VOLKSWAGEN GOLF PLUS 2005 (01) PDF Document

The first step for a visual and functional examination of the steering system for a VOLKSWAGEN GOLF PLUS 2005 after an accident is a visual examination for deformation and cracks.

When repairing the front suspension of a VOLKSWAGEN GOLF PLUS 2005, always renew self-locking nuts.

When repairing the front suspension of a VOLKSWAGEN GOLF PLUS 2005, always renew corroded nuts and bolts.

Threaded connections of components with bonded rubber bushes should only be tightened when the wheel bearing housing is raised to unladen position for a VOLKSWAGEN GOLF PLUS 2005.

The required ride height -a- in mm for Standard running gear (2UA) when raising the wheel suspension to unladen position for a VOLKSWAGEN GOLF PLUS 2005 is 383 ± 10 mm.

The required ride height -a- in mm for Heavy-duty running gear (2UB) when raising the wheel suspension to unladen position for a VOLKSWAGEN GOLF PLUS 2005 is 403 ± 10 mm.

The required ride height -a- in mm for Sports running gear except 18″ wheels (2UC) when raising the wheel suspension to unladen position for a VOLKSWAGEN GOLF PLUS 2005 is 368 ± 10 mm.

The required ride height -a- in mm for Sports running gear with 18″ wheels (G02/G07/2UC) when raising the wheel suspension to unladen position for a VOLKSWAGEN GOLF PLUS 2005 is 368 ± 10 mm.

The required ride height -a- in mm for CrossGolf (2UB) when raising the wheel suspension to unladen position for a VOLKSWAGEN GOLF PLUS 2005 is 400 ± 10 mm.

The required ride height -a- in mm for BlueMotion (G06) when raising the wheel suspension to unladen position for a VOLKSWAGEN GOLF PLUS 2005 is 373 ± 10 mm.

The torque specification for Bolt 5 (Bolt) in the Subframe, anti-roll bar, suspension link assembly overview for the VOLKSWAGEN GOLF PLUS 2005 is 50 Nm + 90° further. Always renew after removing.

The torque specification for Bolt 6 (Bolt) in the Subframe, anti-roll bar, suspension link assembly overview for the VOLKSWAGEN GOLF PLUS 2005 is 70 Nm + 90° further (M12 x 1.5 x 90). Always renew after removing.

The torque specification for Bolt 7 (Bolt) in the Subframe, anti-roll bar, suspension link assembly overview for the VOLKSWAGEN GOLF PLUS 2005 is 70 Nm + 90° further (M12 x 1.5 x 90). Always renew after removing.

The torque specification for Nut 1 (Nut) in the Subframe, anti-roll bar, suspension link assembly overview for the VOLKSWAGEN GOLF PLUS 2005 is 65 Nm (Self-locking, Always renew after removing).

The torque specification for Nut 12 (Nut) in the Subframe, anti-roll bar, suspension link assembly overview for the VOLKSWAGEN GOLF PLUS 2005 is 60 Nm (M12 x 1.5, Self-locking, Always renew after removing).

The specified torque for the Swivel joint to cast steel suspension link connection when repairing the subframe (front-wheel drive) for a VOLKSWAGEN GOLF PLUS 2005 is 60 Nm. Use new nuts.

The specified torque for the Swivel joint to sheet steel or forged aluminium suspension link connection when repairing the subframe (front-wheel drive) for a VOLKSWAGEN GOLF PLUS 2005 is 100 Nm. Use new nuts.

The specified torques for pendulum support to gearbox when repairing the subframe (front-wheel drive) for a VOLKSWAGEN GOLF PLUS 2005 are:

Bolt M10 x 35 strength class 8.8: 40 Nm + 90° further. Use new bolt.

Bolt M10 x 35 strength class 10.9: 50 Nm + 90° further. Use new bolt.

Bolt M10 x 75 strength class 8.8: 40 Nm + 90° further. Use new bolt.

Bolt M10 x 75 strength class 10.9: 50 Nm + 90° further. Use new bolt.

To check the swivel joint for the VOLKSWAGEN GOLF PLUS 2005:

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.

The torque specification for the Wheel hub with wheel bearing to wheel bearing housing when removing and installing the wheel bearing/wheel hub unit for the VOLKSWAGEN GOLF PLUS 2005 (rear suspension, four-wheel drive, subframe made from aluminium and wheel bearing housing made from cast steel) is 70 Nm + 90° further. Use new bolt.

The specified torque for the Brake disc to wheel bearing housing connection when removing and installing the wheel bearing/wheel hub unit for the VOLKSWAGEN GOLF PLUS 2005 (rear suspension, four-wheel drive, subframe made from aluminium and wheel bearing housing made from cast steel) is 4 Nm.

The specified torques for the Upper transverse link to wheel bearing housing when installing the upper transverse link for the VOLKSWAGEN GOLF PLUS 2005 (rear suspension, four-wheel drive, subframe made from steel and wheel bearing housing made from aluminium) are 130 Nm + 90° further. Use new nuts and bolts. Tighten threaded connections only when vehicle is in the normal running position.

