Volkswagen Golf V: Subframe, stabilizer bar, control arms (eng.)

Volkswagen Golf V: Subframe, stabilizer bar, control arms (eng.)
Volkswagen Golf 5 - Subframe, stabilizer bar, control arms
Стр. 1 из 39
40 - 4
Subframe, stabilizer bar, control arms
Subframe, stabilizer bar, control arms, assembly
overview
Caution!
„
„
Welding and straightening work on supporting
or wheel carrying components of suspension is
not permitted.
„
Always replace self-locking nuts.
„
Always replaced corroded bolts/nuts.
Nut
Subframe, stabilizer bar, control arms
„
„
Torque specification
40-3
„
When tightening,
counterhold on hex socket
head of joint bolt
„
Self-locking
„
Always replace after
removal
„
„
„
„
Topic
Coupling rod
„
„
Стр. 2 из 39
Linking stabilizer to
suspension strut
Console
„
Securing
console
40-4, Securing
„
If a console is replaced,
alignment must be checked
44-6, Wheel alignment
Mounting bracket
„
Securing 40-4, Securing
mounting bracket
„
With bonded rubber bushing
Hex head bolt
„
Torque specification
40-3
„
Always replace after
removal
Topic
Hex head bolt
„
Torque specification
40-3
„
Always replace after
removal
Hex head bolt
Topic
Subframe, stabilizer bar, control arms
„
„
Torque specification
40-3
„
Always replace after
removal
„
Can be checked in Guided
Fault Finding using
Vehicle Diagnosis, Testing
and Information System VAS
5051
Hex head bolt
„
„
Topic
Left Front Level Control System
Sensor G78
„
„
Стр. 3 из 39
Torque specification
40-3
Topic
Control arm
„
Version: Cast steel
„
Application Electronic
Parts Catalog "ETKA"
„
If damaged, also replace
lower ball joint
„
Removing and installing
40-4, Control arm with
mounting bracket, removing
and installing
„
Replace bearing 40-4,
Bonded rubber bushing for
control arm, replacing
Control arm
„
Version: Steel plate
„
Application Electronic
Parts Catalog "ETKA"
„
If damaged, also replace
lower ball joint
„
Removing and installing
40-4, Control arm with
mounting bracket, removing
Subframe, stabilizer bar, control arms
Стр. 4 из 39
and installing
„
„
„
„
„
Nut
„
Torque specification
40-3
„
Self-locking
„
Always replace after
removal
Topic
Ball joint
„
Checking
checking
„
Removing and installing
40-4, Ball joint, removing
and installing
„
Replace when control arm is
damaged
40-4, Ball joint,
Nut
„
Torque specification
40-3
„
Self-locking
„
Always replace after
removal
Topic
Nut
„
„
Replace bearing 40-4,
Bonded rubber bushing for
control arm, replacing
Torque specification
40-3
Topic
Hex bolt
„
Torque specification
40-3
„
Always replace after
removal
Topic
Subframe, stabilizer bar, control arms
„
„
„
„
Hex bolt
„
Torque specification
40-3
„
Always replace after
removal
„
„
Topic
Hex bolt
„
Torque specification
40-3
„
Always replace after
removal
Topic
Hex bolt
„
Torque specification
40-3
„
Only tighten if pendulum
support is bolted to
transmission
„
Always replace after
removal
Topic
Underride protection bracket
„
„
Стр. 5 из 39
Application Electronic
Parts Catalog "ETKA"
Hex bolt
„
Torque specification
40-3
„
Always replace after
removal
Topic
Hex bolt
„
Torque specification
40-3
„
Always replace after
removal
Topic
Bracket on pendulum support
Subframe, stabilizer bar, control arms
„
„
„
No replacement part
Pendulum support
„
First, bolt to transmission,
then bolt to subframe
„
Various versions
„
Application Electronic
Parts Catalog "ETKA"
Lower bonded rubber bushing
for pendulum support
„
Pressing out and in
Subframe, servicing
„
Shield
„
Torx bolt
„
„
„
Torque specification
40-3
40-4,
Topic
Subframe
„
Removing and installing
40-4, Subframe, removing
and installing
„
Various versions
„
Application Electronic
Parts Catalog "ETKA"
Upper bonded rubber bushing
for pendulum support
„
„
Стр. 6 из 39
Pressing out and in
Subframe, servicing
40-4,
Hex bolt
„
Torque specification
40-3
„
Always replace after
removal
Topic
Subframe, stabilizer bar, control arms
„
„
„
Стр. 7 из 39
Only tighten in curb weight
position 40-2, Wheel
bearing, lifting to curb weight
position
Hex nut
„
Torque specification
40-3
Topic
„
When tightening,
counterhold on hex socket
head of joint bolt
„
Self-locking
„
Always replace after
removal
Stabilizer bar
„
Various versions
„
Application Electronic
Parts Catalog "ETKA"
„
Removing and installing
40-4, Stabilizer bar,
removing and installing
Longmember thread, servicing
Servicing weld nut threads in longmember is possible
under certain circumstances
Repair Manual, Body Collision Repair , Repair Group
50,
.
