VW Golf Mk5 2004 & Golf Plus Mk5 2005 - Running gear, axles, steering - Workshop Manual

1 Checklist for evaluating running gear of accident vehicles......Page 9
2 General information......Page 11
1 Appraisal of accident vehicles......Page 12
2.1 Overview - front axle......Page 13
2.2 Raising wheel suspension to unladen position, Golf......Page 14
2.3 Raising wheel suspension to unladen position, Golf Plus, CrossGolf......Page 16
3.1 Assembly overview: subframe, anti-roll bar, suspension links......Page 18
3.2 Assembly overview - front left vehicle level sender -G78-......Page 22
3.3 Removing and installing front left vehicle level sender -G78-......Page 23
3.5 Fixing position of subframe and brackets......Page 24
3.6 Lowering subframe......Page 25
3.7 Removing and installing subframe without steering box......Page 29
3.8 Removing and installing subframe with steering box......Page 31
3.9 Repairing subframe (front-wheel drive)......Page 36
3.10 Repairing subframe (four-wheel drive)......Page 39
3.11 Checking swivel joint......Page 41
3.12 Removing and installing swivel joint......Page 42
3.13 Removing and installing suspension link with mounting bracket......Page 44
3.14 Removing and installing suspension link with mounting bracket (left side for vehicles with DSG or automatic gearboxes)......Page 47
3.15 Removing and installing suspension link with mounting bracket (right side for vehicles with 6-cylinder engines)......Page 51
3.16 Renewing bonded rubber bush for suspension link......Page 55
3.17 Renewing mounting bracket with suspension link bush......Page 57
3.18 Removing and installing anti-roll bar......Page 59
4 Assembly overview - wheel bearing......Page 64
4.1 Removing and installing wheel bearing housing (3-point mounting)......Page 65
4.2 Removing and installing wheel bearing housing (4-point mounting)......Page 66
4.3 Removing and installing wheel bearing housing......Page 68
5 Assembly overview: suspension strut......Page 72
5.1 Removing and installing suspension strut, Golf......Page 73
5.2 Removing and installing suspension strut, Golf Plus, CrossGolf......Page 78
5.3 Repairing suspension strut......Page 83
6.1 Loosening and tightening drive shaft hexagon bolt......Page 85
6.2 Loosening and tightening 12-point flange bolt securing drive shaft......Page 86
6.3 Removing and installing drive shaft with constant velocity joint......Page 87
6.4 Removing and installing left drive shaft with (push-on) constant velocity slip joint......Page 89
6.5 Removing and installing right drive shaft with (push-on) constant velocity slip joint......Page 93
6.6 Removing and installing drive shafts with triple roller joint AAR2600i......Page 96
6.7 Removing and installing drive shafts with triple roller joint AAR3300i......Page 98
6.8 Removing and installing intermediate shaft......Page 100
7 Repairing drive shaft - overview of drive shafts......Page 102
7.1 Heat shields for drive shafts......Page 104
8 Assembly overview - drive shaft with VL90 or VL100 constant velocity joint......Page 105
8.1 Dismantling and assembling drive shaft with VL90 or VL100 constant velocity joint......Page 107
8.2 Checking outer constant velocity joint......Page 111
8.3 Checking inner constant velocity joint......Page 112
9 Assembly overview - drive shaft with VL107 constant velocity joint (bolt-on)......Page 115
9.1 Dismantling and assembling drive shaft with VL107 constant velocity joint......Page 117
9.2 Repairing intermediate shaft......Page 122
10 Assembly overview - drive shaft with VL107 constant velocity slip joint (push-on)......Page 124
10.1 Dismantling and assembling drive shaft with VL107 (push-on) constant velocity slip joint......Page 125
10.2 Checking outer constant velocity joint......Page 127
11 Assembly overview - drive shaft with triple roller joint AAR2600i......Page 129
11.1 Dismantling and assembling drive shaft with triple roller joint AAR2600i......Page 130
12 Assembly overview - drive shaft with triple roller joint AAR3300i......Page 135
