VOLKSWAGEN GOLF 2004 (01) PDF Document

The visual and functional examination of the steering system for a VOLKSWAGEN GOLF 2004 after an accident includes the following:

• Visual examination for deformation and cracks.
• Examination for play in track rod joints and steering box.
• Visual examination for tears in boots.
• Examine electrical and hydraulic lines and hoses for chafing, cuts and kinks.
• Examine hydraulic lines, threaded connections and steering gear for leaks.
• Check steering box and lines for secure seating.
• Check for flawless function from lock to lock by moving the steering from stop to stop. In the process, the steering wheel must turn with a constant force without resistance.

The visual inspection and functional check of the running gear for a VOLKSWAGEN GOLF 2004 after an accident involves:

Adhere to the sequence of the following inspection steps!

• Exam all components shown in the assembly overviews for deformation, cracks and other damage.
• Renew damaged parts.
• Align wheels on a VOLKSWAGEN AG-approved wheel alignment stand.

The visual and functional check of wheels and tyres for a VOLKSWAGEN GOLF 2004 after an accident involves the following:

• Check for true running and imbalance: refer to Wheels, tyres, wheel alignment; Rep. Gr. 44.
• Check tyres for cuts and impact damage in the profile and on the flanks: refer to Wheels, tyres, wheel alignment; Rep. Gr. 44.
• Check tyre inflation pressure: see tyre inflation pressure sticker in fuel tank flap or Maintenance; Booklet; Check tyres: condition, profile, inflation pressure, depth of tread.

If the rim of the wheel and/or tyre is damaged, renew the tyre. This also applies if the circumstances of the accident and the damage to the vehicle indicate possible damage which is not visible. A further factor in the decision is the age of the tyre. Tyres should not be older than 6 years.

Generally, in case of doubt:

• Whenever a safety risk cannot be excluded, the tyre(s) must be renewed.

Check other vehicle systems as well for a VOLKSWAGEN GOLF 2004 after an accident, for example:

• Brake system including ABS.
• Visual and functional examination of exhaust system and passenger protection.

Specifications for testing and adjusting can be found in the respective workshop manual in ELSA.

Safety-relevant systems like, for example, ABS/EDL; airbags; electronically regulated suspension systems; electromechanical or electrohydraulic steering and other driver assist systems, must be read with the vehicle diagnosis, testing and information system -VAS 5051- for possible stored fault messages for a VOLKSWAGEN GOLF 2004 after an accident. If faults are saved in the fault memories of the systems mentioned above, repair them according to instructions in workshop manuals in ELSA. Following repairs, read fault memories of the affected systems again to be sure that complete function has been restored.

Information concerning wheels, tyres and snow chains for a VOLKSWAGEN GOLF 2004 can be found in “Wheel and Tyre Guide” in Wheels, tyres, wheel alignment; Rep. Gr. 44.

For the Standard running gear (2UA) on a VOLKSWAGEN GOLF 2004, the ride height -a- in mm when raising the wheel suspension to unladen position is 382 ± 10 mm.

For the Heavy-duty running gear (2UB) on a VOLKSWAGEN GOLF 2004, the ride height -a- in mm when raising the wheel suspension to unladen position is 402 ± 10 mm.

For the Sports running gear except 18″ wheels (2UC) on a VOLKSWAGEN GOLF 2004, the ride height -a- in mm when raising the wheel suspension to unladen position is 367 ± 10 mm.

For the Sports running gear GTI (G08) on a VOLKSWAGEN GOLF 2004, the ride height -a- in mm when raising the wheel suspension to unladen position is 360 ± 10 mm.

For the Sports running gear R32 (G09) on a VOLKSWAGEN GOLF 2004, the ride height -a- in mm when raising the wheel suspension to unladen position is 362 ± 10 mm.

The torque specification for Nut (1) when dealing with the subframe, anti-roll bar, suspension link on a VOLKSWAGEN GOLF 2004 is 65 Nm.

The torque specification for Bolt (5) when dealing with the subframe, anti-roll bar, suspension link on a VOLKSWAGEN GOLF 2004 is 50 Nm + 90° further. Always renew after removing.

The torque specification for Bolt (6) when dealing with the subframe, anti-roll bar, suspension link on a VOLKSWAGEN GOLF 2004 is 70 Nm + 90° further. Always renew after removing.

The torque specification for Bolt (7) when dealing with the subframe, anti-roll bar, suspension link on a VOLKSWAGEN GOLF 2004 is 70 Nm + 90° further. Always renew after removing.

The specified torque for the Bolt on subframe when removing and installing the front left vehicle level sender -G78- on a VOLKSWAGEN GOLF 2004 is 9 Nm.

The specified torque for the Nut when removing and installing the front left vehicle level sender -G78- on a VOLKSWAGEN GOLF 2004 is 9 Nm. Always renew after removing.

The specified torque for Nut (15) when dealing with the subframe, anti-roll bar, suspension link on a VOLKSWAGEN GOLF 2004 is 9 Nm.

The specified torque for Bolt (16) when dealing with the subframe, anti-roll bar, suspension link on a VOLKSWAGEN GOLF 2004 is 70 Nm + 90° further. Always renew after removing.

The specified torque for Bolt (17) when dealing with the subframe, anti-roll bar, suspension link on a VOLKSWAGEN GOLF 2004 is 20 Nm + 90° further. Always renew after removing.

The specified torque for Bolt (18) when dealing with the subframe, anti-roll bar, suspension link on a VOLKSWAGEN GOLF 2004 is 70 Nm + 90° further.

The torque setting for the M10 x 75 strength class 8.8 bolt used in the pendulum support to gearbox when repairing the subframe (front-wheel drive) of a VOLKSWAGEN GOLF 2004 is 40 Nm + 90° further. Use new bolt.

The torque setting for the M10 x 75 strength class 10.9 bolt used in the pendulum support to gearbox when repairing the subframe (front-wheel drive) of a VOLKSWAGEN GOLF 2004 is 50 Nm + 90° further. Use new bolt.

