cast Steel)
Golf 2004 ➤ , Golf Plus 2005 ➤ Running gear, axles, steering - Edition 08.2009 Assembly overview - shock absorber, coil spring (four-wheel drive, subframe made from aluminium and wheel bearing housing made from cast steel) 1 - Upper spring seat 2 - Coil spring ❑...
Page 266 Golf 2004 ➤ , Golf Plus 2005 ➤ Running gear, axles, steering - Edition 08.2009 ♦ Spring retainer -V.A.G 1752/4- ♦ Adapter -V.A.G 1752/9- , not illustrated Removing – Remove wheel. – Insert spring compressor -3-. WARNING Make sure coil spring is properly seated in spring retainer - V.A.G 1752/4- (risk of accident).
Page 267: Removing And Installing Shock Absorbers
Golf 2004 ➤ , Golf Plus 2005 ➤ Running gear, axles, steering - Edition 08.2009 – Insert this pin in holes in lower transverse link -arrows-. – Then insert top spring seat into upper end of spring. – Release tension from spring. When doing so, locate upper spring seat onto lug on body.
Page 268: Repairing Shock Absorber
Golf 2004 ➤ , Golf Plus 2005 ➤ Running gear, axles, steering - Edition 08.2009 – Remove bolt -arrow-. – Remove shock absorber. Installing Install in reverse order. Note the following points: – Install wheel and tighten ⇒ page 288 The shock absorber may be bolted to the wheel bearing housing only when the dimension measured between the centre of wheel hub and edge of wheel housing before assembly has been at‐...
Page 269 Golf 2004 ➤ , Golf Plus 2005 ➤ Running gear, axles, steering - Edition 08.2009 8 - Cover 9 - Shock absorber mounting ❑ For shock absorbers without support ring ⇒ Item 4 (page 177) ❑ Allocation ⇒ Electronic parts catalogue “ETKA” 10 - Bump stop ❑...
Page 270: Assembly Overview - Shock Absorber, Coil Spring (Four-Wheel Drive, Subframe Made From Steel And Wheel Bearing Housing Made From Aluminium)
Golf 2004 ➤ , Golf Plus 2005 ➤ Running gear, axles, steering - Edition 08.2009 Assembly overview - shock absorber, coil spring (four-wheel drive, subframe made from steel and wheel bearing housing made from alu‐ minium) 1 - Lower spring seat ❑...
Page 271 Golf 2004 ➤ , Golf Plus 2005 ➤ Running gear, axles, steering - Edition 08.2009 ♦ Torque wrench -V.A.G 1332- Removing – Remove wheel. – Remove wheel housing liner ⇒ General body repairs, exterior; Rep. Gr. 66 . – Remove coil spring ⇒...
Page 272: Repairing Shock Absorber
Golf 2004 ➤ , Golf Plus 2005 ➤ Running gear, axles, steering - Edition 08.2009 – Tighten bolt -arrow-. Note Make sure that the plate between wheel bearing housing and shock absorber is also installed. – Install coil spring ⇒ page 257 –...
Page 273: Assembly Overview - Anti-Roll Bar (Four-Wheel Drive, Subframe Made From Aluminium And Wheel Bearing Housing Made From Cast Steel)
Golf 2004 ➤ , Golf Plus 2005 ➤ Running gear, axles, steering - Edition 08.2009 Assembly overview - anti-roll bar (four-wheel drive, subframe made from aluminium and wheel bearing housing made from cast steel) -Arrow- indicates direction of travel. 1 - Anti-roll bar ❑...
Page 274 Golf 2004 ➤ , Golf Plus 2005 ➤ Running gear, axles, steering - Edition 08.2009 ♦ Torque wrench -V.A.G 1331- 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 275 Golf 2004 ➤ , Golf Plus 2005 ➤ Running gear, axles, steering - Edition 08.2009 – Now strap vehicle to the lifting platform arms on both sides of the vehicle 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 276 Golf 2004 ➤ , Golf Plus 2005 ➤ Running gear, axles, steering - Edition 08.2009 Component Specified torque Anti-roll bar to coupling rod 45 Nm ♦ Use new nut Rep. Gr.42 - Rear suspension...
Page 277: Assembly Overview - Anti-Roll Bar (Four-Wheel Drive, Subframe Made From Steel And Wheel Bearing Housing Made From Aluminium)
Golf 2004 ➤ , Golf Plus 2005 ➤ Running gear, axles, steering - Edition 08.2009 Assembly overview - anti-roll bar (four-wheel drive, subframe made from steel and wheel bearing housing made from aluminium) -Arrow- indicates direction of travel. 1 - Anti-roll bar ❑...
Page 278 Golf 2004 ➤ , Golf Plus 2005 ➤ Running gear, axles, steering - Edition 08.2009 ♦ Torque wrench -V.A.G 1331- 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 279 Golf 2004 ➤ , Golf Plus 2005 ➤ Running gear, axles, steering - Edition 08.2009 – Now strap vehicle to the lifting platform arms on both sides of the vehicle 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 280 Golf 2004 ➤ , Golf Plus 2005 ➤ Running gear, axles, steering - Edition 08.2009 Component Specified torque Anti-roll bar to coupling rod 45 Nm ♦ Use new nut. Rep. Gr.42 - Rear suspension...
Page 281: Assembly Overview - Drive Shaft
Golf 2004 ➤ , Golf Plus 2005 ➤ Running gear, axles, steering - Edition 08.2009 Assembly overview - drive shaft 1 - Outer constant velocity joint ❑ Renew only as com‐ plete unit ❑ Removing ⇒ page 280 ❑ Installing: drive onto shaft to stop using a plastic mallet ❑...
