Removing and installing suspension strut with clamped connection (for vehicles up to 3000 kg GVW) — VW

Removing and installing suspension strut with clamped connection (for vehicles up to 3000 kg GVW)
Special tools and workshop equipment required
Spreader
3424
Torque wrench
V.A.G 1331
Torque wrench
V.A.G 1332
Engine and gearbox jack
V.A.G 1383 A
Shock absorber set
T10001
Support
T10149
Ball joint puller
T40010
Remover
T10103
Adapter
T 10103/1
Removing
Remove plenum chamber bulkhead
Rep. gr.
50
Plenum chamber bulkhead; Assembly overview - plenum chamber bulkhead
.
Loosen 12-point nut
1
of axle shaft
2
.
Remove wheel
Chapter
“
Fitting wheels
”
.
Unbolt coupling rod
1
from suspension strut.
Swing coupling rod towards rear.
Press brake line out of retainer on suspension strut.
Pull off connector for
front left brake pad wear sender
G34
/
rear right brake pad wear sender
G37
Brake systems
Rep. gr.
46
Brake mechanism; Front brake; Removing and installing brake pads
.
Pull off connector for
front right speed sensor
G45
/
front left speed sensor
G47
Brake systems
Rep. gr.
45
ABS, ACC, TCS, EDL, ESP; Sensors; Removing and installing speed sensors on front axle
.
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
Brake mechanism; 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
engine and gearbox jack
V.A.G 1383 A
under vehicle longer than necessary.
Loosen bolts
Item
of swivel joint
Item
.
Push suspension link off swivel joint using
puller
T 40010
.
Push drive shaft out of wheel hub using
remover
T 10103
and
adapter
T 10103/1
.
Secure drive shaft to body.
Press off track rods using
ball joint puller
T40010
.
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
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
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
“
Fitting wheels
”
Chapter
“
Drive shaft
”
Install brake caliper
Brake systems
Rep. gr.
46
Brake mechanism; Front brake; Removing and installing brake caliper
.
Plenum chamber bulkhead; Assembly overview - plenum chamber bulkhead
Rep. gr.
50
Plenum chamber bulkhead