The specified torques for the Subframe to body connection when lowering the subframe on a VOLKSWAGEN GOLF 2004 are 70 Nm + 90°. Use new bolts!

The specified torque for Subframe to bracket when lowering the subframe on a VOLKSWAGEN GOLF 2004 is 70 Nm + 90°. Use new bolts!

The specified torque for Anti-roll bar to coupling rod when lowering the subframe on a VOLKSWAGEN GOLF 2004 is 65 Nm. Use new nut. Counterhold on multi-point socket of joint pin.

The specified torque for Universal joint to steering box when lowering the subframe on a VOLKSWAGEN GOLF 2004 is 30 Nm. Use new bolt.

The specified torques for the pendulum support to gearbox when lowering the subframe on a VOLKSWAGEN GOLF 2004 are as follows:

The specified torques for the Subframe to body connection when removing and installing the subframe with steering box on a VOLKSWAGEN GOLF 2004 are 70 Nm + 90°. Use new bolts!

The specified torque for Anti-roll bar to subframe when removing and installing the subframe with steering box on a VOLKSWAGEN GOLF 2004 is 20 Nm + 90°. Use new bolts!

The specified torque for Universal joint to steering box when removing and installing the subframe with steering box on a VOLKSWAGEN GOLF 2004 is 30 Nm.

The specified torques for the pendulum support to gearbox when removing and installing the subframe with steering box on a VOLKSWAGEN GOLF 2004 are as follows:

The specified torques for the Subframe to body connection when removing and installing the subframe without steering box on a VOLKSWAGEN GOLF 2004 are 70 Nm + 90°. Use new bolts!

The specified torque for Anti-roll bar to subframe when removing and installing the subframe without steering box on a VOLKSWAGEN GOLF 2004 is 20 Nm + 90°. Use new bolts.

The specified torque for Swivel joint to cast steel suspension link when removing and installing the subframe without steering box on a VOLKSWAGEN GOLF 2004 is 60 Nm. Use new nuts.

The specified torque for Swivel joint to sheet steel or forged aluminium suspension link when removing and installing the subframe without steering box on a VOLKSWAGEN GOLF 2004 is 100 Nm. Use new nuts.

The specified torques for the pendulum support to gearbox bolts when lowering the subframe on a VOLKSWAGEN GOLF 2004 are:

The specified torque for the Drive shaft to wheel hub “hexagon bolt” when removing and installing drive shaft with constant velocity joint on a VOLKSWAGEN GOLF 2004 is 200 Nm +180°. Use new bolt.

The specified torque for the Drive shaft to wheel hub “12-point bolt” when removing and installing drive shaft with constant velocity joint on a VOLKSWAGEN GOLF 2004 is 70 Nm + 90°. Use new bolt.

The specified torque for the Swivel joint to cast steel suspension link when removing and installing drive shaft with constant velocity joint on a VOLKSWAGEN GOLF 2004 is 60 Nm. Use new nuts.

The specified torque for the Swivel joint to sheet steel or forged aluminium suspension link when removing and installing drive shaft with constant velocity joint on a VOLKSWAGEN GOLF 2004 is 100 Nm. Use new nuts.

The specified torque for the Drive shaft to flange shaft on gearbox “M8 multi-point socket” when removing and installing left drive shaft with (push-on) constant velocity slip joint on a VOLKSWAGEN GOLF 2004 is 40 Nm. Initially tighten diagonally to 10 Nm. Use new bolts and new backing plates.

The specified torque for the Drive shaft to flange shaft on gearbox “M10 multi-point socket” when removing and installing left drive shaft with (push-on) constant velocity slip joint on a VOLKSWAGEN GOLF 2004 is 70 Nm. Initially tighten diagonally to 10 Nm. Use new bolts and new backing plates.

The specified torque for the Intermediate shaft bearing to bearing bracket when removing and installing intermediate shaft on a VOLKSWAGEN GOLF 2004 is 20 Nm.

The procedure for checking the outer constant velocity joint when repairing the drive shaft with VL90 or VL100 constant velocity joint on a VOLKSWAGEN GOLF 2004 involves:

• The joint is to be dismantled to renew the grease if it is heavily soiled, or to check the running surfaces of the balls for wear and damage.
• Before dismantling, mark position of ball hub in relation to ball cage and joint body with an electric scriber or oil stone.
• Swing ball hub and ball cage.
• Remove balls one at a time.
• Turn cage until the two rectangular windows -arrow- align with joint body.
• Take out cage with hub.
• Swing segment of hub into square cage window.
• Tip hub out of cage.
• The six balls for each joint belong to a tolerance group. Check stub axle, hub, cage and balls for small indentations (pitting) and traces of seizing. Too much circumferential backlash in the joint becomes noticeable during load change jolts; in such cases, the joint must be renewed. Smoothing and traces of wear of the balls are no reason to change the joint.

The procedure for installing the outer constant velocity joint when repairing the drive shaft with VL90 or VL100 constant velocity joint on a VOLKSWAGEN GOLF 2004 involves:

• Pack half of total grease quantity (40 g) into joint body.
• Fit cage with hub into joint body.
• Press in opposing balls one after the other; the original position of the hub relative to the cage and joint body must be restored.
• Fit new retaining ring into hub.
• Distribute remaining grease in boot.
• The constant velocity joint is correctly assembled if the ball hub can be moved by hand backwards and forwards over its entire range of axial movement.

The procedure for checking the inner constant velocity joint when repairing the drive shaft with VL90 or VL100 constant velocity joint on a VOLKSWAGEN GOLF 2004 involves:

• The joint is to be dismantled to renew the grease if it is heavily soiled, and to check the running surfaces and the balls for wear and damage.
• Swing ball hub and ball cage.
• Press out joint body in direction of arrow.
• Press balls out of cage.
• The ball hub and joint body are paired. Do not interchange them.

