Running gear Manual Pages - Full Index

Running gear

• Running gear
  • Technical data
    • Running gear
      • Ground clearance
    • Steering
    • Technical data|Brakes
    • Wheels, tyres
      • Vehicles with front-wheel drive
      • Vehicles with four-wheel drive
  • Front suspension, drive shafts
    • Repairing front suspension
      • Removing and installing subframe, anti-roll bar and wishbone
      • Reworking cap nut in longitudinal member
        • Subframe version up to 01.84
        • Subframe version as of 02.84, chassis No. 19-E-499 394
        • Assembly mounting
        • Aligning engine/gearbox assembly
      • Removing and installing wheel bearing, suspension strut and drive shaft
      • Repairing front suspension strut
        • Checking shock absorber
      • Coil spring allocation
        • Heavy-duty version, M103
      • Shock absorber allocation
    • Repairing drive shaft
      • Checking outer constant velocity joint
        • Removing
        • Installing
      • Checking inner constant velocity joint
        • Removing
        • Installing
        • Checking function of constant velocity joint:
  • Rear suspension, drive shaft
    • Repairing rear axle
      • Removing and installing bonded rubber bush
        • Removing
        • Installing
      • Reworking cap nut in longitudinal member
      • Rear axle assembly allocation
    • Removing and installing rear axle - Golf syncro, Jetta syncro, Rally Golf
    • Dismantling and assembling suspension strut (vehicles with front- and four-wheel drive)
      • Coil spring allocation
      • Shock absorber allocation
    • Repairing wheel bearing
      • Repairing wheel bearings, drum brakes, front-wheel drive vehicles
      • Repairing wheel bearings, disc brakes, front-wheel drive vehicles
      • Repairing wheel bearings, vehicles with four-wheel drive and suspension link with wheel bearing diameter 68 mm
      • Repairing wheel bearings, vehicles with four-wheel drive and suspension link with wheel bearing diameter 72 mm
        • Distinguishing features of suspension link with wheel bearing diameter 72 mm
    • Golf Country - removing and installing spacer frame
  • Wheels, tyres. axle align
    • Wheel alignment
      • Test prerequisites
      • Wheel alignment specifications
      • Adjusting front wheel camber
      • Calculating the direction of travel
  • ABS, ADR, TCS, EDL, ESP
    • Notes for repair work on anti-lock brake system (ABS)
    • Various hydraulic unit design stages
    • Checking hydraulic unit
    • Removing and installing hydraulic unit complete
      • Removing and installing hydraulic unit complete
        • Removing
        • Installing
        • Torque settings
    • Dismantling and assembling hydraulic unit, design stages 1 and 2 (ABS)
      • Design stage 1: hydraulic unit 191 614 111 , tandem brake master cylinder ? 19.05 mm
        • Features:
        • Repair options:
      • Design stage 2: hydraulic unit 191 614 111 A , tandem brake master cylinder ? 19.05 mm
        • Features:
        • Repair options:
        • Pressure accumulator distinguishing features
    • Dismantling and assembling hydraulic unit, design stage 3 (ABS)
      • Design stage 3: Hydraulic unit 191 614 111 A , tandem brake master cylinder ? 19.05 mm hydraulic unit 535 614 111 , tandem bra
        • Features:
        • Repair options:
    • Dismantling and assembling hydraulic unit (ABS/EDL)
      • Removing and installing pressure warning switch
      • Pump unit modification
      • Removing and installing control unit
        • Location:
      • Removing and installing speed sensor and speed sensor rotor
  • Brake, brake mechanics
    • Repairing front brakes
      • Repairing front brakes, brake caliper VW I and VW II
      • Removing and installing brake pads
      • Repairing front brakes, Girling brake caliper
        • Allocation:
      • Removing and installing brake pads
    • Repairing rear brakes, drum brakes
      • Removing and installing rear brakes
      • Repairing rear brakes
      • Removing and installing brake shoes
        • Removing
        • Installing
      • Adjusting handbrake, drum brakes
    • Repairing rear brakes, vehicles with disc brakes up to 07.87
      • Removing and installing brake pads
        • Removing
        • Installing
      • Bringing piston to basic position
      • Adjusting handbrake, vehicles with disc brakes up to 07.87
    • Repairing rear brakes, vehicles with disc brakes as of 08.87 and vehicles with ABS
      • Removing and installing brake pads
        • Removing
        • Installing
      • Adjusting handbrake, vehicles with disc brakes as of 08.87
    • Removing and installing brake pedal/brake servo and brake master cylinder
      • Removing and installing brake pedal/brake servo and brake master cylinder
        • Checking brake servo
        • Checking non-return valve
  • Brakes, hydraulics, regulator, servo
