Volkswagen Golf / Golf GTI / Golf Variant. Manual — part 804

00 – Technical Data

1

Evaluating Vehicles in Collisions

(Edition 03.2016)

⇒ “1.1 Collision Vehicle Evaluation Checklist”, page 1

1.1

Collision Vehicle Evaluation Checklist

When servicing load-bearing or wheel-supporting components on

accident vehicles, damages on suspension could remain undis‐

covered. These undiscovered damages may lead to heavy dam‐

ages in continued vehicle operation. Therefore, on accident

vehicles, the listed components must be checked in the described

manner and sequence, independent of performing an axle align‐

ment. If no deviations from the specified values were determined

during an axle alignment, then no deformations of the chassis are

present.
Visual and Function Check of Steering System
♦ Visual check for deformations and cracks
♦ Check for play in tie rod joints and steering gear
♦ Visual inspection for faulty boots and grease boots
♦ Check electric and hydraulic lines and hoses for chafe marks,

cuts and kinks.

♦ Check of hydraulic lines, threaded connections and steering

gear for proper seal

♦ Make sure the steering gear and lines are securely fastened.
♦ Check proper function through entire steering angle by turning

steering wheel from stop to stop. Steering wheel must be ro‐

tary without hitching at equal force.

Visual and Function Check of Suspension
• Observe the sequence of the following test steps!
♦ Check all components shown in assembly overviews for de‐

formation, cracks and other damages

♦ Replace damaged components
♦ Perform a vehicle alignment on a Volkswagen AG approved

alignment rack.

Visual and Function Check for Wheels, Tires
♦ Check for run-out and imbalance.
♦ Check tires for cuts and impact damage on tread and flanks.
♦ Check the tire pressure. Refer to the tire pressure label on the

driver side B-pillar or on the fuel filler door for the correct tire

pressure.

Replace the tire if the wheel rim and/or the tire are damaged. This

also applies when the course of the accident and damage on the

vehicle points to possible non-visible damages.
Another criteria is the age of the tires: the tires must not be older

than 6 years.
If in Doubt
• As soon as a safety risk cannot be ruled out, the tire(s) must

be replaced.

Entire Vehicle
Check other vehicle systems, for example:
♦ Brake system including ABS
♦ Exhaust system and passenger protection by visual and func‐

tion check

Test values, adjustment values and notes can be found in re‐

spective repair manuals/ELSA.
Checking of accident vehicles described here, refers to suspen‐

sion and does not lay claim to completeness for entire vehicle.
Electronic Vehicle Systems
Safety related systems, such as: ABS/EDS; Airbag; electronically

controlled suspension systems; electromechanical; electrohy‐

draulic steering and other driver assist systems, must be checked

for possible stored fault messages using the Vehicle Diagnostic

Tester . If a fault is stored in the Diagnostic Trouble Code (DTC)

memory, then perform the corresponding repair in the repair man‐

ual/ELSA. After the repair the corresponding system must be

checked again for stored faults to be sure that the function is es‐

tablished again.

2

Safety Precautions

⇒ “2.1 Start/Stop System Safety Precautions”, page 3
⇒ “2.2 Subframe Safety Precautions”, page 3

2.1

Start/Stop System Safety Precautions

WARNING

If vehicle will be driven on the streets, all bolts and nuts must

be tightened properly!

WARNING

Risk of injury due to the engine automatically starting on vehi‐

cles with a Start/Stop system.

♦ For vehicles with an active start/stop system, the engine

can automatically start if necessary.

♦ Make sure the start/stop system is off whenever working

on the vehicle. Turn off the ignition and turn it back on only

when necessary.

2.2

Subframe Safety Precautions

♦ Welding and straightening work on supporting or wheel car‐

rying components of the suspension is not permitted.

♦ Always replace corroded bolts/nuts.
♦ Bonded rubber bushings can only be turned to a limited extent.

Therefore, the threaded connections of the components with

bonded rubber bushings should only be tightened when the

wheel bearing housing is lifted (curb weight position). Refer to

⇒ “3.8.1 Wheel Bearing in Curb Weight, Lifting Vehicles with

Coil Spring, Front Axle”, page 6

.

3

Repair Information

⇒ “3.1 Shock Absorber Leaks”, page 4
⇒ “3.2 Shock Absorber Noises”, page 4
⇒ “3.3 Shock Absorbers, Checking when Removed”, page 5
⇒ “3.4 Steering Gear”, page 5
⇒ “3.5 Seals, Sealing Rings”, page 6
⇒ “3.6 Bolts and Nuts”, page 6
⇒ “3.7 Electrical Components”, page 6
⇒ “3.8 Wheel Bearing in Curb Weight, Lifting Vehicles with Coil

Spring”, page 6

3.1

Shock Absorber Leaks

Shock absorbers are frequently rejected and exchanged because

of leaks. Examinations on the test stand and on the vehicle have

shown that the replacement of a large number of rejected shock

absorbers was not justified.
Slight leaking of oil (“sweating”) at piston rod seal is no reason to

replace a shock absorber. A shock absorber damp with oil is OK

under the following circumstances:
♦ Oil leakage (shaded in illustration) is visible, but dull, matte

and possibly dry due to dust.

♦ Oil excretion extends from upper shock absorber connection

(piston rod oil seal) no further than lower spring plate -arrow-

3.2

Shock Absorber Noises

Shock absorbers are frequently rejected and exchanged because

of rumbling noises. Examinations on the test stand and vehicle

have shown that there was not complaint with approximately 70%

of the rejected shock absorbers and the replacement was not

justified.
With complaints that are interpreted as rumbling or knocking

sounds, proceed as follows.
– Determine where, when and how the sounds change during a

road test on a dry stretch of road with irregularities.