The procedure for installing the inner constant velocity joint when repairing the drive shaft with VL90 or VL100 constant velocity joint on a VOLKSWAGEN GOLF 2004 involves:

• Insert hub into cage via the two chamfers. The hub can be installed in any position. Press balls into cage.
• The ball hub has two different distances between the ball tracks: a smaller one and a larger one.
• Insert hub complete with cage and balls into joint body, making sure that a smaller gap -b- faces open side of joint body.
• Also make sure that chamfer on inner circumference of ball hub is visible after swinging it into place.
• Swing ball hub into place by swinging hub out of cage as shown in figure -arrows-.
• Swivel in hub with balls by applying firm pressure to cage -arrow-.

The constant velocity joint is correctly assembled if the ball hub can be moved by hand backwards and forwards over its entire range of axial movement when checking the function of the constant velocity joint when repairing the drive shaft with VL90 or VL100 constant velocity joint on a VOLKSWAGEN GOLF 2004.

The wheel alignment specifications for the Front axle of a VOLKSWAGEN GOLF 2004 with Standard running gear (PR 2UA) are:

1) Toe-out on turns can be displayed as a negative value on the wheel alignment computer, depending on the manufacturer.

The wheel alignment specifications for the Front axle of a VOLKSWAGEN GOLF 2004 with Sports running gear except 18″ wheels (PR 2UC) are:

1) Toe-out on turns can be displayed as a negative value on the wheel alignment computer, depending on the manufacturer.

The wheel alignment specifications for the Front axle of a VOLKSWAGEN GOLF 2004 with Sports running gear with 18″ wheels (PR G02, G05, G07, 2UC) are:

1) Toe-out on turns can be displayed as a negative value on the wheel alignment computer, depending on the manufacturer.

The wheel alignment specifications for the Front axle of a VOLKSWAGEN GOLF 2004 with Heavy-duty running gear (PR 2UB) are:

1) Toe-out on turns can be displayed as a negative value on the wheel alignment computer, depending on the manufacturer.

The wheel alignment specifications for the Front axle of a VOLKSWAGEN GOLF 2004 with Sports running gear GTI (PR G08) are:

1) Toe-out on turns can be displayed as a negative value on the wheel alignment computer, depending on the manufacturer.

The wheel alignment specifications for the Front axle of a VOLKSWAGEN GOLF 2004 with Sports running gear GTI US version (PR G11) are:

1) Toe-out on turns can be displayed as a negative value on the wheel alignment computer, depending on the manufacturer.

The wheel alignment specifications for the Front axle of a VOLKSWAGEN GOLF 2004 with Sports running gear R32 (PR G09) are:

1) Toe-out on turns can be displayed as a negative value on the wheel alignment computer, depending on the manufacturer.

The wheel alignment specifications for the Front axle of a VOLKSWAGEN GOLF 2004 with BlueMotion (PR G04/2UC) are:

1) Toe-out on turns can be displayed as a negative value on the wheel alignment computer, depending on the manufacturer.

The procedure for correcting front axle camber when performing wheel alignment on a VOLKSWAGEN GOLF 2004 is:

• Camber correction is necessary only after body repairs. The camber is not adjustable, but can be equalized by moving the brackets and/or the subframe.
• Move subframe only to left or right, but never in or opposite to direction of normal travel!
• Remove noise insulation.
• Loosen bolts -1- for bracket attachment and subframe to body on both sides.
• The camber adjustment range is limited by the tolerances within the bores in the brackets and the subframe. If the specified value is not reached by moving the components, these and the body must be inspected.
• Specification for camber may be adjusted by moving subframe at brackets.
• Tighten bolts for subframe and brackets to body to specified torque plus extra turn angle.
• Following the movement of the subframe and, consequently, the steering box, clearance between the steering column universal joint and the notch in the bulkhead must be checked.
• Remove securing nuts -arrows- and remove footwell trim. There must be a clearance of 5 mm all round between universal joint -2- and recess in bulkhead.

Specified torques:

The procedure for checking the radial and lateral runout on the wheel when balancing wheels on a VOLKSWAGEN GOLF 2004 is:

• Mount the wheel on the wheel balancer.
• Use the wheel balancing machine centring system -VAS 5271-.
• Preload tyre gauge about 2 mm.
• Slowly rotate the wheel.
• Note the smallest and the largest dial readings. S – Lateral runout, H – Radial runout.
• Compare the measured values with the specifications in the table.

Note: Extreme values on the tyre gauge due to small irregularities may be disregarded.

Specifications for radial and lateral runout on wheel:

Note: If the measured value exceeds the specification, acceptably smooth running cannot be attained.

The procedure for match mounting when performing wheel alignment on a VOLKSWAGEN GOLF 2004 is:

• Before match mounting the used wheels which are fitted on the vehicle, run the tyres warm to eliminate any flat spots caused by storage or handling.
• Deflate the tyre.
• Press the tyre beads off the rim flanges.
• Coat the tyre bead all round with tyre fitting paste.
• Rotate the tyre 180° relative to the wheel.
• Inflate the tyre to approx. 4 bar.
• Mount the wheel with tyre on the wheel balancer.
• Check true running, that is, radial and lateral runout.

Note:

• If the specified values for radial and lateral runout are not exceeded, the wheel can be balanced to 0 gram. Specified values appear on page 328.
• If the radial and lateral runout is not within the specifications, the tyre must be rotated again.
• Deflate the tyre and press off the tyre beads from the rim flanges.
• Rotate the tyre 90° with respect to the wheel (1/4 of a turn).
• Inflate the tyre to 4 bar again and check true running.
• If the specified values for radial and lateral runout are not exceeded, the wheel can be balanced to 0 gram.
• If the radial and lateral runout are not within the specified values, the tyre must be rotated again.
• Press the tyre off the rim flanges again as described above.
• Rotate the tyre 180° with respect to the wheel (1/2 a turn).

The wheel bolt to wheel hub torque setting for all vehicles when setting torque settings for wheel bolts on a VOLKSWAGEN GOLF 2004 is 120 Nm.

The specified torque for the Wheel bolt to wheel hub for all vehicles when setting torque settings for wheel bolts on a VOLKSWAGEN GOLF 2004 is 120 Nm.