The specified torques for the Upper transverse link to subframe when installing the upper transverse link for the VOLKSWAGEN GOLF PLUS 2005 (rear suspension, four-wheel drive, subframe made from steel and wheel bearing housing made from aluminium) are 95 Nm. Use new nut. Tighten threaded connections only when vehicle is in the normal running position. To tighten nuts, set torque wrench -V.A.G 1332- to 80 Nm. Applies only in conjunction with insert tool, 18 mm -T10179-.

The specified torque for the Wheel bolt to wheel hub for all vehicles when setting torque for wheel bolts on the VOLKSWAGEN GOLF PLUS 2005 is 120 Nm.

Assuming a minimum room temperature of 19 °C and a tyre temperature of 0 °C or more, a tyre should be kept at least at 19 °C for at least 2 hours when warming cold tyres for a VOLKSWAGEN GOLF PLUS 2005 before fitting them to wheel rims with run-flat capability. If the tyre temperature is below 0 °C, a tyre should be kept at least at 19 °C for at least 2.5 hours.

If the tyre fitting unit for a VOLKSWAGEN GOLF PLUS 2005 has not been modified for new wheel rims with a modified contour (since model year 2005), contact the manufacture of the unit.

Never increase the inflation pressure when the tyre bead of a VOLKSWAGEN GOLF PLUS 2005 does not lie completely against the wheel rim flange during run-flat tyre fitting, as this would lead to damage to the tyre and/or the wheel rim.

If the tyre bead of a VOLKSWAGEN GOLF PLUS 2005 does not lie completely against the wheel rim flange after initial inflation, deflate the tyre, press tyre bead off wheel rim flange and generously coat again with tyre assembly paste. Then inflate the tyre to a pressure of max. 3.3 bar (bead seating pressure).

If the tyre beads of a VOLKSWAGEN GOLF PLUS 2005 seat perfectly against the shoulder of the wheel rim, increase pressure to 4 bar to “seat” the tyre, then fit a new nickel-plated valve insert and inflate tyre to prescribed inflation pressure.

The specified torque for the wheel bolt to wheel hub for all vehicles when fitting wheels on the VOLKSWAGEN GOLF PLUS 2005 is approximately 30 Nm initially tightened in diagonal sequence, and then tightened to the specified torque (page 288) diagonally.

After making changes like wheel swaps on a VOLKSWAGEN GOLF PLUS 2005, press and hold the tyre pressure monitor display button -E492- until a confirmation is sounded.

If the ESP and TCS warning lamp -K155- or the traction control system warning lamp -K86- are displayed on a VOLKSWAGEN GOLF PLUS 2005, connect the vehicle diagnosis, testing and information system -VAS 5051- and select “Guided fault finding” in the “Tyre pressure monitor display / Tyre pressure warning” function. Follow instructions on screen to perform basic setting.

When the TPM button on the VOLKSWAGEN GOLF PLUS 2005 is pressed for 3-7 seconds while switching on the system, the actual state is “Partial tyre load monitored (gong)”, the switch action is “Full tyre load on!”, and on release, there is a “Confirmation of switching via gong”.

When the TPM button on the VOLKSWAGEN GOLF PLUS 2005 is pressed for 8-10 seconds during a status query when TPM is off (actual state is “TPM off! or Partial tyre load monitored (gong)”), the switch action is “Partial tyre load on! or Full tyre load on!” and on release, there is a “Confirmation of switching via gong”.

When the TPM button on the VOLKSWAGEN GOLF PLUS 2005 is pressed for 11-15 seconds when switching on the system, the actual state is “TPM off!”, the switch action is “Partial tyre load on!”, and on release, there is a “Confirmation of switching via gong”.

The torque setting for the Union nut to tyre pressure sensor when removing and installing the tyre pressure sensor for the VOLKSWAGEN GOLF PLUS 2005 is 8 Nm.

Before installing a tyre pressure sensor on a VOLKSWAGEN GOLF PLUS 2005, clean the valve hole.

It must be ensured that the tyre pressure sensor is pressed tyre pressure sensor -1- onto bed of rim at the points marked by -arrows- and the union nut is tightened to 8 Nm for the VOLKSWAGEN GOLF PLUS 2005.

To ensure optimal safety, smoothest possible running, and even wear throughout a tyre’s service life for a VOLKSWAGEN GOLF PLUS 2005, it is recommended to have the wheels and tyres balanced at least twice during the tyre’s service life.

Before balancing the wheels on a stationary wheel balancing machine for a VOLKSWAGEN GOLF PLUS 2005, the following requirements must be met:

The tyre pressure must be OK.

The tyre tread must not show one-sided wear and should be at least 4 mm deep.

The tyre must not show any signs of damage, for example cuts, piercing, foreign bodies, etc.

The wheel suspension, steering and steering linkage, including the shock absorbers, must be in perfect condition.

You must have conducted a road test.

The maximum permissible radial runout (mm) for a Steel wheel with tyre for a VOLKSWAGEN GOLF PLUS 2005 is 0.9.