Subframe and consoles, securing
Special tools, testers and auxiliary items required
Subframe, stabilizer bar, control arms
„
Locating pins T10096
„
Engine/transmission jack V.A.G 1383 A
Locating pins T10096 , installing
To locate subframe with consoles, locating pins T10096
must be bolted to positions - 1 - , - 8 - , - 9 - and - 18 - ,
Стр. 8 из 39
Subframe, stabilizer bar, control arms
Стр. 9 из 39
one after the other.
Note:
„
Locating pins T10096 must only be tightened to
maximum of 20 Nm, otherwise threads of locating
pins may be damaged.
- Replace bolts of mounting bracket one after the other on
both sides with locating pins T10096 and tighten them to
20 Nm.
Securing mounting bracket
- Replace bolts of consoles one after the other with
locating pins T10096 and tighten to 20 Nm.
Securing console
Position of front axle is now secured.
Continue with removing stabilizer bar
Topic 40-4 .
Continue with removing steering gear
Topic 48-5 .
Subframe, stabilizer bar, control arms
Locating pins T10096 , removing
Removal is performed in reverse order of installation. Make
sure that the locating pins T10096 are replaced one after
the other with new bolts.
- Perform road test after repair work is completed; if
steering wheel is crooked, vehicle alignment must be
performed 44-6, Wheel alignment .
Torque specifications
torques
40-3, Front axle, tightening
Subframe, removing and installing
Special tools, testers and auxiliary items required
„
Torque wrench V.A.G 1331
„
Torque wrench V.A.G 1332
Removing
- Remove lower noise insulation
Стр. 10 из 39
Subframe, stabilizer bar, control arms
Repair Manual, Body Exterior, Repair Group 50,
.
- Remove bracket for exhaust system from subframe.
- Remove bolts - arrows - from heat shield.
- Remove heat shield from subframe.
- Remove pendulum support from transmission, to do so,
remove bolt - 14 - .
- Remove bolts for:
„
Steering gear - 3 - and - 6 -
„
Stabilizer bar - 11 - and - 16 -
„
And subframe - 4 - , - 5 - , - 12 - and - 15 - .
Стр. 11 из 39
Subframe, stabilizer bar, control arms
Стр. 12 из 39
Installing
Installation is performed in the reverse order of removal.
- Tighten bolts, tightening torques
tightening torques .
40-3, Front axle,
- Install noise insulation and tighten, tightening torques
Repair Manual, Body Exterior, Repair Group 50,
.
Subframe, servicing
Special tools, testers and auxiliary items
required
„
Installation device 3372
Subframe, stabilizer bar, control arms
„
Assembly tool T10214
„
Assembly tool T10244
Bonded rubber bushing, pressing out
- Remove subframe
installing .
40-4, Subframe, removing and
- Attach assembly tool T10244 to subframe.
- Press out both bonded rubber bushings simultaneously,
as depicted in illustration.
Note:
„
The flattened side of the installation device 3372/1
must face toward traverse T10244 insert - A - ,
otherwise insert can be damaged.
„
Tube T10244/3 has a larger and a smaller diameter.
Subframe must contact larger inner diameter of tube
T10244/3 .
Pressing in bonded rubber bushing
Стр. 13 из 39
Subframe, stabilizer bar, control arms
- Bolt both bonded rubber bushings onto original bolt,
cutouts - arrows - must align.
- Insert bolted bonded-rubber bushing with bolt head
facing downward into tube T10214/2 .
