Volkswagen 2005 Golf Plus User Manual

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Contents
00 - Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1 Checklist for evaluating running gear of accident vehicles . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2 General information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
40 - Front suspension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
1 Appraisal of accident vehicles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
2 Repairing front suspension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
2.1 Overview - front axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
2.2 Raising wheel suspension to unladen position, Golf . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
2.3 Raising wheel suspension to unladen position, Golf Plus, CrossGolf . . . . . . . . . . . . . . . . 8
3 Subframe, anti-roll bar, suspension link . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
3.1 Assembly overview: subframe, anti-roll bar, suspension links . . . . . . . . . . . . . . . . . . . . . . 10
3.2 Assembly overview - front left vehicle level sender G78 . . . . . . . . . . . . . . . . . . . . . . . . . . 14
3.3 Removing and installing front left vehicle level sender G78 . . . . . . . . . . . . . . . . . . . . . . . . 15
3.4 Repairing thread in longitudinal member . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
3.5 Fixing position of subframe and brackets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
3.6 Lowering subframe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
3.7 Removing and installing subframe without steering box . . . . . . . . . . . . . . . . . . . . . . . . . . 21
3.8 Removing and installing subframe with steering box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
3.9 Repairing subframe (front-wheel drive) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
3.10 Repairing subframe (four-wheel drive) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
3.11 Checking swivel joint . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
3.12 Removing and installing swivel joint . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
3.13 Removing and installing suspension link with mounting bracket . . . . . . . . . . . . . . . . . . . . 36
3.14 Removing and installing suspension link with mounting bracket (left side for vehicles with
DSG or automatic gearboxes) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
3.15 Removing and installing suspension link with mounting bracket (right side for vehicles with
6-cylinder engines) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
3.16 Renewing bonded rubber bush for suspension link . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
3.17 Renewing mounting bracket with suspension link bush . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
3.18 Removing and installing anti-roll bar . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
4 Assembly overview - wheel bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
4.1 Removing and installing wheel bearing housing (3-point mounting) . . . . . . . . . . . . . . . . . . 57
4.2 Removing and installing wheel bearing housing (4-point mounting) . . . . . . . . . . . . . . . . . . 58
4.3 Removing and installing wheel bearing housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
5 Assembly overview: suspension strut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
5.1 Removing and installing suspension strut, Golf . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
5.2 Removing and installing suspension strut, Golf Plus, CrossGolf . . . . . . . . . . . . . . . . . . . . 70
5.3 Repairing suspension strut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
6 Removing and installing drive shafts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
6.1 Loosening and tightening drive shaft hexagon bolt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
6.2 Loosening and tightening 12-point flange bolt securing drive shaft . . . . . . . . . . . . . . . . . . 78
6.3 Removing and installing drive shaft with constant velocity joint . . . . . . . . . . . . . . . . . . . . . . 79
6.4 Removing and installing left drive shaft with (push-on) constant velocity slip joint . . . . . . 81
6.5 Removing and installing right drive shaft with (push-on) constant velocity slip joint . . . . . . 85
6.6 Removing and installing drive shafts with triple roller joint AAR2600i . . . . . . . . . . . . . . . . 88
6.7 Removing and installing drive shafts with triple roller joint AAR3300i . . . . . . . . . . . . . . . . 90
6.8 Removing and installing intermediate shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
7 Repairing drive shaft - overview of drive shafts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
7.1 Heat shields for drive shafts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
8 Assembly overview - drive shaft with VL90 or VL100 constant velocity joint . . . . . . . . . . . . 97
8.1 Dismantling and assembling drive shaft with VL90 or VL100 constant velocity joint . . . . . . 99
Golf 2004 ➤ , Golf Plus 2005 ➤
Running gear, axles, steering - Edition 08.2009
Contents i

Volkswagen 2005 Golf Plus Specifications

General

Brand	Volkswagen
Model	2005 Golf Plus
Category	Automobile
Language	English