Page 282: Loosening And Tightening Drive Shaft Hexagon Bolt
Golf 2004 ➤ , Golf Plus 2005 ➤ Running gear, axles, steering - Edition 08.2009 ❑ Drive off constant velocity joint with a drift ❑ Coat sealing surface of constant velocity joint with -D 454 300 A2- before installing. 11 - Hose clip ❑...
Page 283: Loosening And Tightening 12-Point Bolt For Drive Shaft
Golf 2004 ➤ , Golf Plus 2005 ➤ Running gear, axles, steering - Edition 08.2009 Do not attempt to move the vehicle without the drive shafts fitted as this would result in wheel bearing damage. If the vehicle does have to be moved, always note the following points: –...
Page 284: Removing And Installing Drive Shaft
Golf 2004 ➤ , Golf Plus 2005 ➤ Running gear, axles, steering - Edition 08.2009 ♦ Torque/angle wrench -V.A.G 1756- 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 285 Golf 2004 ➤ , Golf Plus 2005 ➤ Running gear, axles, steering - Edition 08.2009 – Remove wheel. – Unscrew bolts securing track rod -1- and lower transverse link -3- from wheel bearing housing -4-. – Remove bolt -arrow-. – Loosen drive shaft at gearbox flange. –...
Page 286: Dismantling And Assembling Drive Shaft
Golf 2004 ➤ , Golf Plus 2005 ➤ Running gear, axles, steering - Edition 08.2009 19.4 Dismantling and assembling drive shaft Special tools and workshop equipment required ♦ Thrust plate -VW 401- ♦ Thrust plate -VW 402- ♦ Press tool -VW 408 A- ♦...
Page 287 Golf 2004 ➤ , Golf Plus 2005 ➤ Running gear, axles, steering - Edition 08.2009 ♦ Circlip pliers -VW 161 A- ♦ Torque wrench -V.A.G 1331- ♦ Torque wrench -V.A.G 1332- ♦ Special pliers -V.A.G 1682- ♦ Assembly tool -T10065- ♦...
Page 288 Golf 2004 ➤ , Golf Plus 2005 ➤ Running gear, axles, steering - Edition 08.2009 ♦ 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- .
Page 289 Golf 2004 ➤ , Golf Plus 2005 ➤ Running gear, axles, steering - Edition 08.2009 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.
Page 290 Golf 2004 ➤ , Golf Plus 2005 ➤ Running gear, axles, steering - Edition 08.2009 Tighten hose clip on outer joint – Tighten hose clip by turning spindle with a torque wrench (do not cant pliers). Note Because a stainless steel hose clip is required due to the hard ♦...
Page 291: Checking Outer Constant Velocity Joint
Golf 2004 ➤ , Golf Plus 2005 ➤ Running gear, axles, steering - Edition 08.2009 Pressing on inner constant velocity joint Note Chamfer on internal circumference of ball hub (splines) must face contact shoulder on drive shaft. – Apply special pliers -V.A.G 1682- as shown in diagram. En‐ sure that the jaws of the pliers seat in the ends of the hose clip -arrows B-.
Page 292: Checking Inner Constant Velocity Joint
Golf 2004 ➤ , Golf Plus 2005 ➤ Running gear, axles, steering - Edition 08.2009 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. –...
Page 293 Golf 2004 ➤ , Golf Plus 2005 ➤ Running gear, axles, steering - Edition 08.2009 – 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. –...
Page 294 Golf 2004 ➤ , Golf Plus 2005 ➤ Running gear, axles, steering - Edition 08.2009 – Swing ball hub into place by swinging hub out of cage as shown in figure -arrows-. – Swivel in hub with balls by applying firm pressure to cage -arrow-.
Page 295: Wheels, Tyres, Vehicle Geometry
Golf 2004 ➤ , Golf Plus 2005 ➤ Running gear, axles, steering - Edition 08.2009 44 – Wheels, tyres, vehicle geometry Appraisal of accident vehicles A checklist for evaluating running gear of accident vehicles can be found under ⇒ page 1 1.
Page 296: Torque Settings For Wheel Bolts
Golf 2004 ➤ , Golf Plus 2005 ➤ Running gear, axles, steering - Edition 08.2009 Torque settings for wheel bolts Wheel bolt to wheel hub for all vehicles Specified torque: 120 Nm. Rep. Gr.44 - Wheels, tyres, vehicle geometry...
Page 297: Fitting Wheel And Tyre
Golf 2004 ➤ , Golf Plus 2005 ➤ Running gear, axles, steering - Edition 08.2009 Fitting wheel and tyre General information Since model year 2005, new wheel rims with a modified contour have been used in all vehicles. The tyre fitting unit must be fitted with the tyre fitting head de‐ signed for these wheels.
Page 298: Removing And Fitting Tyres (Wheels With Tyre Pressure Monitoring)
20 minutes. Note When changing wheels, note that only Volkswagen-approved ♦ wheel and tyre combinations with the tyre inflation pressure specified in the tank flap may be installed.
Page 299: Pressing Tyre Off Wheel Rim
The wheel electronics for the wheels of the second wheel set are not automatically detected and learned by the TPM system (unlike the wheel electronics for the wheel set with Volkswagen-ap‐ proved wheel and tyre combinations). The following work has to be performed to switch to the second wheel set: ♦...