    • Repairing front brake caliper, brake caliper VW II
    • Repairing Girling front brake calipers
    • Repairing rear brake caliper
    • Repairing wheel brake cylinder
    • Checking and adjusting brake pressure regulator, vehicles without ABS
      • Checking and adjusting brake pressure regulator, vehicles without ABS
        • Checking function
        • Checking and adjusting pressure
        • Load-dependent brake pressure regulator setting values
    • Checking and adjusting brake pressure regulator, vehicles with ABS
    • Bleeding brake system and changing brake fluid, vehicles without ABS
      • Bleeding brake system with brake filling and bleeding unit VW 1238/1 or V.A.G 1238 B
      • Bleeding without brake filling and bleeding unit
      • Changing brake fluid with brake filling and bleeding unit VW 1238/1 or V.A.G 1238 B
        • Changing brake fluid
      • Changing brake fluid without brake filling and bleeding unit
    • Bleeding brake system and changing brake fluid, vehicles with ABS
      • Bleeding brake system with brake filling and bleeding unit VW 1238/1 or V.A.G 1238 B
        • Front axle
        • Rear axle
      • Bleeding without brake filling and bleeding unit
        • Front axle
        • Rear axle
      • Changing brake fluid
        • Front axle
        • Rear axle
  • Steering
    • Removing and installing steering column with column tube, vehicles up to 06.84
    • Removing and installing steering column with column tube, vehicles as of 07.84
      • Installing modified steering column (? 22 mm)
        • Vehicles with fine-splined steering wheel AAA
        • Vehicles with coarse-splined steering wheel
    • Assembly overview - mechanical steering box
      • Adjusting steering box
      • Removing and installing manual steering box
        • Removing
        • Installing
      • Bolting track rod onto steering rack
    • Repairing power assisted steering
      • Checking pump delivery pressure
      • Checking system pressure
      • Removing and installing power assisted steering box
        • Removing
        • Installing
      • Assembly overview - power assisted steering box (TRW)
      • Repairing TRW power-assisted steering
      • Dismantling and assembling power assisted steering box (TRW)
        • Dismantling
        • Removing valve body oil seal
        • Pulling out inner steering rack oil seal
        • Assembling
        • Installing steering rack inner oil seal
        • Checking steering rack for scoring
        • Fitting the steering rack
      • Adjusting power steering box when installed (TRW)
      • Adjusting power steering box with new steering rack (TRW)
      • Assembly overview - power steering box (ZF)
      • Repairing ZF power assisted steering box
      • Dismantling and assembling power assisted steering box (ZF)
        • Dismantling
        • Removing centre roller bearing for valve body
        • Removing valve body oil seal
        • Removing inner steering rack oil seal
        • Assembling
        • Installing steering rack inner oil seal
        • Checking steering rack for scoring
        • Renewing steering rack oil seal
        • Fitting the steering rack
      • Adjusting power steering box (ZF)
      • Removing and installing track rod (TRW and ZF power steering box)
        • Removing
        • Installing
        • Installing boot
        • Bellows installation position
        • Clamp installation position
      • Checking and adjusting length of left track rod
    • Assembly overview - vane pump for power assisted steering, reservoir and hydraulic lines
      • Removing and installing vane pump, vehicles up to 82 kW engine
      • Removing and installing vane pump, vehicles with 1.8 l 16V engine and air conditioner
      • Removing and installing vane pump, vehicles with G60 engine
        • Adjusting V belt tension
    • Additional information
• Power unit
  • 2EE carburettor, TSZ-H ignition system
    • Self diagnosis, V.A.G Inspection Service
      • Self-diagnosis
        • Operation
        • Technical data of self-diagnosis
        • Reading fault memory
          • Reading fault memory with fault reader V.A.G 1551
          • Reading fault memory with voltage tester V.A.G 1527B
          • Reading flash code for fault display
          • Evaluating the flash pulses
          • Ending fault output
        • Fault table
        • Final control diagnosis
          • Final control diagnosis with fault reader V.A.G 1551
          • Final control diagnosis with voltage tester V.A.G 1527B
          • Final control diagnosis table
          • Fitting location of and checking intake manifold preheating relay J81
          • Checking vent and breather valve actuation
      • Electrical test
        • Line and component test with basic test box V.A.G 1598/14
          • Checks at wiring harness connector
          • Tests with control unit connected
    • Mixture preparation carb.