12.1 Dismantling and assembling drive shaft with triple roller joint AAR3300i......Page 137
1 Appraisal of accident vehicles......Page 142
2.1 Overview - rear axle......Page 143
2.2 Rear axle in unladen position, Golf......Page 144
2.3 Rear axle in unladen position, Golf Plus, CrossGolf......Page 146
3 Assembly overview: subframe, transverse link, track rod (front-wheel drive)......Page 148
3.1 Removing and installing rear axle......Page 151
3.3 Renew vehicle level sender in vehicle......Page 156
3.4 Removing and installing upper transverse link......Page 157
3.5 Removing and installing lower transverse link......Page 159
3.6 Removing and installing track rod......Page 160
4 Assembly overview: wheel bearing housing, trailing arm (front-wheel drive)......Page 164
4.1 Removing and installing wheel bearing housing......Page 165
4.2 Renewing bonded rubber bush for wheel bearing housing......Page 169
4.3 Removing and installing wheel bearing/wheel hub unit......Page 172
4.4 Removing and installing trailing arm with mounting bracket......Page 174
4.5 Repairing trailing arm......Page 178
5.1 Removing and installing coil spring......Page 181
5.2 Removing and installing shock absorbers......Page 183
5.3 Repairing shock absorber......Page 185
6.1 Removing and installing anti-roll bar......Page 187
7 Assembly overview - attachment parts for subframe Golf BlueMotion, Golf Plus BlueMotion (front-wheel drive)......Page 190
8.1 Overview of rear axle (aluminium)......Page 191
8.2 Overview of rear axle (steel)......Page 193
8.3 Rear axle in unladen state (aluminium and steel)......Page 195
9.1 Removing and installing rear axle......Page 197
9.2 Repairing subframe......Page 203
10.1 Removing and installing rear axle......Page 207
10.2 Repairing subframe......Page 213
11 Assembly overview - control arm, track rod (four-wheel drive, subframe made from aluminium and wheel bearing housing made from cast steel)......Page 220
11.1 Overview - rear left vehicle level sender -G76-......Page 222
11.3 Removing and installing upper transverse link......Page 223
11.4 Removing and installing lower transverse link......Page 225
11.5 Removing and installing track rod......Page 227
12 Assembly overview - control arm, track rod (four-wheel drive, subframe made from steel and wheel bearing housing made from aluminium)......Page 231
12.2 Renew vehicle level sender in vehicle......Page 234
12.3 Removing and installing upper transverse link......Page 235
12.4 Removing and installing lower transverse link......Page 237
12.5 Removing and installing track rod......Page 239
13 Assembly overview - wheel bearing housing, trailing link (four-wheel drive, subframe made from aluminium and wheel bearing housing made from cast steel)......Page 242
13.1 Changing from wheel housing bearing made from cast steel to wheel bearing housing made from aluminium......Page 243
13.2 Removing and installing wheel bearing housing......Page 244
13.3 Renewing bonded rubber bush for wheel bearing housing......Page 248
13.4 Removing and installing wheel bearing/wheel hub unit......Page 250
13.5 Removing and installing trailing arm with mounting bracket......Page 251
13.6 Repairing trailing arm......Page 256
14 Assembly overview - wheel bearing housing, trailing link (four-wheel drive, subframe made from steel and wheel bearing housing made from aluminium)......Page 259
14.1 Removing and installing wheel bearing housing......Page 260
14.3 Removing and installing wheel bearing/wheel hub unit......Page 263
15.1 Removing and installing coil spring......Page 265
15.2 Removing and installing shock absorbers......Page 267
15.3 Repairing shock absorber......Page 268
16.2 Removing and installing shock absorbers......Page 270
16.3 Repairing shock absorber......Page 272
17.1 Removing and installing anti-roll bar......Page 273
18.1 Removing and installing anti-roll bar......Page 277
19 Assembly overview - drive shaft......Page 281
19.1 Loosening and tightening drive shaft hexagon bolt......Page 282
19.2 Loosening and tightening 12-point bolt for drive shaft......Page 283