Page 300: Removing Tyre From Wheel
Golf 2004 ➤ , Golf Plus 2005 ➤ Running gear, axles, steering - Edition 08.2009 Removing tyre from wheel Caution ♦ Comply with the notes on safety and conditions ⇒ page 290 ♦ 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 301 Golf 2004 ➤ , Golf Plus 2005 ➤ Running gear, axles, steering - Edition 08.2009 – Turn wheel on tyre fitting unit so that tyre valve/ tyre pressure 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.
Page 302: Removing And Fitting Tyres With Run-Flat Capability To Wheel Rims
Golf 2004 ➤ , Golf Plus 2005 ➤ Running gear, axles, steering - Edition 08.2009 Removing and fitting tyres with run- flat capability to wheel rims Notes on safety • Only specially trained mechanics may remove or install tyres with run-flat capability. •...
Page 303 Golf 2004 ➤ , Golf Plus 2005 ➤ Running gear, axles, steering - Edition 08.2009 WARNING The minimum installation temperature of a tyre is 15 °C and the temperature in the core of the tyre should not be more than 30 °C.
Page 304: Pressing Tyre Off Wheel Rim
Golf 2004 ➤ , Golf Plus 2005 ➤ Running gear, axles, steering - Edition 08.2009 Pressing tyre off wheel rim Caution ♦ Follow the notes on safety ⇒ page 294 – Deflate tyre by unscrewing nickel-plated valve insert. – When pressing off a tyre using tyre fitting equipment with a press-off plate, always ensure that the tyre valve/ tyre pres‐...
Page 305 Golf 2004 ➤ , Golf Plus 2005 ➤ Running gear, axles, steering - Edition 08.2009 – Turn wheel on tyre fitting unit so that tyre valve/ tyre pressure 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 .
Page 306: Fitting Tyre To Wheel Rim
Golf 2004 ➤ , Golf Plus 2005 ➤ Running gear, axles, steering - Edition 08.2009 – 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.
Page 307 Golf 2004 ➤ , Golf Plus 2005 ➤ Running gear, axles, steering - Edition 08.2009 – 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. –...
Page 308: Tyre Monitor Display
Golf 2004 ➤ , Golf Plus 2005 ➤ Running gear, axles, steering - Edition 08.2009 Tyre monitor display General notes: 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.
Page 309 Golf 2004 ➤ , Golf Plus 2005 ➤ Running gear, axles, steering - Edition 08.2009 Following any change to the wheels, with the ignition switched on and the vehicle stationary, press the button -2- until an au‐ dible signal sounds. The audible signal confirms basic setting. 6.
Page 310: Tyre Pressure Monitor (Tpm)
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.
Page 311: Assembly Overview - Tyre Pressure Sensor
Golf 2004 ➤ , Golf Plus 2005 ➤ Running gear, axles, steering - Edition 08.2009 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 Deactivation Full tyre load moni‐...
Page 312: Removing And Installing Tyre Pressure Sensor
Golf 2004 ➤ , Golf Plus 2005 ➤ Running gear, axles, steering - Edition 08.2009 ❑ Do not use convenience valve caps or metal valve caps. Removing and installing tyre pressure sensor Removing – Unscrew union nut -1-. – Remove tyre pressure sensor -2- from bed of wheel rim. Installing Caution ♦...
Page 313: Wheel Alignment
Golf 2004 ➤ , Golf Plus 2005 ➤ Running gear, axles, steering - Edition 08.2009 Wheel alignment Special tools and workshop equipment required ♦ Wheel alignment computer -V.A.G 1813- or VW/Audi- approved wheel alignment computer ♦ Brake pedal actuator - V.A.G 1869/2- ♦...
Page 314 Golf 2004 ➤ , Golf Plus 2005 ➤ Running gear, axles, steering - Edition 08.2009 ⇒ 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.
Page 315: Test Prerequisites
Golf 2004 ➤ , Golf Plus 2005 ➤ Running gear, axles, steering - Edition 08.2009 Prerequisite: the positions of the subframe and brackets fixed before they were removed ⇒ page 16 Test prerequisites • Check suspension, wheel bearing, steering and steering link‐ age for excessive play and damage.
Page 316: Wheel Alignment Specifications, Golf
Golf 2004 ➤ , Golf Plus 2005 ➤ Running gear, axles, steering - Edition 08.2009 – Fit brake pedal actuator -V.A.G 1869/2- . – Use brake pedal depressor to depress brake pedal. Wheel alignment specifications, Golf These specifications apply to all engines. ♦...
Page 317: Wheel Alignment Specifications, Golf Plus, Crossgolf
Golf 2004 ➤ , Golf Plus 2005 ➤ Running gear, axles, steering - Edition 08.2009 Front axle Sports running Sports running Sports running BlueMotion gear GTI gear GTI US ver‐ gear R32 sion PR numbers G04/2UC Ride height 360 ± 10 mm 382 ±...
Page 318 Golf 2004 ➤ , Golf Plus 2005 ➤ Running gear, axles, steering - Edition 08.2009 The ride heights shown in the table refer to dimension -a-. Front axle Standard running Sports running Sports running Heavy-duty run‐ gear gear gear ning gear except 18' with 18' wheels wheels...
Page 319: Overview - Wheel Alignment Procedure
Golf 2004 ➤ , Golf Plus 2005 ➤ Running gear, axles, steering - Edition 08.2009 Rear axle, front-wheel drive Standard running Sports running Sports running Heavy-duty run‐ and 4WD gear gear gear ning gear except 18' with 18' wheels wheels Camber -1°...