      • Removing and installing carburettor and intake manifold
        • Air filter
        • Checking automatic intake air preheating
        • Checking temperature regulator
      • Repairing 2EE carburettor
        • Carburettor upper part
        • Carburettor lower part
        • Safety precautions
        • Rules for cleanliness
        • Checking and adjustment data
        • Carburettor assembly
        • Upper nozzle layout in carburettor upper part
        • Lower nozzle layout in carburettor upper part
        • Adjusting pipe for full-load enrichment
        • Idle setting
          • Test and adjustment prerequisites:
          • Checking idling speed
        • Check and adjust CO content
          • Checking CO content (vehicles with activated charcoal filter system)
          • Checking CO content (vehicles without activated charcoal filter system)
          • Adjusting CO content (vehicles with and without activated charcoal filter system)
        • Ecotronic control unit J184 quick function test
          • Lambda control air flap positioner V63 emergency running mode
          • Checking Lambda probe G39
        • Checking throttle valve positioner V60
          • Checking breather and vent valve for function and leaks
          • Checking throttle valve positioner V60 resistances
        • Checking and adjusting throttle valve positioner V60 control range
        • Checking air flap positioner V63
          • Checking ease of air flap movement
          • Checking calibration angle with test ring 3229
          • Checking function of air flap positioner V63
          • Checking resistance of air flap positioner V63
        • Checking throttle valve potentiometer G69
          • Checking ease of movement
          • Checking throttle valve potentiometer G69 resistances
        • Checking throttle valve positioner V60 fuel cut-off and starting function
        • Checking cold start and warm-up enrichment
        • Checking cold idle speed increase
        • Checking acceleration enrichment
        • Checking float chamber breather change-over valve N116
          • Vehicles with activated charcoal filter system only
          • Checking voltage supply
        • Checking dynamic float chamber breather cut-off valve N141
          • Checking voltage supply
          • Checking function
        • Checking function of throttle valve stage II
          • Checking vacuum unit for leaks
          • Checking function of throttle valve stage II
        • Basic setting of throttle valve stage II
          • Checking and adjusting play at locking lever for stage II
        • Checking vacuum for vacuum unit for stage II
        • Vacuum connections
    • Ignition system, glow plug system
      • Repairing TSZ-H ignition system
        • Safety precautions
        • Adjustment data, spark plugs Q
        • Technical data, ignition distributor O
        • Installing ignition distributor O
        • Checking and adjusting ignition timing
        • Checking ignition timing setting
          • Checking centrifugal advance with TDC sender
          • Checking vacuum advance
          • Checking advance vacuum unit for leaks
        • Checking transistorized ignition system with Hall sender switch unit N41 and Hall sender G40
          • Checking with hand-held multimeter V.A.G 1526C or multimeter V.A.G 1715
          • Checking transistorized ignition system with Hall sender switch unit N41
          • Checking Hall sender G40
          • Removing and installing ring