Volkswagen Golf / Golf GTI / Golf Variant. Manual — part 805
Note
Only in the rarest of cases shock absorbers are the fault for
noises.
3.3
Shock Absorbers, Checking when Re‐
moved
Defective shock absorbers are noticeable when driving due to
loud rumbling noises - a result of wheel hopping - especially on
poor stretches of road. Moreover, they can be recognized by a
large loss of oil.
Note
Shock absorbers are maintenance-free, shock absorber oil can‐
not be topped off.
A removed shock absorber can be checked by hand as follows:
– Push the shock absorber together by hand.
• Piston rod must move with even resistance throughout entire
stroke and without jerking.
– Release piston rods.
• For shock absorbers with sufficient gas pressure, piston rod
returns to initial position automatically.
Note
♦
If this is not the case, the shock absorber must be replaced.
As long as there is no large loss of oil, the mode of operation
corresponds to that of a conventional shock absorber.
♦
The damping function is also completely available without gas
pressure, as long as there is no large loss of oil. However,
noise may increase.
3.4
Steering Gear
To perform a problem-free and successful steering gear repair,
extreme caution and cleanliness, as well as properly functioning
tools are an important requirement. Understandably, general
safety guidelines apply when performing repairs.
A series of applicable general notes for individual repair proce‐
dures - otherwise listed several times at many points in the repair
manual - has been collected here. They apply for this repair man‐
ual.
♦ Thoroughly clean connecting points and their surrounding
areas before loosening.
♦ When installing steering gear, make sure centering sleeves
are correctly seated between console and steering gear.
♦ Place removed parts on a clean surface and cover to prevent
contamination. Use foils and paper. Only use lint-free cloths!
♦ Install clean parts only: remove the replacement part from its
packaging just before installing it.
♦ Use exclusively lubricants and sealants marked with part num‐
bers.
♦ Carefully cover or seal open components, if repairs are not
carried out immediately.
3.5
Seals, Sealing Rings
♦ Always replace the gaskets and seals.
♦ After removing seals, inspect contact surface on housings and
shafts for burrs and damage and repair if necessary.
♦ Remove all residual sealant of fluid seals from sealing surfa‐
ces, no sealant residue must enter the steering gear housing
when doing this.
3.6
Bolts and Nuts
♦ Loosen and tighten the bolt and nut from the covers and hous‐
ings diagonally.
♦ Do not cant but loosen and tighten especially sensitive parts
in diagonal manner in stages, for example servo motor with
control module.
♦ Tightening specifications for non-lubricated bolts and nuts are
given.
♦ Always replace self-locking nuts and bolts.
3.7
Electrical Components
Surely everyone has been shocked at one time or another when
coming into contact with a metal object. The reason for this is the
build-up of static electricity in the human body. This charge can
lead to malfunctions by touching the electrical components of
steering gear and steering column.
– Touch a grounded object, for example a water pipe or a vehicle
hoist, before working on electrical components. Do not make
direct contact on connector terminals.
3.8
Wheel Bearing in Curb Weight, Lifting
Vehicles with Coil Spring
⇒ “3.8.1 Wheel Bearing in Curb Weight, Lifting Vehicles with Coil
Spring, Front Axle”, page 6
⇒ “3.8.2 Wheel Bearing in Curb Weight, Rear Axle, Lifting Vehi‐
cles with Coil Spring”, page 8
3.8.1
Wheel Bearing in Curb Weight, Lifting
Vehicles with Coil Spring, Front Axle
Special tools and workshop equipment required
♦ Engine and Gearbox Jack - VAS6931-
♦ Tensioning Strap - T10038-
♦ Engine/Gearbox Jack Adapter - Wheel Hub Support - T10149-
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 appropriate suspension using Engine and Gearbox
Jack - VAS6931- and Engine/Gearbox Jack Adapter - Wheel Hub
Support - T10149- , this position can be simulated on the hoist.
Note
Before appropriate suspension is raised, vehicle must be strap‐
ped to lift arms of hoist using 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 on wheel hub.
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+2UA/G02+2UA/
G07+2UA/G18/G22)
383 ± 10 mm
Sport (G01+2UC+GM1/G01
+2UP/G02+2UC+GM1/G07
+2UC/G21/G26)
368 ± 10 mm
Raised (G01+2UF/G02+2UF/
G24/G25/G27)
398 ± 10 mm
DCC (G03+2UQ/G03+2UH)
373 ± 10 mm
GTI (G06+2UC/G06+2UC
+GM1+A8H/G06+2UC+GM3
+A8G/G06+2UJ/G04+2UM/
G29)
368 ± 10 mm
GTI heavy duty suspension
(G06+2UN)
383 ± 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 and Gearbox
Jack - VAS6931- 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 and Gearbox Jack - VAS6931-
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 Engine/Gearbox Jack Adapter - Wheel Hub Support
- T10149- .
3.8.2
Wheel Bearing in Curb Weight, Rear
Axle, Lifting Vehicles with Coil Spring
Special tools and workshop equipment required
♦ Engine and Gearbox Jack - VAS6931-
♦ Tensioning Strap - T10038-
♦ Engine/Gearbox Jack Adapter - Wheel Hub Support - T10149-
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