Page 320: Correcting Front Axle Camber
Golf 2004 ➤ , Golf Plus 2005 ➤ Running gear, axles, steering - Edition 08.2009 ↓ Check rear axle camber → Is actual value within toler‐ → ance? ↓ ↓ ↓ ← ← Adjust ⇒ page 314 ↓ ↓ ↓ ←...
Page 321 Golf 2004 ➤ , Golf Plus 2005 ➤ Running gear, axles, steering - Edition 08.2009 Note Camber correction is necessary only after body repairs. The ♦ camber is not adjustable, but can be equalized by moving the brackets and/or the subframe. Move subframe only to left or right, but never in or opposite to ♦...
Page 322: Adjusting Camber On Rear Axle
Golf 2004 ➤ , Golf Plus 2005 ➤ Running gear, axles, steering - Edition 08.2009 Adjusting camber on rear axle Special tools and workshop equipment required ♦ Shock absorber set -T10001- ♦ Tool insert 18 mm -T10179- – Loosen upper transverse link nut -A- on subframe. –...
Page 323: Adjusting Toe At Rear Axle
Golf 2004 ➤ , Golf Plus 2005 ➤ Running gear, axles, steering - Edition 08.2009 – 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) ♦...
Page 324: Adjusting Front Axle Toe
Golf 2004 ➤ , Golf Plus 2005 ➤ Running gear, axles, steering - Edition 08.2009 – Loosen nut -1-. – Turn eccentric bolt -2- until specification is attained. – Now tighten nut. Specified torque Component Specified torque Lower transverse link to subframe 95 Nm ♦...
Page 325: Basic Setting For Steering Angle Sender G85
Golf 2004 ➤ , Golf Plus 2005 ➤ Running gear, axles, steering - Edition 08.2009 – Tighten lock nut using tool insert 24 mm -V.A.G 1332/11- while counterholding on track rod ball joint -1-. – Check toe values again. It is possible that the value will change slightly when lock nut is tightened.
Page 326: Wheels, Tyres
Golf 2004 ➤ , Golf Plus 2005 ➤ Running gear, axles, steering - Edition 08.2009 Wheels, tyres Models with breakdown set Golf models 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.
Page 327: Fitting A New Tyre
Golf 2004 ➤ , Golf Plus 2005 ➤ Running gear, axles, steering - Edition 08.2009 – 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 328 Golf 2004 ➤ , Golf Plus 2005 ➤ Running gear, axles, steering - Edition 08.2009 1 - Wheel 2 - Valve cap 3 - Nut ❑ 4 Nm 4 - Washer 5 - Sealing ring 6 - Metal valve Rep. Gr.44 - Wheels, tyres, vehicle geometry...
Page 329: Instructions For Changing Or Fitting Wheels
Golf 2004 ➤ , Golf Plus 2005 ➤ Running gear, axles, steering - Edition 08.2009 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.
Page 330: Fitting Wheels
Golf 2004 ➤ , Golf Plus 2005 ➤ Running gear, axles, steering - Edition 08.2009 – Check whether the wheel bolts can be easily screwed in by hand. The thread of the wheel bolts must not come into contact 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.
Page 331: Protecting Wheel Centring Seat Against Corrosion
Golf 2004 ➤ , Golf Plus 2005 ➤ Running gear, axles, steering - Edition 08.2009 Protecting wheel centring seat against corrosion Valid for light 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.
Page 332: Rough Running Due To Wheels/Tyres - Causes And Rectification
Golf 2004 ➤ , Golf Plus 2005 ➤ Running gear, axles, steering - Edition 08.2009 Rough running due to wheels/tyres - causes and rectification Causes of rough running ⇒ page 324 Balancing wheels ⇒ page 324 Conducting a road test before balancing wheels ⇒...
Page 333: Conducting A Road Test Before Balancing Wheels
Golf 2004 ➤ , Golf Plus 2005 ➤ Running gear, axles, steering - Edition 08.2009 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. ♦...
Page 334 Golf 2004 ➤ , Golf Plus 2005 ➤ Running gear, axles, steering - Edition 08.2009 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 ♦...
Page 335: Vibration Control System Vas 6230
Golf 2004 ➤ , Golf Plus 2005 ➤ Running gear, axles, steering - Edition 08.2009 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.
Page 336: Radial And Lateral Runout Of Wheels And Tyres
Golf 2004 ➤ , Golf Plus 2005 ➤ Running gear, axles, steering - Edition 08.2009 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.
Page 337: Checking Radial And Lateral Runout On Wheel
Golf 2004 ➤ , Golf Plus 2005 ➤ Running gear, axles, steering - Edition 08.2009 – 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.
Page 338: Matching
Golf 2004 ➤ , Golf Plus 2005 ➤ Running gear, axles, steering - Edition 08.2009 Wheel Radial runout (mm) Lateral runout (mm) Alloy wheel 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.
Page 339: Flat Spots Caused By Storage Or Handling
Golf 2004 ➤ , Golf Plus 2005 ➤ Running gear, axles, steering - Edition 08.2009 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 329 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.
Page 340 Golf 2004 ➤ , Golf Plus 2005 ➤ Running gear, axles, steering - Edition 08.2009 – Drive the car on a motorway where possible. – Traffic and road conditions permitting, drive a 20 to 30 km stretch at a speed of 120 to 150 km/h. WARNING ♦...
Page 341: Steering
Golf 2004 ➤ , Golf Plus 2005 ➤ Running gear, axles, steering - Edition 08.2009 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...