The warning for pressing tyre off the wheel rim when removing and fitting tyres (wheels with tyre pressure monitoring) on a VOLKSWAGEN GOLF 2004 is to Comply with the notes on safety and conditions on page 290.

The caution regarding the assembly head when pressing a tyre off the wheel rim using tyre fitting equipment on a VOLKSWAGEN GOLF 2004 is that The assembly head -1- must never be within area -a- of tyre valve/tyre pressure sensor -2-, or the assembly head will damage the tyre pressure sensor.

If the tyre bead does not lie completely against the wheel rim flange when inflating a tyre during the process of removing and fitting tyres with run-flat capability to wheel rims on a VOLKSWAGEN GOLF 2004, the following should be done:

• Deflate the tyre, press tyre bead off wheel rim flange and generously coat again with tyre assembly paste.
• Inflate tyre to a pressure of max. 3.3 bar (bead seating pressure).
• If the tyre beads seat perfectly against the shoulder of the wheel rim, increase pressure to 4 bar to “seat” the tyre.
• Fit a new nickel-plated valve insert and inflate tyre to prescribed inflation pressure.

The general notes for the Tyre monitor display on a VOLKSWAGEN GOLF 2004 are:

• The tyre pressure monitor system is part of the software in the ABS control unit -J104- . The system is used to detect slow tyre pressure loss from a wheel. Fault memory entries for the tyre monitor display are stored in the ABS control unit -J104- . The tyre pressure display compares the wheel speeds and consequently the rolling circumference of the individual wheels via the ABS sensors.
• After the following work or modifications, the tyre pressure monitor display button -E492- must be pressed and held until a confirmation is sounded:
  • Change in tyre pressure.
  • Changing one or more wheels.
  • Interchanging wheels, e.g. from front to rear.
• A change in the wheel’s rolling circumference will be indicated by the TPM warning lamp -K220- lighting up in the instrument cluster. A tyre’s rolling circumference may change as a result of:
  • Insufficient tyre inflation pressure.
  • Structural tyre damage.
  • One-sided loading of vehicle.
  • Increased load on one axle, e.g. due to towing a trailer.
  • Use of snow chains.
  • Spare wheel installed.
  • Wheel renewal.
• If a fault in the ABS is displayed by the ESP and TCS warning lamp -K155- or the traction control system warning lamp -K86- , then the tyre pressure monitor warning lamp -K220- -arrow- will also light up. However, no fault will be stored in the system for the tyre monitor display. The warning lamp cannot be extinguished by pressing the TPM button -E492- . In this case, please carry out the following steps:
  • Connect vehicle diagnosis, testing and information system -VAS 5051- and select “Guided fault finding” ⇒ Vehicle diagnosis, testing and information system VAS 5051.

The time conditions for pressing the SET button (-2-) in the centre console for the Tyre pressure monitor (TPM) on a VOLKSWAGEN GOLF 2004 are:

The table continues:

The components of the tyre pressure sensor assembly (7.2 Assembly overview – tyre pressure sensor) on a VOLKSWAGEN GOLF 2004 are:

• 1 – Tyre pressure sensor (Supplied complete as spare part. Removing and installing on page 304. Replace complete tyre pressure sensor when battery is dead. After using breakdown set, wipe clean hole for valve and opening for pressure sensor).
• 2 – Valve core (Allocation ⇒ Electronic parts catalogue “ETKA”. Always renew when changing tyre).
• 3 – Sealing washer.
• 4 – Sealing ring (Will be slightly deformed when the union nut ⇒ Item 6 (page 303) is tightened).
• 5 – Wheel (Fitting tyres of wheels with tyre pressure monitoring on page 290. Fitting tyres with run-flat capabilities on page 294).
• 6 – Union nut (8 Nm).
• 7 – Valve cap (Use only genuine valve caps from repair set ⇒ Electronic parts catalogue “ETKA”).

The specified torque for the Union nut to tyre pressure sensor when removing and installing the tyre pressure sensor on a VOLKSWAGEN GOLF 2004 is 8 Nm.

The wheel alignment procedure on a VOLKSWAGEN GOLF 2004 is:

• Start → Carry out wheel run-out compensation. → Bounce springs.
• Turn steering wheel to straight-ahead position and lock in place 1) ← Measure vehicle height. ← Fit brake pedal depressor -V.A.G 1869/2-.
• Check front axle camber → Is actual value within tolerance?

  No: Adjust ⇒ page 312 .

  Yes: (Continue down the flow chart)

• Check rear axle camber → Is actual value within tolerance?

  No: Adjust ⇒ page 314 .

  Yes: (Continue down the flow chart)

• Check rear axle toe → Is actual value within tolerance?

  No: Adjust ⇒ page 315 .

  Yes: (Continue down the flow chart)

• Check front axle caster. → Is actual value within tolerance?

  No: Inspect axle components and body.

  Yes: (Continue down the flow chart)

• Check front axle toe → Is actual value within tolerance?

  No: Adjust ⇒ page 316 .

  Yes: End.

1) If steering wheel is not centred, it must be straightened after wheel alignment is finished. Then perform basic settings for steering angle sensor -G85- using vehicle diagnosis, testing and information system -VAS 5051- .

The torque settings for the wheel bolts on a VOLKSWAGEN GOLF 2004 are:

• When fitting the wheel, screw in all wheel bolts uniformly by hand.
• Tighten the wheel bolts in diagonal sequence to approx. 30 Nm.
• Lower the vehicle to the floor and tighten all wheel bolts diagonally to the specified torque using the torque wrench on page 288.

WARNING: Do not use an impact driver when screwing in the bolts!

The warning when fitting wheels on a VOLKSWAGEN GOLF 2004 is: Perform the checks and follow the instructions listed below. This is important to ensure that the wheel bolts and the wheels are properly secured.

The procedure for cleaning contact surfaces when instructions for changing or fitting wheels on a VOLKSWAGEN GOLF 2004 is:

• Check to ensure that contact surfaces -arrows- on brake disc are free of corrosion and dirt.
• Check to ensure that contact surface -arrow- on centring seat of brake disc are free of corrosion and dirt.
• Check to ensure that contact surface -arrow- on inner side of wheel (rim) and also centring seat of rim are free of corrosion and dirt.
• The spherical caps * in the holes for the wheel bolts and the threads of the wheel bolts must also be free of corrosion and dirt, oil or grease.