„
„
„
„
„
„
Press piece T10214/3
Bonded rubber bushing
Tube T10214/2
Tube T10214/1
Thrust plate VW 401
Thrust plate VW 402
Стр. 14 из 39
Subframe, stabilizer bar, control arms
- Press bonded rubber bushing - 1 - in until dimension - A
- is achieved.
Dimension - A - = 2 - 3 mm.
- Align tube T10214/2 with pressed in bonded rubber
bushings on to subframe. While doing this, the corners of
the inner core must describe an imaginary line lying
parallel to edge of assembly tool T10244 .
Distance - a - must be identical at left and right to
guarantee parallelism.
- Place subframe on smaller interior diameter of tube
T10244/3 .
Стр. 15 из 39
Subframe, stabilizer bar, control arms
- Press in mounting onto stop, and until force of 20 Nm is
reached.
- Remove assembly tool T10244 from subframe and
check seating of pressed in bonded rubber bushing.
„
The outer diameter - 1 - of both bonded rubber
bushings must not extend more than 2 mm into the
area of the pendulum support opening.
„
Cutouts in bonded rubber bushings must be in
center of subframe opening.
„
A gap - arrow - between bonded rubber bushings is
permitted.
- Install subframe
Ball joint, checking
40-4, Installing .
Стр. 16 из 39
Subframe, stabilizer bar, control arms
Checking axial play
- Pull control arm firmly downward in direction of - arrow and press back up again.
Radial clearance, checking
- Press wheel firmly in and out at bottom in direction of arrow - .
Note:
„
There should not be any noticeable or visible "play"
in either of the two checks.
„
Observe ball joint during checks.
„
Make allowance for any wheel bearing play or "play"
in strut mounting at top.
„
Check rubber boot for damage, replace lower ball
joint, if necessary.
Ball joint, removing and installing
Стр. 17 из 39
Subframe, stabilizer bar, control arms
Special tools, testers and auxiliary items
required
„
Ball joint puller 3287A
„
Torque wrench V.A.G 1332
„
Engine/transmission jack V.A.G
1383 A
„
Angle wrench V.A.G 1756
Removing
- Loosen drive axle hex bolt
40-7, Drive axle hex bolt
connection, loosening and tightening .
- Remove wheel.
Стр. 18 из 39
Subframe, stabilizer bar, control arms
- Remove nuts - arrows - .
- Pull drive axle slightly out of wheel hub.
- Pull ball joint out of control arm.
- Move control arm downward as far as possible.
- Attach ball joint puller 3287 A as depicted in illustration
and press out ball joint.
Note:
„
Place engine/transmission jack V.A.G 1383 A or
similar underneath (risk of accident if components
fall off when pressing out ball joint).
„
To protect ball joint threads and for safety reasons
leave nut on a few turns.
Installing
- Install ball joint in wheel bearing housing.
- Install drive axle in wheel hub.
- Install new self-locking nut, and counter-hold with internal
Стр. 19 из 39
Subframe, stabilizer bar, control arms
Стр. 20 из 39
Torx bit T40 .
- Tighten nuts - arrows - .
Note:
„
Check boot for damage or twisting.
- Install and fasten wheel, torque specification
Torque specification for wheel bolts .
44-2,
- Tighten drive axle hex bolt.
Note:
„
When doing this, vehicle must not stand on wheels,
otherwise wheel bearing may be damaged.
Torque specifications
torques
40-3, Front axle, tightening
Control arm with mounting bracket, removing and
installing
Special tools, testers and auxiliary items required
„
Torque wrench V.A.G 1332
Subframe, stabilizer bar, control arms
„
Стр. 21 из 39
Locating pins T10096
Removing
- Remove wheel.
- Remove lower noise insulation
Repair Manual, Body Exterior, Repair Group 50,
.
- Remove bolts - Arrows - .
- Pull control arm out of lower ball joint.
- Secure position for mounting bracket
mounting bracket
40-4, Securing
Subframe, stabilizer bar, control arms
- Replace bolt - 1 - for left side, - 8 - for right side using
locating pins T10096 and tighten locating pins to 20 Nm.
Note:
„
Locating pins T10096 must only be tightened to
maximum of 20 Nm, otherwise threads of locating
pins may be damaged.
