Volkswagen Golf / Golf GTI / Golf Variant. Manual — part 806
Caution
All bolts at suspension parts with bonded rubber bushings must
always be tightened in curb weight position (unloaded condi‐
tion).
Bonded rubber bushings have a limited range of motion.
Axle components with bonded rubber bushings must be
brought into the position they will be in during driving before
tightening (curb weight position).
Otherwise, the bonded rubber bushing will be stressed result‐
ing in a shortened service life.
By raising the axle on one side using the Engine and Gearbox
Jack - VAS6931- and Engine/Gearbox Jack Adapter - Wheel Hub
Support - T10149- , this position can be simulated on the hoist.
Note
Before lifting the axle on one side, the vehicle must be secured
on both sides to the lift arms of the lift using Tensioning Strap -
T10038- .
1 - Tensioning Strap - T10038-
WARNING
The vehicle could fall off the hoist if it is not secured.
– Turn the wheel hub until one of the holes for the wheel bolts
is on top.
– Install Engine/Gearbox Jack Adapter - Wheel Hub Support -
T10149- with wheel bolt.
Note
Tightening of the respective bolts/nuts must then only occur after
dimension -a- between the wheel hub center and the lower edge
of wheel housing has been attained.
Dimension -a- is dependent on standing height of installed sus‐
pension:
Chassis
1)
Standing Height -a- in mm
Basic (G01/G02/G07/G18/G22
+2UA)
385 ± 10 mm
Sport (G01/G02/G07 +2UC,
G21)
370 ± 10 mm
Raised (G01/G02 +2UF)
400 ± 10 mm
DCC (G03)
375 ± 10 mm
GTI (G06+2UC/ G06 + 2UJ/
G04 + 2UM)
370 ± 10 mm
GTI heavy duty suspension
(G06 + 2UN)
385 ± 10 mm
1)
The suspension that the vehicle is equipped with is indicated
on the vehicle data plate. The suspension is indicated by a PR
number. Allocation of the PR number according to the suspen‐
sion.
– Lift the wheel bearing housing using the engine/gearbox jack
until dimension -a- is reached.
WARNING
♦ Do not lift or lower the vehicle when the Engine and Gear‐
box Jack - VAS6931- is below the vehicle.
♦ Do not leave the engine/gearbox jack under the vehicle
any longer than necessary.
– Tighten the bolts and nuts.
– Lower the wheel bearing housing.
– Remove the Engine and Gearbox Jack - VAS6931- from under
the vehicle.
– Remove the Engine/Gearbox Jack Adapter - Wheel Hub Sup‐
port - T10149-
4
Disposal
⇒ “4.1 Front Shock Absorbers, Venting and Emptying”,
page 11
⇒ “4.2 Rear Shock Absorbers, Venting and Emptying”,
4.1
Front Shock Absorbers, Venting and
Emptying
⇒ “4.1.1 Front Shock Absorbers, Venting and Emptying, Standard
Shock Absorber”, page 11
⇒ “4.1.2 Front Shock Absorbers, Venting and Emptying, DCC
4.1.1
Front Shock Absorbers, Venting and
Emptying, Standard Shock Absorber
– Secure the gas-filled shock absorber vertically in vise, with
piston rod facing down.
WARNING
Wear protective eyewear while drilling.
– Drill a 3 mm hole -A- through the shock absorber outer tube.
Note
Gas escapes when drilling.
– Continue drilling until the tube inside is drilled through (ap‐
proximately 25 mm deep).
– Drill a second 6 mm hole -B- through the outer and inner shock
absorber tubes.
– Hold the shock absorber over an appropriate container for
catching oil and move the piston rod repeatedly through the
entire stroke until no more oil flows out.
4.1.2
Front Shock Absorbers, Venting and
Emptying, DCC Shock Absorber
– Tension the gas-filled shock absorber vertically in the vise.
WARNING
Wear protective eyewear while drilling.
– Drill a 3 mm hole -A- through the shock absorber outer tube.
Note
Gas escapes when drilling.
– Continue drilling until the tube inside is drilled through (ap‐
proximately 25 mm deep).
– Drill a second 6 mm hole -B- through the outer and inner shock
absorber tubes.
– Hold the shock absorber over an appropriate container for
catching oil and move the piston rod repeatedly through the
entire stroke until no more oil flows out.
4.2
Rear Shock Absorbers, Venting and
Emptying
⇒ “4.2.1 Rear Shock Absorbers, Venting and Emptying, Standard
Shock Absorber”, page 12
⇒ “4.2.2 Rear Shock Absorbers, Venting and Emptying, DCC
4.2.1
Rear Shock Absorbers, Venting and
Emptying, Standard Shock Absorber
– Tension the gas-filled shock absorber vertically in the vise.
WARNING
Wear protective eyewear while drilling.
– Drill a 3 mm hole -A- through the shock absorber outer tube.
Note
Gas escapes when drilling.
– Continue drilling until the tube inside is drilled through (ap‐
proximately 25 mm deep).
– Drill a second 6 mm hole -B- through the outer and inner shock
absorber tubes.
– Hold the shock absorber over an appropriate container for
catching oil and move the piston rod repeatedly through the
entire stroke until no more oil flows out.
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