The general information regarding fitting wheel and tyre on a VOLKSWAGEN GOLF 2004 is:

• Since model year 2005, new wheel rims with a modified contour have been used in all vehicles.
• The tyre fitting unit must be fitted with the tyre fitting head designed for these wheels.

WARNING: Otherwise there is a danger that the wheel will be damaged.

If the tyre fitting unit has not been modified, please contact the manufacture of the unit.

The general information for models with a breakdown set on a VOLKSWAGEN GOLF 2004 is that VOLKSWAGEN GOLF 2004 models are equipped with either a spare wheel or a breakdown set. The breakdown set is located in the luggage compartment where normally the spare wheel would sit. It consists of a compressor and a bottle of tyre sealant.

The tyre sealant in the bottle has a limited shelf-life on a VOLKSWAGEN GOLF 2004. The bottle therefore has an expiry date. If the bottle has been opened, e.g. to repair a tyre, then it must also be renewed.

The warning when removing a tyre that has been filled or sealed using tyre sealant on a VOLKSWAGEN GOLF 2004 is:

• Avoid eye and skin contact with tyre sealant.
• It is a health hazard and may cause eye irritation and allergies.
• Wear eye protection and protective gloves whilst working on the tyre.

The general repair instructions for the steering box on a VOLKSWAGEN GOLF 2004 are:

• Thoroughly clean all unions and the adjacent areas before disconnecting.
• When installing the steering box, make sure that dowel sleeves between bracket and steering box are seated correctly.
• Place removed parts on a clean surface and cover them to prevent them from getting dirty. Use sheeting and paper for this purpose. Use only lint-free cloths.
• Fit only clean parts; remove new parts from their packaging only immediately prior to fitting.
• Use only the grease and sealants with specified part numbers.
• If repairs cannot be carried out immediately, carefully cover or seal open components.
• Two different types of steering boxes were fitted in model year 2004. Notes on identification on page 398.
• From model year 2009, a new, 3rd generation, steering box is being used. Notes on differentiating between 2nd and 3rd generations on page 399.

The safety precautions before starting work on the electrical system and removing the steering wheel when repairing the steering column for a VOLKSWAGEN GOLF 2004 are:

• Disconnect earth strap from battery ⇒ Electrical system; Rep. Gr. 27 ; Battery; Disconnecting and reconnecting battery.
• Wheels must be in straight-ahead position.

Failure to comply with these precautions may lead to subsequent failure of the airbag system!

The specified torque for the Steering wheel to steering column connection when removing and installing the steering wheel on a VOLKSWAGEN GOLF 2004 is 30 Nm + 90° further. Always renew bolt.

The specified torques for component tightening when repairing the steering column, Golf on a VOLKSWAGEN GOLF 2004 are:

The torque setting for the hexagon bolt when loosening the drive shaft hexagon bolt on a VOLKSWAGEN GOLF 2004 is 200 Nm, then turn 180° further. Renew hexagon bolt.

The procedure for loosening the hexagon bolt when dealing with the drive shaft hexagon bolt on a VOLKSWAGEN GOLF 2004 is:

• For vehicles which are still standing on their wheels, loosen the hexagon bolt a maximum of 90°, as the wheel bearing will otherwise be damaged.
• Raise vehicle so that wheels are off the ground.
• Have second mechanic apply brakes.
• Remove hexagon bolt -arrow-.

The procedure for tightening the hexagon bolt when dealing with the drive shaft hexagon bolt on a VOLKSWAGEN GOLF 2004 is:

• Renew hexagon bolt.
• The wheels must not be in contact with the ground when the drive shaft bolt is tightened; otherwise, the wheel bearing will be damaged.
• Have second mechanic apply brakes.
• Tighten hexagon bolt to 180 Nm.
• Lower vehicle onto its wheels.
• Turn hexagon bolt 180° further.

To avoid damage to wheel bearing, do not loosen 12-point bolt using 24 mm socket -T10361- further than 90° with vehicle still standing on its wheels when loosening the 12-point bolt for drive shaft on a VOLKSWAGEN GOLF 2004.

The procedure for loosening the 12-point bolt for drive shaft on a VOLKSWAGEN GOLF 2004 is:

• Do not attempt to move the vehicle without the drive shafts fitted as this would result in wheel bearing damage. If the vehicle does have to be moved, always note the following points:
  • Fit an outer joint in place of drive shaft.
  • Tighten outer joint to 120 Nm.
• With vehicle still standing on its wheels, loosen the twelve-point bolt a maximum of 90°, as the wheel bearing will otherwise be damaged.
• Raise vehicle so that wheels are off the ground.
• Have second mechanic apply brakes.
• Remove 12-point bolt -arrow-.

The procedure for fitting the 12-point bolt for drive shaft on a VOLKSWAGEN GOLF 2004 is:

• Renew 12-point bolt.
• The wheels must not be in contact with the ground when the drive shaft bolt is tightened; otherwise, the wheel bearing will be damaged.
• Have second mechanic apply brakes.
• Tighten 12-point bolt to 70 Nm.
• Lower vehicle onto its wheels.
• Turn 12-point bolt 90° further.

The specified torque for the Drive shaft to wheel hub “hexagon bolt” when removing and installing drive shaft with constant velocity joint on a VOLKSWAGEN GOLF 2004 is 200 Nm +180°. Use new bolt.

The specified torque for the Drive shaft to wheel hub “12-point bolt” when removing and installing drive shaft with constant velocity joint on a VOLKSWAGEN GOLF 2004 is 70 Nm + 90°. Use new bolt.

The specified torque for the Swivel joint to cast steel suspension link when removing and installing drive shaft with constant velocity joint on a VOLKSWAGEN GOLF 2004 is 60 Nm. Use new nuts.