Page 342: General Repair Instructions
Golf 2004 ➤ , Golf Plus 2005 ➤ Running gear, axles, steering - Edition 08.2009 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.
Page 343: Electrical Components
Golf 2004 ➤ , Golf Plus 2005 ➤ Running gear, axles, steering - Edition 08.2009 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.
Page 344: Steering Wheel
Golf 2004 ➤ , Golf Plus 2005 ➤ Running gear, axles, steering - Edition 08.2009 Steering wheel Removing and installing steering wheel Special tools and workshop equipment required ♦ Torque wrench -V.A.G 1332- Removing – Remove driver side airbag unit ⇒ Rep. Gr. 69 ; Airbag; Re‐ moving and installing driver side airbag unit .
Page 345 Golf 2004 ➤ , Golf Plus 2005 ➤ Running gear, axles, steering - Edition 08.2009 – 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 346 Golf 2004 ➤ , Golf Plus 2005 ➤ Running gear, axles, steering - Edition 08.2009 – Guide connector for steering angle sender -G85- into intended opening in the base of steering wheel. – Join connector -1- with connector -2- of steering angle sender -G85- .
Page 347: Steering Column, Golf
Golf 2004 ➤ , Golf Plus 2005 ➤ Running gear, axles, steering - Edition 08.2009 Steering column, Golf Assembly overview: steering column Note It is not permitted to weld or straighten load-bearing or wheel-guiding components of the suspension. ♦ Always renew self-locking nuts. ♦...
Page 348 Golf 2004 ➤ , Golf Plus 2005 ➤ Running gear, axles, steering - Edition 08.2009 ♦ 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. The steering lock housing can be transferred ⇒...
Page 349 Golf 2004 ➤ , Golf Plus 2005 ➤ Running gear, axles, steering - Edition 08.2009 – 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 350 Golf 2004 ➤ , Golf Plus 2005 ➤ Running gear, axles, steering - Edition 08.2009 – Remove earth cable -arrow- and cable -1- from steering col‐ umn. – Remove bolts -2-. Vehicles with crash bars – Remove ground cable -arrow- and cable -1- from steering col‐ umn.
Page 351 Golf 2004 ➤ , Golf Plus 2005 ➤ Running gear, axles, steering - Edition 08.2009 – Tighten steering column bolts -2-. – Attach earth wire -arrow- and wire -1- to steering column. Vehicles with crash bars – Tighten steering column bolts -2-. –...
Page 352 Golf 2004 ➤ , Golf Plus 2005 ➤ Running gear, axles, steering - Edition 08.2009 – 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.
Page 353: Basic Setting For Steering Angle Sensor G85 Steering Angle Sender Must Be Checked After The Following Repair Work
Golf 2004 ➤ , Golf Plus 2005 ➤ Running gear, axles, steering - Edition 08.2009 Specified torques Component Specified torque Universal joint to steering box 30 Nm ♦ Use new bolt Steering column to mounting bracket 20 Nm Basic setting for steering angle sensor G85 steering angle sender must be checked after the following repair work: ♦...
Page 354: Checking Steering Column For Damage
Golf 2004 ➤ , Golf Plus 2005 ➤ Running gear, axles, steering - Edition 08.2009 Improper handling of steering column Transportation using the following parts leads to primary steering column damage: Clamping lever Weight compensation springs Deformation element Improper handling of steering column with safety risks The following methods of handling will damage the universal joint bushes of the lower steering column bearing: ♦...
Page 355 Golf 2004 ➤ , Golf Plus 2005 ➤ Running gear, axles, steering - Edition 08.2009 ♦ Torque wrench -V.A.G 1331- Removing – Remove steering column ⇒ page 351 – Remove dash panel insert ⇒ Electrical system; Rep. Gr. 90 ; Dash panel insert;...
Page 356: Removing And Installing Strut
Golf 2004 ➤ , Golf Plus 2005 ➤ Running gear, axles, steering - Edition 08.2009 – Insert mounting bracket and screw in bolts -1- and -2-. – Install bolts -arrows B-. Note Bolts -arrows B- are screwed in from cross member. –...
Page 357 Golf 2004 ➤ , Golf Plus 2005 ➤ Running gear, axles, steering - Edition 08.2009 ♦ Torque wrench -V.A.G 1331- Removing – Remove plenum chamber bulkhead ⇒ General body repairs, exterior; Rep. Gr. 50 ; Assembly overview - plenum chamber bulkhead .
Page 358 Golf 2004 ➤ , Golf Plus 2005 ➤ Running gear, axles, steering - Edition 08.2009 – Install securing bolt -2- and tighten. – Tighten bolt -1- for strut -3-. – Install steering column ⇒ page 354 – Install plenum chamber bulkhead ⇒ General body repairs, exterior;...
Page 359: Steering Column, Golf Plus, Crossgolf
Golf 2004 ➤ , Golf Plus 2005 ➤ Running gear, axles, steering - Edition 08.2009 Steering column, Golf Plus, Cross‐ Golf Assembly overview: steering column Note It is not permitted to weld or straighten load-bearing or wheel-guiding components of the suspension. ♦...
Page 360 Golf 2004 ➤ , Golf Plus 2005 ➤ Running gear, axles, steering - Edition 08.2009 ♦ 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. The steering lock housing can be transferred ⇒...
