Volkswagen Golf / Golf GTI / Golf Variant. Service 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-