The maximum permissible lateral runout (mm) for a Steel wheel with tyre for a VOLKSWAGEN GOLF PLUS 2005 is 1.1 (1.3 in vicinity of lettering).

The maximum permissible radial runout (mm) for an Alloy wheel with tyre for a VOLKSWAGEN GOLF PLUS 2005 is 0.5.

The maximum permissible lateral runout (mm) for an Alloy wheel with tyre for a VOLKSWAGEN GOLF PLUS 2005 is 0.8.

The specifications for radial and lateral runout on a Steel wheel for a VOLKSWAGEN GOLF PLUS 2005 are:

Radial runout (mm): 0.5

Lateral runout (mm): 0.5

The specifications for radial and lateral runout on an Alloy wheel for a VOLKSWAGEN GOLF PLUS 2005 are:

Radial runout (mm): 0.5

Lateral runout (mm): 0.8

The procedure for match mounting to reduce imbalance on a VOLKSWAGEN GOLF PLUS 2005 is:

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.

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 basic setting for the steering angle sender -G85- must be checked after the following repair work on a VOLKSWAGEN GOLF PLUS 2005 steering system:

When vehicle steering angle sensor -G85- is removed or renewed.

If steering column was removed or renewed.

If steering lock housing with steering column switch was removed or renewed.

If steering box was removed or renewed.

If steering wheel was repositioned.

The specified torque for the Steering wheel to steering column connection when installing the steering wheel on a VOLKSWAGEN GOLF PLUS 2005 is 30 Nm + 90° further. Always renew bolt.

The specified torque for the Universal joint to steering box connection when installing the steering column on a VOLKSWAGEN GOLF PLUS 2005 (Golf) is 30 Nm. Use new bolt.

The specified torque for the Steering column to mounting bracket connection when installing the steering column on a VOLKSWAGEN GOLF PLUS 2005 (Golf) is 20 Nm.

The specified torques for the Strut to mounting bracket and Strut to body connections when installing the strut on a VOLKSWAGEN GOLF PLUS 2005 (Golf) are 20 Nm each.

The specified torques for the Universal joint to steering box connection are 30 Nm (Use new bolt). The specified torque for the Steering column to mounting bracket connection is 20 Nm.

The proper steering column handling and transport for a VOLKSWAGEN GOLF PLUS 2005 requires the following:

Use both hands to transport steering column.

Hold steering column upper jacket tube and in area of upper universal joint.

The 1st generation steering box on a VOLKSWAGEN GOLF PLUS 2005 (Golf) has 4 bolts for the bearing cover, while the 2nd generation steering box has 2.

The 2nd generation steering box on a VOLKSWAGEN GOLF PLUS 2005 is attached to the subframe with 4 bolts, and the 3rd generation steering box is attached with 3 bolts.

The necessary steps to repair the electromechanical steering box (1st generation) boot on a VOLKSWAGEN GOLF PLUS 2005 are:

Turn steering wheel to straight-ahead position.

Remove wheel.

Clean outside of steering box in vicinity of boot.

Mark position of nut -3- on steering rack.

Loosen nut -3- while counterholding on head of track rod -2-.

Loosen hose clip -1- from boot using hose clip pliers -V.A.G 1275- and push onto track rod.

Remove hose clip and pull boot from steering box housing.

Now turn track rod out of track rod head.

Pull boot with spring-type clip off track rod.

Turn steering wheel to straight-ahead position.

Thread new clamps and rubber boot onto track rod.

Screw in track rod to mark made during removal.

Tighten lock nut -3- to specified torque while counterholding track rod ball joint -2-.

Lightly lubricate seal point between boot and track rod with grease -G 052 168 A1- (from repair kit Fuchs Renolit JP1619).

Push rubber boot -2- onto track rod -1- as shown in figure.

Secure spring-type clip on rubber boot using hose clip pliers -V.A.G 1275- .

Lightly lubricate seal point between boot and steering box with grease -G 052 168 A1- (from repair kit Fuchs Renolit JP1619).

Push rubber boot onto steering box housing to stop.

The specified torque for the Track rod ball joint to track rod connection when repairing the electromechanical steering box (1st generation) boot on a VOLKSWAGEN GOLF PLUS 2005 is 50 Nm.

The specified torque for the Track rod ball joint to wheel bearing housing connection when repairing the electromechanical steering box (1st generation) boot on a VOLKSWAGEN GOLF PLUS 2005 is 20 Nm + 90°. Use new nut.

The specified torque for the Track rod to steering rack in steering box connection when repairing the electromechanical steering box (1st generation) boot on a VOLKSWAGEN GOLF PLUS 2005 is 100 Nm.

The specified torque for the Track rod ball joint to track rod connection when repairing the electromechanical steering box (2nd and 3rd generations) boot on a VOLKSWAGEN GOLF PLUS 2005 is 50 Nm.

The specified torque for the Track rod ball joint to wheel bearing housing connection when repairing the electromechanical steering box (2nd and 3rd generations) boot on a VOLKSWAGEN GOLF PLUS 2005 is 20 Nm + 90°.