Removing and installing suspension strut, suspension strut secured with clamp — VW

Removing and installing suspension strut, suspension strut secured with clamp
(For vehicles to 3000 kg gross vehicle weight rating)
Special tools and workshop equipment required
Spreader
3424
Shock absorber set
T10001
Adapter
T10103/1
Bolts
T10103/2
Ball joint puller
T10187
Retainer
T10149
Remover
T10520
Torque wrench
V.A.G 1331
Torque wrench
V.A.G 1332
Engine and gearbox jack
VAS 6931
or
engine and gearbox jack
V.A.G 1383 A
Removing
Remove plenum chamber bulkhead
General body repairs, exterior
Rep. gr.
50
Bulkhead; Assembly overview - plenum chamber bulkhead
.
Loosen nut for drive shaft
Chapter
.
Caution
Wheel bearings must not be subjected to load after bolt securing drive shaft to wheel hub has been loosened.
If wheel bearings are loaded with weight of vehicle, bearing will be damaged. This reduces the service life of the wheel bearing.
It is not permissible to loosen drive shaft bolt more than 90° if vehicle is standing on its wheels.
Do not attempt to move the vehicle without the drive shafts fitted as this would damage the wheel bearing. If a vehicle nevertheless has to be moved, comply with the following:
Install an outer joint instead of the drive shaft.
Tighten outer joint to 120 Nm.
Loosen wheel bolts.
Raise vehicle
Maintenance
Booklet
20.1
Description of work; Raising vehicle with lifting platform and trolley jack
.
Remove wheel.
Unbolt coupling rod
1
from suspension strut.
Swing coupling rod towards rear.
Press brake line out of retainer on suspension strut.
Pull off electrical connector for
front left brake pad wear sender
G34
/
rear right brake pad wear sender
G37
Brake system
Rep. gr.
46
Front brake; Assembly overview - front brake
.
Pull off electrical connector for
front right speed sensor
G45
/
front left speed sensor
G47
Brake system
Rep. gr.
45
Sensors; Removing and installing speed sensors on front axle
G45
/
G47
.
Push wire for
front left brake pad wear sender
G34
/
rear right brake pad wear sender
G37
out of retainer on suspension strut.
Push wire for
front right speed sensor
G45
/
front left speed sensor
G47
out of retainer on suspension strut.
Remove brake caliper
Brake system
Rep. gr.
46
Front brake; Removing and installing brake caliper
.
Secure brake caliper to vehicle with wire.
Note
Observe the following procedure to prevent damage to the drive shaft caused by overstretching.
Turn wheel hub until one of the wheel bolt holes is at the top.
Attach
support
T10149
to wheel hub using wheel bolt.
Support wheel bearing housing using
engine and gearbox jack
V.A.G 1383 A
.
WARNING
Never raise or lower the vehicle while the engine and gearbox jack is positioned beneath the vehicle.
Do not leave the
engine and gearbox jack
VAS 6931
or
engine and gearbox jack
V.A.G 1383 A
under the vehicle longer than necessary.
Vehicles with left/right vehicle level sender
Unscrew nut
1
.
Pull
front left vehicle level sender
G78
/
front right vehicle level sender
G289
2
out of suspension link
3
.
Continuation for all vehicles
Loosen nut
1
on swivel joint but do not remove it completely.
Caution
Leave nut screwed on a few turns to protect thread on pin.
Press suspension link off swivel joint using
ball joint puller
T10187
2
.
Unscrew nut
1
.
Pull suspension link off swivel joint.
Before using
press tool
T10520
ensure that thrust piece
1
is inserted.
Using
press tool
T10520
:
Use
bolts
T10103/2
to secure
adapter
T 10103/1
1
to wheel bearing.
To allow for pressing out drive shaft
3
, secure
press tool
T10520
2
to wheel hub using 3 wheel bolts
3
.
It is essential to follow specified sequence.
I
Tighten knurled nut
1
hand-tight.
II
Turn only bolt
2
using a spanner in order to press out drive shaft with
press tool
T10520
.
Note
At the end of the procedure or for pressing out drive shaft further the spindle must be moved to its original position in order to deploy the hydraulic force!
Secure drive shaft to body with wire.
Loosen nut
1
on track rod ball joint but do not remove completely.
Caution
Leave nut screwed on a few turns to protect thread on pin.
Press track rod off wheel bearing housing using
ball joint puller
T10187
2
.
Unscrew nut
1
.
Vehicles with adaptive chassis control DCC
Disconnect connector
2
on shock absorber
3
.
Pull line
3
off shock absorber
4
.
Note
If there is moisture in the area of the connector, blow compressed air on the contacts on the shock absorber and the connector.
Continuation for all vehicles
Separate threaded connection of shock absorber on body.
1
Commercially available ratchet handle
2
T10001/8
3
T10001/11
4
T10001/5
Lower
engine and gearbox jack
VAS 6931
or
engine and gearbox jack
V.A.G 1383 A
as far as necessary.
Remove shock absorber with wheel bearing housing.
Place shock absorber with wheel bearing housing on a suitable surface.
Unscrew nut
1
from wheel bearing housing
3
.
Pull out bolts
2
.
Open wheel bearing housing
1
with
spreader
3424
at position
A
.
Remove shock absorber
2
in
direction of arrow B
.
Installing
Installation is performed in reverse sequence; note the following:
Check alignment of suspension strut relative to wheel bearing housing.
When installing, the metal tab on suspension strut must slip into groove
arrow A
in wheel bearing housing.
If necessary, turn suspension strut further until this position is reached.
Insert wheel bearing housing far enough that suspension strut sits on stop
arrow B
in wheel bearing housing.
Insert suspension strut.
Secure threaded connection of shock absorber on body.
1
Commercially available ratchet handle
2
T10001/8
3
T10001/11
4
T10001/5
Vehicles with adaptive chassis control DCC
Clip line
3
into shock absorber
1
.
Connect connector
2
to shock absorber
1
, and engage it audibly.
Continuation for all vehicles
If components such as damper have been renewed, it may be necessary to carry out wheel alignment.
For information on the necessity of wheel alignment refer to
Chapter
.
Specified torques
Chapter
“
Assembly overview - subframe
”
Chapter
“
Drive shaft
”
Chapter
“
Torque settings for wheel bolts
”
Install brake caliper
Brake system
Rep. gr.
46
Front brake; Removing and installing brake caliper
Plenum chamber bulkhead; Assembly overview - plenum chamber bulkhead
General body repairs, exterior
Rep. gr.
50
Bulkhead; Assembly overview - plenum chamber bulkhead