The specified torque for the Swivel joint to sheet steel or forged aluminium suspension link when removing and installing drive shaft with constant velocity joint on a VOLKSWAGEN GOLF 2004 is 100 Nm. Use new nuts.

The specified torque for the Drive shaft to flange shaft on gearbox “M8 multi-point socket” when removing and installing left drive shaft with (push-on) constant velocity slip joint on a VOLKSWAGEN GOLF 2004 is 40 Nm. Initially tighten diagonally to 10 Nm. Use new bolts and new backing plates.

The specified torque for the Drive shaft to flange shaft on gearbox “M10 multi-point socket” when removing and installing left drive shaft with (push-on) constant velocity slip joint on a VOLKSWAGEN GOLF 2004 is 70 Nm. Initially tighten diagonally to 10 Nm. Use new bolts and new backing plates.

The specified torque for the Intermediate shaft bearing to bearing bracket when removing and installing intermediate shaft on a VOLKSWAGEN GOLF 2004 is 20 Nm.

The specified torque for the Swivel joint to cast steel suspension link when removing and installing drive shafts with triple roller joint AAR2600i on a VOLKSWAGEN GOLF 2004 is 60 Nm.

The specified torque for the Drive shaft to wheel hub “12-point bolt” when removing and installing drive shafts with triple roller joint AAR2600i on a VOLKSWAGEN GOLF 2004 is 70 Nm + 90° further. Use new bolt.

The specified torques for the Front-wheel drive when checking heat shields for drive shafts on a VOLKSWAGEN GOLF 2004 are:

The specified torques for the Four-wheel drive when checking heat shields for drive shafts on a VOLKSWAGEN GOLF 2004 are:

The installation position for the Dished spring (7) and Thrust washer (8) on the outer joint when assembling the drive shaft with VL90 or VL100 constant velocity joint on a VOLKSWAGEN GOLF 2004 is as follows: Dished spring (1) and Thrust washer (2) on the outer joint.

The installation position for the Dished spring at the inner joint when pressing on the inner constant velocity joint when assembling the drive shaft with VL90 or VL100 constant velocity joint on a VOLKSWAGEN GOLF 2004 is: 1 – Dished spring.

The specified torque for the Hexagon bolt (2) when assembling the drive shaft with VL107 constant velocity joint (bolt-on) on a VOLKSWAGEN GOLF 2004 is 200 Nm and turn +180° further. Always renew after removing.

The specified torque for the 12-point bolt when assembling the drive shaft with VL107 constant velocity joint (bolt-on) on a VOLKSWAGEN GOLF 2004 is 70 Nm + 90° further. Always renew after removing.

The specified torque for the Multi-point socket head bolt (20) when assembling the drive shaft with VL107 constant velocity slip joint (push-on) on a VOLKSWAGEN GOLF 2004 is as follows: Initially tighten diagonally to 10 Nm and then tighten diagonally to specified torque. M8 bolt: 40 Nm, M10 bolt: 70 Nm. Always renew bolts after removing.

The specified torque for the Bolt (2) when assembling the drive shaft with triple roller joint AAR2600i on a VOLKSWAGEN GOLF 2004 is:

• Hexagon bolt: 200 Nm and turn +180° further.
• 12-point bolt: 70 Nm + 90° further.

Always renew after removing.

The specified torque for the Swivel joint to cast steel suspension link when assembling the drive shaft with triple roller joint AAR2600i on a VOLKSWAGEN GOLF 2004 is 60 Nm. Use new nuts.

The specified torque for the Bolt (2) when assembling the drive shaft with triple roller joint AAR3300i on a VOLKSWAGEN GOLF 2004 is:

• Hexagon bolt: 200 Nm and turn +180° further.
• 12-point bolt: 70 Nm + 90° further.

Always renew after removing.

The specified torque for the Swivel joint to cast steel suspension link when assembling the drive shaft with triple roller joint AAR3300i on a VOLKSWAGEN GOLF 2004 is 60 Nm. Use new nuts.

The specified torque for the Multi-point socket head bolt (20) when assembling the control arm, track rod (four-wheel drive, subframe made from aluminium and wheel bearing housing made from cast steel) on a VOLKSWAGEN GOLF 2004 is M12 x 1.5 x 125, 90 Nm + 90° further. Always tighten threaded connections in unladen position on page 187.

The specified torque for the Nut (26) when assembling the control arm, track rod (four-wheel drive, subframe made from aluminium and wheel bearing housing made from cast steel) on a VOLKSWAGEN GOLF 2004 is M12 x 1.5, 90 Nm + 90° further. Self-locking. Always renew after removing. Always tighten threaded connections in unladen position on page 187.

The procedure for checking the swivel joint when dealing with the subframe, anti-roll bar, suspension link on a VOLKSWAGEN GOLF 2004 is:

• Checking axial play: Firmly pull suspension link down in -direction of arrow- and press up again.
• Checking radial play: Press lower part of wheel forcefully inwards and outwards in -direction of arrow-.

Note:

• There should be no palpable or visible “play” during both tests.
• Observe swivel joint while performing tests.
• Take into account possible existing “play” in wheel bearing or in upper suspension strut mounting.
• Check rubber boot for damage and renew swivel joint if necessary.

The specified torque for Swivel joint to cast steel suspension link when removing and installing the swivel joint on a VOLKSWAGEN GOLF 2004 is 60 Nm. Use new nuts.

The specified torque for Swivel joint to sheet steel or forged aluminium suspension link when removing and installing the swivel joint on a VOLKSWAGEN GOLF 2004 is 100 Nm. Use new nuts.

The specified torque for the Suspension strut to wheel bearing housing when installing the suspension strut, Golf on a VOLKSWAGEN GOLF 2004 is 70 Nm + 90°. Use new nut.

The specified torque for the Suspension strut to body (suspension turret) when installing the suspension strut, Golf on a VOLKSWAGEN GOLF 2004 is 15 Nm + 90°. Use new bolts.

The specified torque for the Coupling rod to suspension strut when installing the suspension strut, Golf on a VOLKSWAGEN GOLF 2004 is 65 Nm. Use new nut. Counterhold on multi-point socket of joint pin.