Page 361 Golf 2004 ➤ , Golf Plus 2005 ➤ Running gear, axles, steering - Edition 08.2009 – 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 362 Golf 2004 ➤ , Golf Plus 2005 ➤ Running gear, axles, steering - Edition 08.2009 – Remove earth cable -arrow- and cable -1- from steering col‐ umn. – Remove bolts -2-. Vehicles with crash bars – Remove ground cable -arrow- and cable -1- from steering col‐ umn.
Page 363 Golf 2004 ➤ , Golf Plus 2005 ➤ Running gear, axles, steering - Edition 08.2009 – Tighten steering column bolts -2-. – Attach earth wire -arrow- and wire -1- to steering column. Vehicles with crash bars – Tighten steering column bolts -2-. –...
Page 364 Golf 2004 ➤ , Golf Plus 2005 ➤ Running gear, axles, steering - Edition 08.2009 – 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.
Page 365: Basic Setting For Steering Angle Sensor G85 Steering Angle Sender Must Be Checked After The Following Repair Work
Golf 2004 ➤ , Golf Plus 2005 ➤ Running gear, axles, steering - Edition 08.2009 Specified torques Component Specified torque Universal joint to steering box 30 Nm ♦ Use new bolt Steering column to mounting bracket 20 Nm Basic setting for steering angle sensor G85 steering angle sender must be checked after the following repair work: ♦...
Page 366: Checking Steering Column For Damage
Golf 2004 ➤ , Golf Plus 2005 ➤ Running gear, axles, steering - Edition 08.2009 Improper handling of steering column Transportation using the following parts leads to primary steering column damage: Clamping lever Weight compensation springs Deformation element Improper handling of steering column with safety risks Following methods of handling will damage universal joint bushes of lower steering column bearing: ♦...
Page 367 Golf 2004 ➤ , Golf Plus 2005 ➤ Running gear, axles, steering - Edition 08.2009 ♦ Torque wrench -V.A.G 1331- Removing – Remove steering column ⇒ page 339 – Remove dash panel insert ⇒ Electrical system; Rep. Gr. 90 ; Dash panel insert;...
Page 368: Removing And Installing Strut
Golf 2004 ➤ , Golf Plus 2005 ➤ Running gear, axles, steering - Edition 08.2009 – Insert mounting bracket and screw bolt -1- in. – Install bolts -arrows-. Note Bolts -arrows- are screwed in from cross member. – Insert connector -1- into support in mounting bracket and push to stop opposite -direction of arrow-.
Page 369 Golf 2004 ➤ , Golf Plus 2005 ➤ Running gear, axles, steering - Edition 08.2009 ♦ Torque wrench -V.A.G 1331- Removing – Remove plenum chamber bulkhead ⇒ General body repairs, exterior; Rep. Gr. 50 ; Assembly overview - plenum chamber bulkhead .
Page 370 Golf 2004 ➤ , Golf Plus 2005 ➤ Running gear, axles, steering - Edition 08.2009 – Install securing bolt -1- and tighten. – Install steering column ⇒ page 354 – Install plenum chamber bulkhead ⇒ General body repairs, exterior; Rep. Gr. 50 ; Assembly overview - plenum chamber bulkhead .
Page 371: Electromechanical Steering Box Up To Model Year 2008
Golf 2004 ➤ , Golf Plus 2005 ➤ Running gear, axles, steering - Edition 08.2009 Electromechanical steering box up to model year 2008 Assembly overview - electromechanical steering box, left-hand drive (1st and 2nd generations) up to model year 2008 Note There are no 2nd generation steering boxes available as spare parts.
Page 372 Golf 2004 ➤ , Golf Plus 2005 ➤ Running gear, axles, steering - Edition 08.2009 7 - Subframe with brackets 8 - Bolt ❑ 50 Nm + 90° further ❑ Always renew clamp for steering box ❑ Always renew after removing 9 - Shield 10 - Bolt ❑...
Page 373: Assembly Overview - Electromechanical Steering Box, Right-Hand Drive (2Nd Generation) Up
Golf 2004 ➤ , Golf Plus 2005 ➤ Running gear, axles, steering - Edition 08.2009 Assembly overview - electromechanical steering box, right-hand drive (2nd generation) up to model year 2008 Note There are no 2nd generation steering boxes available as spare parts. ♦...
Page 374: Year 2008
Golf 2004 ➤ , Golf Plus 2005 ➤ Running gear, axles, steering - Edition 08.2009 ❑ Self-locking ❑ Always renew after removing 12 - Subframe 13 - Bolt ❑ M10 x 70 ❑ 50 Nm + 90° further ❑ Always renew after removing Removing and installing steering box, left-hand drive (1st and 2nd genera‐...
Page 375 Golf 2004 ➤ , Golf Plus 2005 ➤ Running gear, axles, steering - Edition 08.2009 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 376 Golf 2004 ➤ , Golf Plus 2005 ➤ Running gear, axles, steering - Edition 08.2009 – Press track rod ball joint off wheel bearing housing with -3287A-. – Remove lower noise insulation ⇒ Rep. Gr. 50 ; Assembly overview - noise insulation . –...
Page 377 Golf 2004 ➤ , Golf Plus 2005 ➤ Running gear, axles, steering - Edition 08.2009 – Now remove bolts -3, 6, 11 and 16- for steering box and anti- roll bar. – Fix position of subframe and brackets. ⇒ page 16 –...
Page 378 Golf 2004 ➤ , Golf Plus 2005 ➤ Running gear, axles, steering - Edition 08.2009 – Remove heat shield -1- over steering box. – Remove bolts -arrows-. – Remove cable guide from subframe -arrow-. – Unclip all remaining cable clips on steering box. –...