- Remove item - 10 - for left side of vehicle, item - 17 - for
right side of vehicle.
- Remove bolts - 1 - .
Installing
- Install control arm with mounting bracket into subframe.
Стр. 22 из 39
Subframe, stabilizer bar, control arms
- Install items - 10 - and - 17 - but do not tighten yet.
- Install bolts - 1 - and tighten.
- Replace locating pins T10096 with new bolts and tighten.
Tightening torque
40-3, Front axle, tightening torques .
- Bolt control arm onto ball joint - arrows - .
Стр. 23 из 39
Subframe, stabilizer bar, control arms
- Bolt control arm onto console in curb weight position - 10
- and - 17 - .
Further installation is in reverse order of removal.
- Install lower noise insulation.
Repair Manual, Body Exterior, Repair Group 50,
.
Note:
„
Check boot for damage or twisting.
Torque specifications
torques
40-3, Front axle, tightening
Removing (left side for vehicles with DSG or automatic
transmission)
Additional tools
Special tools, testers and auxiliary items required
Стр. 24 из 39
Subframe, stabilizer bar, control arms
„
Engine/transmission jack V.A.G 1383 A
- Remove left front wheel.
- Remove lower noise insulation
Repair Manual, Body Exterior, Repair Group 50,
.
- Remove bracket for exhaust system from subframe.
- Remove bolts - arrows - from heat shield.
- Remove heat shield from subframe.
Стр. 25 из 39
Subframe, stabilizer bar, control arms
- Remove pendulum support from transmission, to do so,
remove bolts - 14 - .
- If present, remove Left Front Level Control System
Sensor G78 coupling rod from control arm.
- Secure console and mounting bracket of control arm on
left side of vehicle using locating pins T10096
40-4,
Subframe and consoles, securing .
- Remove nuts - arrows - .
Стр. 26 из 39
Subframe, stabilizer bar, control arms
- Loosen bolt - 17 - .
- Remove bolts for:
„
Steering gear - 3 - and - 6 -
„
Stabilizer bar - 11 - and - 16 -
„
Subframe on right side - 5 - and - 12 -
- Place engine/transmission jack V.A.G 1383 A below
subframe.
- Place, for example, a piece of wood - 1 - between
engine/transmission jack V.A.G 1383 A and subframe.
Стр. 27 из 39
Subframe, stabilizer bar, control arms
Стр. 28 из 39
- Remove bolts - 2 - , - 4 - , - 5 - and - 12 - and lower
subframe with consoles as far as necessary.
- When doing this, pry alignment bushings of steering gear
out of left console.
- Remove bolt - 17 - and remove control arm from
console.
Installing (left side for vehicles with DSG or automatic
transmission)
Installation is performed in the reverse order of removal.
Note:
„
Make sure alignment bushings of steering gear fit
correctly in console!
Tightening torques of front axle
tightening torques
Tightening torques of steering
specifications
40-3, Front axle,
48-3, Steering, torque
- Install lower noise insulation
Repair Manual, Body Exterior, Repair Group 50,
.
Note:
Subframe, stabilizer bar, control arms
„
Check boot for damage or twisting.
- Perform road test after repair work; if steering wheel is
crooked, vehicle alignment must be performed 44-6,
Wheel alignment .
Bonded rubber bushing for control arm, replacing
Special tools, testers and auxiliary items
required
„
Tube T10219/1
„
Thrust plate VW 402
„
Punch VW 411
„
Drift T10219/2
Стр. 29 из 39
Subframe, stabilizer bar, control arms
Bonded rubber bushing, pressing out
- Press out bonded rubber bushing, as illustrated.
„
„
„
Punch VW 411
Tube T10219/1
Thrust plate VW 402
Pressing in bonded rubber bushing
Bonded rubber bushing must be installed at an angle to
avoid damage when pressing in. When pressing in, bonded
rubber bushing will straighten itself out.
- Apply installation lubricant G 294 421 A1 on outer
bonded rubber bushing.
- Place bonded rubber bushing at an angle (in direction of
control arm), lip - arrow - must slip into opening as
illustrated.
„
„
Drift T10219/2
Tube T10219/1
Стр. 30 из 39
Subframe, stabilizer bar, control arms
„
Thrust plate VW 402
- Press bonded rubber bushing in until core - 1 - and
opening of control arm - 2 - are at the same height.