The specified torque for the Drive shaft to wheel hub “hexagon bolt” when installing the suspension strut, Golf on a VOLKSWAGEN GOLF 2004 is 200 Nm +180°. Use new bolt.

The specified torque for the Drive shaft to wheel hub “12-point bolt” when installing the suspension strut, Golf on a VOLKSWAGEN GOLF 2004 is 70 Nm + 90°. Use new bolt.

The specified torque for the Suspension strut mounting to shock absorber when removing and installing the coil spring on a VOLKSWAGEN GOLF 2004 is 60 Nm. Use new nut.

The specified torque for the Shock absorber to body when installing the shock absorber on a VOLKSWAGEN GOLF 2004 is 50 Nm + 45° further. Use new bolts!

The specified torque for the Shock absorber to wheel bearing housing when installing the shock absorber on a VOLKSWAGEN GOLF 2004 is 180 Nm.

The specified torque for the Anti-roll bar to subframe when removing and installing the anti-roll bar (front-wheel drive) on a VOLKSWAGEN GOLF 2004 is 25 Nm + 45° further. Use new bolts. Tighten threaded connections only when vehicle is in the normal running position.

The specified torque for the Anti-roll bar to coupling rod when removing and installing the anti-roll bar (front-wheel drive) on a VOLKSWAGEN GOLF 2004 is 45 Nm. Use new nut.

The specified torque for the Subframe to body connection when removing and installing the subframe made from aluminium, final drive (four-wheel drive) on a VOLKSWAGEN GOLF 2004 is 90 Nm + 90°. Use new bolts.

The specified torque for the Shock absorber to wheel bearing housing when removing and installing the subframe made from aluminium, final drive (four-wheel drive) on a VOLKSWAGEN GOLF 2004 is 180 Nm.

The specified torque for the Mounting bracket to body when removing and installing the subframe made from aluminium, final drive (four-wheel drive) on a VOLKSWAGEN GOLF 2004 is 50 Nm + 45° further. Use new bolts.

The specified torque for the Subframe to body connection when removing and installing the subframe made from steel, final drive (four-wheel drive) on a VOLKSWAGEN GOLF 2004 is 90 Nm + 90° further. Use new bolts!

The specified torque for the Track rod to subframe when assembling the control arm, track rod (four-wheel drive, subframe made from steel and wheel bearing housing made from aluminium) on a VOLKSWAGEN GOLF 2004 is 90 Nm + 90°. Use new nuts and bolts. Tighten threaded connections only when vehicle is in the normal running position.

The specified torque for the Anti-roll bar to subframe when assembling the anti-roll bar (four-wheel drive, subframe made from steel and wheel bearing housing made from aluminium) on a VOLKSWAGEN GOLF 2004 is 25 Nm + 45° further. Use new bolts! Tighten threaded connections only when vehicle is in the normal running position.

The specified torque for the Anti-roll bar to coupling rod when assembling the anti-roll bar (four-wheel drive, subframe made from steel and wheel bearing housing made from aluminium) on a VOLKSWAGEN GOLF 2004 is 45 Nm. Use new nut.

The specified torque for the Wheel hub with wheel bearing to wheel bearing housing when removing and installing wheel bearing/wheel hub unit on a VOLKSWAGEN GOLF 2004 with four-wheel drive, subframe made from steel and wheel bearing housing made from aluminium is 70 Nm + 90° further. Use new bolt.

The specified torque for the Brake disc to wheel bearing housing when removing and installing wheel bearing/wheel hub unit on a VOLKSWAGEN GOLF 2004 with four-wheel drive, subframe made from steel and wheel bearing housing made from aluminium is 4 Nm.

The specified torque for the Shock absorber to body when removing and installing coil spring on a VOLKSWAGEN GOLF 2004 with four-wheel drive, subframe made from steel and wheel bearing housing made from aluminium is 50 Nm + 45° further. Use new bolts!

The specified torque for the Shock absorber to wheel bearing housing when removing and installing shock absorbers on a VOLKSWAGEN GOLF 2004 with four-wheel drive, subframe made from steel and wheel bearing housing made from aluminium is 180 Nm.

The specified torque for the Subframe to body connection when repairing the subframe made from steel, final drive (four-wheel drive) on a VOLKSWAGEN GOLF 2004 is 90 Nm + 90° further. Use new bolts!

The specified torque for the Track rod to subframe when repairing the subframe made from steel, final drive (four-wheel drive) on a VOLKSWAGEN GOLF 2004 is 90 Nm + 90°. Use new nuts and bolts. Tighten threaded connections only when vehicle is in the normal running position.

The specified torque for the Track rod ball joint to wheel bearing housing when repairing the subframe made from steel, final drive (four-wheel drive) on a VOLKSWAGEN GOLF 2004 is 20 Nm + 90°. Use new nut.

The wheel alignment specifications for the Rear axle, front-wheel drive and 4WD of a VOLKSWAGEN GOLF 2004 with Standard running gear are:

The wheel alignment specifications for the Rear axle, front-wheel drive and 4WD of a VOLKSWAGEN GOLF 2004 with Sports running gear except 18″ wheels are:

The wheel alignment specifications for the Rear axle, front-wheel drive and 4WD of a VOLKSWAGEN GOLF 2004 with Sports running gear with 18″ wheels are:

The wheel alignment specifications for the Rear axle, front-wheel drive and 4WD of a VOLKSWAGEN GOLF 2004 with Heavy-duty running gear are:

The wheel alignment specifications for the Rear axle, front-wheel drive and 4WD of a VOLKSWAGEN GOLF 2004 with CrossGolf are:

The wheel alignment specifications for the Rear axle, front-wheel drive and 4WD of a VOLKSWAGEN GOLF 2004 with Golf Plus BlueMotion are:

The specified torque for the Track rod ball joint to wheel bearing housing when assembling the control arm, track rod (four-wheel drive, subframe made from steel and wheel bearing housing made from aluminium) on a VOLKSWAGEN GOLF 2004 is 130 Nm + 90°. Use new nuts and bolts. Tighten threaded connections only when vehicle is in the normal running position.