19.3 Removing and installing drive shaft......Page 284
19.4 Dismantling and assembling drive shaft......Page 286
19.5 Checking outer constant velocity joint......Page 291
19.6 Checking inner constant velocity joint......Page 292
1 Appraisal of accident vehicles......Page 295
2 Torque settings for wheel bolts......Page 296
3.1 General information......Page 297
4.2 Wheel change......Page 298
4.3 Pressing tyre off wheel rim......Page 299
4.5 Fitting tyre to wheel rim......Page 300
5.2 Installation conditions......Page 302
5.4 Removing tyre from wheel......Page 304
5.5 Fitting tyre to wheel rim......Page 306
6 Tyre monitor display......Page 308
7.1 Button behaviour......Page 310
7.2 Assembly overview - tyre pressure sensor......Page 311
7.3 Removing and installing tyre pressure sensor......Page 312
8.1 General......Page 313
8.3 Test preparations......Page 315
8.4 Wheel alignment specifications, Golf......Page 316
8.5 Wheel alignment specifications, Golf Plus, CrossGolf......Page 317
8.6 Overview - wheel alignment procedure......Page 319
8.7 Correcting front axle camber......Page 320
8.8 Adjusting camber on rear axle......Page 322
8.9 Adjusting toe at rear axle......Page 323
8.10 Adjusting front axle toe......Page 324
8.12 Vehicle data sticker......Page 325
9.3 Removing a tyre......Page 326
9.6 Alloy wheels with metal valves......Page 327
10 Instructions for changing or fitting wheels......Page 329
10.1 Fitting wheels......Page 330
11 Protecting wheel centring seat against corrosion......Page 331
12.2 Balancing wheels......Page 332
12.4 Balancing wheels on stationary wheel balancing machine......Page 333
12.6 Finish balancer......Page 335
12.8 Checking radial and lateral runout on wheels and tyres with tyre gauge -V.A.G 1435-......Page 336
12.9 Checking radial and lateral runout on wheel......Page 337
12.10 Matching......Page 338
12.11 Flat spots caused by storage or handling......Page 339
1 Appraisal of accident vehicles......Page 341
2.3 Nuts and bolts......Page 342
2.5 Guided fault-finding, vehicle self-diagnosis and test instruments......Page 343
3.1 Removing and installing steering wheel......Page 344
4.2 Removing and installing steering column......Page 347
4.4 Handling and transporting steering column......Page 353
4.6 Removing and installing mounting bracket......Page 354
4.7 Removing and installing strut......Page 356
5.2 Removing and installing steering column......Page 359
5.4 Handling and transporting steering column......Page 365
5.6 Removing and installing mounting bracket......Page 366
5.7 Removing and installing strut......Page 368
6.1 Assembly overview - electromechanical steering box, left-hand drive (1st and 2nd generations) up to model year 2008......Page 371
6.2 Assembly overview - electromechanical steering box, right-hand drive (2nd generation) up to model year 2008......Page 373
6.3 Removing and installing steering box, left-hand drive (1st and 2nd generations) up to model year 2008......Page 374
6.4 Removing and installing steering box, right-hand drive (2nd generation) up to model year 2008......Page 382
7.1 Assembly overview - electromechanical steering box, left-hand drive (3rd generation) after model year 2009......Page 391
7.2 Assembly overview - electromechanical steering box, right-hand drive (3rd generation) after model year 2009......Page 392
7.3 Removing and installing steering box, left-hand drive (3rd generation) after model year 2009......Page 393
7.4 Removing and installing steering box, right-hand drive (3rd generation) after model year 2009......Page 399
8 Distinguishing between steering boxes (1st and 2nd generations), Golf......Page 406
9 Differentiating between 2nd and 3rd generation steering boxes......Page 407
10 Exchanging 1st generation steering box for 2nd generation steering box, Golf......Page 408
11.1 Removing and installing boot......Page 409
11.2 Removing and installing track rod......Page 411
12.1 Removing and installing boot......Page 414
12.2 Removing and installing track rod......Page 416