Page 379 Golf 2004 ➤ , Golf Plus 2005 ➤ Running gear, axles, steering - Edition 08.2009 – 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‐ Note Coat seal on steering box with suitable lubricant, e.g.
Page 380 Golf 2004 ➤ , Golf Plus 2005 ➤ Running gear, axles, steering - Edition 08.2009 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 381 Golf 2004 ➤ , Golf Plus 2005 ➤ Running gear, axles, steering - Edition 08.2009 Specified torques 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 ⇒...
Page 382: Removing And Installing Steering Box, Right-Hand Drive (2Nd Generation) Up To Model Year
Golf 2004 ➤ , Golf Plus 2005 ➤ Running gear, axles, steering - Edition 08.2009 Removing and installing steering box, right-hand drive (2nd generation) up to model year 2008 Special tools and workshop equipment required ♦ Torque wrench -V.A.G 1331- ♦...
Page 383 Golf 2004 ➤ , Golf Plus 2005 ➤ Running gear, axles, steering - Edition 08.2009 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 384 Golf 2004 ➤ , Golf Plus 2005 ➤ Running gear, axles, steering - Edition 08.2009 – Press track rod ball joint off wheel bearing housing using ball joint puller -3287A- and remove nut now. – Remove lower noise insulation ⇒ Rep. Gr. 50 ; Assembly overview - noise insulation .
Page 385 Golf 2004 ➤ , Golf Plus 2005 ➤ Running gear, axles, steering - Edition 08.2009 – Remove bolts -arrows- on 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 386 Golf 2004 ➤ , Golf Plus 2005 ➤ Running gear, axles, steering - Edition 08.2009 – 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 387 Golf 2004 ➤ , Golf Plus 2005 ➤ Running gear, axles, steering - Edition 08.2009 – Now lift anti-roll bar -1- forwards over subframe -2- and down while turning anti-roll bar slightly. – Unbolt steering box from subframe. 6. Electromechanical steering box up to model year 2008...
Page 388 Golf 2004 ➤ , Golf Plus 2005 ➤ Running gear, axles, steering - Edition 08.2009 – 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 389 Golf 2004 ➤ , Golf Plus 2005 ➤ Running gear, axles, steering - Edition 08.2009 Component Specified torque Anti-roll bar to subframe 20 Nm + 90° ♦ Use new bolts Anti-roll bar to coupling rod 65 Nm ♦ Use new nut ♦...
Page 390 Golf 2004 ➤ , Golf Plus 2005 ➤ Running gear, axles, steering - Edition 08.2009 Rep. Gr.48 - Steering...
Page 391: Electromechanical Steering Box After Model Year 2009
Golf 2004 ➤ , Golf Plus 2005 ➤ Running gear, axles, steering - Edition 08.2009 Electromechanical steering box after model year 2009 Assembly overview - electromechanical steering box, left-hand drive (3rd generation) after model year 2009 1 - Wiring 2 - Universal joint 3 - Bolt ❑...
Page 392: Assembly Overview - Electromechanical Steering Box, Right-Hand Drive (3Rd Generation) After
Golf 2004 ➤ , Golf Plus 2005 ➤ Running gear, axles, steering - Edition 08.2009 Assembly overview - electromechanical steering box, right-hand drive (3rd generation) after model year 2009 1 - Universal joint 2 - Bolt ❑ M8 x 35 ❑...
Page 393: Removing And Installing Steering Box, Left-Hand Drive (3Rd Generation) After Model Year
Golf 2004 ➤ , Golf Plus 2005 ➤ Running gear, axles, steering - Edition 08.2009 Removing and installing steering box, left-hand drive (3rd generation) after model year 2009 Special tools and workshop equipment required ♦ Torque wrench -V.A.G 1331- ♦ Torque wrench -V.A.G 1332- ♦...
Page 394 Golf 2004 ➤ , Golf Plus 2005 ➤ Running gear, axles, steering - Edition 08.2009 – 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‐ Caution Leave nut screwed a few turns onto pin to protect thread.
Page 395 Golf 2004 ➤ , Golf Plus 2005 ➤ Running gear, axles, steering - Edition 08.2009 – Remove bolts -3- and -6- for steering box. – Remove bolts -11- and -16- for anti-roll bar. – Fix position of subframe and brackets. ⇒...
Page 396 Golf 2004 ➤ , Golf Plus 2005 ➤ Running gear, axles, steering - Edition 08.2009 – Remove bolts -4 and 5- and lower subframe with brackets slightly, observing electrical wires. – Remove heat shield -1- over steering box. – Remove bolts -arrows-. –...
Page 397 Golf 2004 ➤ , Golf Plus 2005 ➤ Running gear, axles, steering - Edition 08.2009 – 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‐ Note Coat seal on steering box with suitable lubricant, e.g.
Page 398 Golf 2004 ➤ , Golf Plus 2005 ➤ Running gear, axles, steering - Edition 08.2009 Component Specified torque Anti-roll bar to subframe 20 Nm + 90° ♦ Use new bolts Anti-roll bar to coupling rod 65 Nm ♦ Use new nut ♦...
Page 399: Removing And Installing Steering Box, Right-Hand Drive (3Rd Generation) After Model Year
Golf 2004 ➤ , Golf Plus 2005 ➤ Running gear, axles, steering - Edition 08.2009 Removing and installing steering box, right-hand drive (3rd generation) after model year 2009 Special tools and workshop equipment required ♦ Torque wrench -V.A.G 1331- ♦ Torque wrench -V.A.G 1332- ♦...