The specified torque for the Track rod to subframe when assembling the control arm, track rod (four-wheel drive, subframe made from steel and wheel bearing housing made from aluminium) on a VOLKSWAGEN GOLF 2004 is 90 Nm + 90°. Use new nuts and bolts. Tighten threaded connections only when vehicle is in the normal running position.

The specified torque for the Anti-roll bar to subframe when assembling the control arm, track rod (four-wheel drive, subframe made from steel and wheel bearing housing made from aluminium) on a VOLKSWAGEN GOLF 2004 is 25 Nm + 45°. Use new bolts. Tighten threaded connections only when vehicle is in the normal running position.

The specified torque for the Anti-roll bar to coupling rod when assembling the control arm, track rod (four-wheel drive, subframe made from steel and wheel bearing housing made from aluminium) on a VOLKSWAGEN GOLF 2004 is 45 Nm. Use new nut.

The specified torque for the Track rod ball joint to track rod when performing wheel alignment on a VOLKSWAGEN GOLF 2004 is 50 Nm.

The specified torque for the Track rod ball joint to wheel bearing housing when performing wheel alignment on a VOLKSWAGEN GOLF 2004 is 20 Nm + 90°. Use new nut.

The specified torque for the Track rod to steering rack in steering box when performing wheel alignment on a VOLKSWAGEN GOLF 2004 is 100 Nm.

The specified torque for the Wheel bolt to wheel hub for all vehicles when fitting wheels on a VOLKSWAGEN GOLF 2004 is to tighten all wheel bolts diagonally to the specified torque using the torque wrench on page 288.

The specified torque for the Wheel bolt to wheel hub when checking radial and lateral runout on wheels and tyres with tyre gauge -V.A.G 1435- on a VOLKSWAGEN GOLF 2004 is to tighten wheel bolts to specified torque if you have not already done so.

The specified torque for the Steering wheel to steering column connection when securing the steering wheel with bolt -3- on a VOLKSWAGEN GOLF 2004 is 30 Nm + 90° further. Always renew bolt.

The specified torques for the Steering column to mounting bracket connection when securing the steering wheel with bolt -3- on a VOLKSWAGEN GOLF 2004 is 20 Nm.

The specified torques for component tightening when repairing the steering column, Golf on a VOLKSWAGEN GOLF 2004 are:

The specified torques for component tightening when repairing the steering column, Golf Plus, CrossGolf on a VOLKSWAGEN GOLF 2004 are:

The specified torques for component tightening when performing Basic setting for steering angle sender G85 steering angle sender must be checked after the following repair work on a VOLKSWAGEN GOLF 2004 are:

The specified torque for the Bolt (3) when performing Assembly overview – electromechanical steering box, left-hand drive (1st and 2nd generations) up to model year 2008 on a VOLKSWAGEN GOLF 2004 is 30 Nm. Always renew after removing.

The specified torque for the Nut (6) when performing Assembly overview – electromechanical steering box, left-hand drive (1st and 2nd generations) up to model year 2008 on a VOLKSWAGEN GOLF 2004 is M12 x 1.5, 20 Nm + 90° further. Self-locking. Always renew after removing.

The specified torque for the Bolt (8) when performing Assembly overview – electromechanical steering box, left-hand drive (1st and 2nd generations) up to model year 2008 on a VOLKSWAGEN GOLF 2004 is 50 Nm + 90° further. Always renew clamp for steering box. Always renew after removing.

The specified torque for the Bolt (10) when performing Assembly overview – electromechanical steering box, left-hand drive (1st and 2nd generations) up to model year 2008 on a VOLKSWAGEN GOLF 2004 is 6 Nm. Self-locking.

The specified torque for the Bolt (22) when performing Assembly overview – electromechanical steering box, right-hand drive (2nd generation) up to model year 2008 on a VOLKSWAGEN GOLF 2004 is 20 Nm. For Golf only.

The specified torque for the Countersunk head bolt (23) when performing Assembly overview – electromechanical steering box, right-hand drive (2nd generation) up to model year 2008 on a VOLKSWAGEN GOLF 2004 is to initially tighten to 5 Nm and then to 35 Nm. For Golf only. Qty. 3.

The specified torque for the Bolt (9) when performing Assembly overview – electromechanical steering box, left-hand drive (3rd generation) after model year 2009 on a VOLKSWAGEN GOLF 2004 is 50 Nm + 90° further. Always renew after removing.

The specified torque for the Nut (8) when performing Assembly overview – electromechanical steering box, right-hand drive (3rd generation) after model year 2009 on a VOLKSWAGEN GOLF 2004 is M12 x 1.5, 20 Nm + 90° further. Self-locking. Always renew after removing.

The specified torque for the Bolt (9) when performing Assembly overview – electromechanical steering box, right-hand drive (3rd generation) after model year 2009 on a VOLKSWAGEN GOLF 2004 is 50 Nm + 90° further. Always renew after removing.

The specified torque for the Bolt (3) when performing Repairing electromechanical steering box (1st generation), Golf on a VOLKSWAGEN GOLF 2004 is 30 Nm. Always renew after removing.

The specified torque for the Track rod ball joint to track rod when performing Repairing electromechanical steering box (1st generation), Golf on a VOLKSWAGEN GOLF 2004 is 50 Nm.

The specified torque for the Track rod ball joint to wheel bearing housing when performing Repairing electromechanical steering box (1st generation), Golf on a VOLKSWAGEN GOLF 2004 is 20 Nm + 90°. Use new nut.

The specified torque for the Track rod to steering rack in steering box when performing Repairing electromechanical steering box (1st generation), Golf on a VOLKSWAGEN GOLF 2004 is 100 Nm.

The specified torques for component tightening when performing Repairing electromechanical steering box (2nd and 3rd generations) on a VOLKSWAGEN GOLF 2004 are:

The specified torque for the Track rod ball joint to track rod when performing Repairing electromechanical steering box (2nd and 3rd generations) on a VOLKSWAGEN GOLF 2004 is 50 Nm.