- Press back bearing slightly in control arm.
„
„
Tube T10219/1
Thrust plate VW 402
Dimension - a - and - b - must be the same.
Mounting bracket with bearing for control arm, replacing
Pressing off mounting bracket with bearing for control arm
Стр. 31 из 39
Subframe, stabilizer bar, control arms
Special tools, testers and auxiliary items
required
„
Guide pin VW 439
„
Thrust plate VW 401
„
Thrust plate VW 402
Bonded rubber bushing is only available with mounting
bracket as one replacement part.
- Pressing off mounting bracket with bonded rubber
bushing from control arm.
Note:
Стр. 32 из 39
Subframe, stabilizer bar, control arms
„
Hold control arm while pressing out
„
Thrust plate VW 401
Guide pin VW 439
Thrust plate VW 402
„
„
Pressing on mounting bracket with bearing on control arm
Special tools, testers and auxiliary items required
„
Thrust plate VW 401
„
Tube 31.5 mm dia. VW 418 A
Стр. 33 из 39
Subframe, stabilizer bar, control arms
- Thinly coat hex of control arm using installation lubricant
G 294 421 A1 (1:20).
- Carefully press bushing onto control arm until stop.
„
„
„
„
Tube 31.5 mm dia. VW 418 A
Mounting bracket with bonded rubber bushing
Control arm
Thrust plate VW 401
- Perform road test after repair work; if steering wheel is
crooked, vehicle alignment must be performed 44-6,
Wheel alignment .
Stabilizer bar, removing and installing
Removing
Стр. 34 из 39
Subframe, stabilizer bar, control arms
Special tools, testers and auxiliary items
required
„
Locating pins T10096
„
Torque wrench V.A.G 1332
„
Engine/transmission jack V.A.G
1383 A
„
Ball joint puller 3287 A
- Remove front wheels.
Стр. 35 из 39
Subframe, stabilizer bar, control arms
- Remove foot well trim, to do so, remove nuts - arrows .
- Remove bolt - 1 - and pull universal joint - 2 - off
steering gear.
- Remove lower noise insulation
Repair Manual, Body Exterior, Repair Group 50,
.
- Remove coupling rods from stabilizer.
Стр. 36 из 39
Subframe, stabilizer bar, control arms
Стр. 37 из 39
- Remove nuts - arrows - .
- Loosen tie rod end nut on both sides, but do not remove
yet.
To protect ball joint thread, screw nut on pin a few
turns.
- Press off tie rod end from wheel bearing housing using
ball joint puller 3287A .
- Secure subframe with consoles
consoles, securing .
40-4, Subframe and
- Remove stabilizer from subframe, remove bolts - 11 and
16 - .
- Remove pendulum support from transmission, to do so,
remove bolts - 14 - .
Subframe, stabilizer bar, control arms
- Place engine/transmission jack V.A.G 1383 A below
subframe.
- Place, for example, a piece of wood - 1 - between
engine/transmission jack V.A.G 1383 A and subframe.
- Loosen bolts - 4 and 5 - and lower subframe with
consoles slightly. When doing so, observe electrical wires.
Стр. 38 из 39
Subframe, stabilizer bar, control arms
Стр. 39 из 39
- Now, lift stabilizer bar - 1 - toward front, over console - 2
- and down from subframe.
Installing
Installation is performed in the reverse order of removal.
Tightening torques of front axle
tightening torques
Tightening torques of steering
specifications
40-3, Front axle,
48-3, Steering, torque
- Remove lower noise insulation
Repair Manual, Body Exterior, Repair Group 50,
.
Note:
„
Coat seal on steering gear using lubricant, e.g.
lubricating soap, before installing steering gear.
„
After attaching steering gear to drive axle, make
sure that seal on steering gear is positioned to
mounting plate without kinks and opening to foot well
is sealed correctly. Ingress of water and/or noises
may be the result.
„
Make sure sealing surfaces are clean.
- After installing, basic setting for Steering Angle Sensor
G85 must be performed Vehicle Diagnosis, Testing and
Information System VAS 5051 .
- Perform road test after repair work; if steering wheel is
crooked, vehicle alignment must be performed 44-6,
Wheel alignment .
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