Page 400 Golf 2004 ➤ , Golf Plus 2005 ➤ Running gear, axles, steering - Edition 08.2009 – 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‐ Caution Leave nut screwed a few turns onto pin to protect thread.
Page 401 Golf 2004 ➤ , Golf Plus 2005 ➤ Running gear, axles, steering - Edition 08.2009 – Detach exhaust system bracket from subframe -arrows-. Vehicles with front-wheel drive – Remove bolts -arrows- on heat shield. – Remove heat shield from subframe. Continuation for all vehicles –...
Page 402 Golf 2004 ➤ , Golf Plus 2005 ➤ Running gear, axles, steering - Edition 08.2009 – 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 403 Golf 2004 ➤ , Golf Plus 2005 ➤ Running gear, axles, steering - Edition 08.2009 – Remove heat shield -1- over steering box. – Remove bolts -arrows-. – Remove cable guide from subframe -arrow-. – Unclip all remaining cable clips on steering box. –...
Page 404 Golf 2004 ➤ , Golf Plus 2005 ➤ Running gear, axles, steering - Edition 08.2009 – 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 405 Golf 2004 ➤ , Golf Plus 2005 ➤ Running gear, axles, steering - Edition 08.2009 Component Specified torque Anti-roll bar to subframe 20 Nm + 90° ♦ Use new bolts Anti-roll bar to coupling rod 65 Nm ♦ Use new nut ♦...
Page 406: Distinguishing Between Steering Boxes (1St And 2Nd Generations), Golf
Golf 2004 ➤ , Golf Plus 2005 ➤ Running gear, axles, steering - Edition 08.2009 Distinguishing between steering box‐ es (1st and 2nd generations), Golf At the start of production of the Golf 2004 ▸, the 1st generation steering box was fitted. During the 2004 model year, this was re‐ placed with the 2nd generation steering box.
Page 407: Differentiating Between 2Nd And 3Rd Generation Steering Boxes
Golf 2004 ➤ , Golf Plus 2005 ➤ Running gear, axles, steering - Edition 08.2009 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.
Page 408: Exchanging 1St Generation Steering Box For 2Nd Generation Steering Box, Golf
Golf 2004 ➤ , Golf Plus 2005 ➤ Running gear, axles, steering - Edition 08.2009 Exchanging 1st generation steering box for 2nd generation steering box, Golf Note There are no new 1st generation steering boxes available as ♦ parts for renewing 1st generation steering boxes. Therefore, 2nd generation steering boxes must be fitted.
Page 409: Repairing Electromechanical Steering Box (1St Generation), Golf
Golf 2004 ➤ , Golf Plus 2005 ➤ Running gear, axles, steering - Edition 08.2009 Repairing electromechanical steer‐ ing box (1st generation), Golf At present, there is no provision for performing repairs on the steering box (1st generation). 11.1 Removing and installing boot Special tools and workshop equipment required ♦...
Page 410 Golf 2004 ➤ , Golf Plus 2005 ➤ Running gear, axles, steering - Edition 08.2009 No dirt must enter the steering box through the damaged boot during this work. – Mark position of nut -3- on steering rack. – Loosen nut -3- while counterholding on head of track rod -2-. –...
Page 411: Removing And Installing Track Rod
Golf 2004 ➤ , Golf Plus 2005 ➤ Running gear, axles, steering - Edition 08.2009 – Install new clamp, as shown in figure, with locking pliers for Phaeton steering box -VAS 6199- . Continue installation in reverse order. – Install wheel and tighten. ⇒...
Page 412 Golf 2004 ➤ , Golf Plus 2005 ➤ Running gear, axles, steering - Edition 08.2009 Removing track rod – Turn steering wheel to straight-ahead position. – Clean outside of steering box in vicinity of boot. Loosen nut -3-, counterholding on track rod ball joint -2-. –...
Page 413 Golf 2004 ➤ , Golf Plus 2005 ➤ Running gear, axles, steering - Edition 08.2009 – Screw track rod into track rod ball joint until dimension -a- is attained. Dimension -a- = 371 ± 1 mm – Screw track rod into steering rack and tighten. –...
Page 414: Repairing Electromechanical Steering Box (2Nd And 3Rd Generations)
Golf 2004 ➤ , Golf Plus 2005 ➤ Running gear, axles, steering - Edition 08.2009 Repairing electromechanical steer‐ ing box (2nd and 3rd generations) At present, there is no provision for performing repairs on the steering box (2nd and 3rd generations). 12.1 Removing and installing boot Special tools and workshop...
Page 415 Golf 2004 ➤ , Golf Plus 2005 ➤ Running gear, axles, steering - Edition 08.2009 No dirt must enter the steering box through the damaged boot during this work. – Mark position of nut -3- on steering rack. – Loosen nut -3- while counterholding on head of track rod -2-. –...
Page 416: Removing And Installing Track Rod
Golf 2004 ➤ , Golf Plus 2005 ➤ Running gear, axles, steering - Edition 08.2009 – Install new clamp, as shown in figure, with locking pliers for Phaeton steering box -VAS 6199- . Continue installation in reverse order. Specified torque for fitting wheels ⇒...
Page 417 Golf 2004 ➤ , Golf Plus 2005 ➤ Running gear, axles, steering - Edition 08.2009 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-. –...
Page 418 Golf 2004 ➤ , Golf Plus 2005 ➤ Running gear, axles, steering - Edition 08.2009 – 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.

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