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Home/Volkswagen/Beetle/Volkswagen Beetle A4 (1997-2005)/Repair manual/Suspension Front/Front Suspension (Hatchback): Overview
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Front Suspension (Hatchback): Overview Volkswagen Beetle A4

Suspension Front 9 illustrations ~2021 words

LEFT FRONT LEVEL CONTROL SYSTEM SENSOR OVERVIEW

General notes VEHICLE LEVEL SENSOR WITH AUTOMATIC HEADLIGHT VERTICAL AIM CONTROL .

Basic setting of headlights Diagnosis and Testing

Scheme 3

Scheme 3: LEFT FRONT LEVEL CONTROL SYSTEM SENSOR OVERVIEW
Scheme 3: LEFT FRONT LEVEL CONTROL SYSTEM SENSOR OVERVIEW
  1. Bracket
  2. Hex nut Tightening specification «FRONT SUSPENSION TIGHTENING SPECIFICATIONS»(ref-492757-S05725060902012080600000) .
  3. Left front level control system sensor -G78- Checked electrically via On Board Diagnostic (OBD) For complaints, Perform Basic Setting in "Guided Fault Finding" using VAS 5051 To do so, enter "Function/Component selection" via the Go to button.
  4. Coupling rod of left front level control system sensor -G78- Tightly coupling rod bolt in area of marking -arrow- of bracket -item: 9
  5. Control arm
  6. Hex bolt Tightening specification, «Stabilizer Bar»(ref-492757-S12353646832012080600000) . Always replace after removal
  7. Coupling link Various versions
  8. Hex nut Tightening specification, «Drive Axle»(ref-492757-S39378720062012080600000) .
  9. Bracket
  10. Stabilizer bar
  11. Connector
  12. Longitudinal member
  13. Pop rivet bolt Pop rivet bolt can be pulled in using pop rivet tongs V.A.G 1765 B.

LEFT REAR LEVEL CONTROL SYSTEM SENSOR OVERVIEW

General notes VEHICLE LEVEL SENSOR WITH AUTOMATIC HEADLIGHT VERTICAL AIM CONTROL .

Basic Setting of headlights Diagnosis and Testing

Scheme 4

Scheme 4: LEFT REAR LEVEL CONTROL SYSTEM SENSOR OVERVIEW
Scheme 4: LEFT REAR LEVEL CONTROL SYSTEM SENSOR OVERVIEW
  1. Left rear level control system sensor -G76- Checked electrically via On Board Diagnostic (OBD) For complaints, perform basic setting in "Guided Fault Finding" using VAS 5051 To do so, enter "Function/Component selection" via the Go to button.
  2. Mounting bracket for rear axle
  3. Coupling rod of left rear level control system sensor -G76- Do not remove coupling link from ball head!
  4. Bracket
  5. Axle beam
  6. Hex bolt M8 x 12 Tightening specification, «Left Rear Level Control System Sensor -G76»(ref-492828-S14713209772012080600000) .
  7. Hex bolt M8 x 12 Tightening specification, «Left Rear Level Control System Sensor -G76»(ref-492828-S14713209772012080600000) .
  8. Heat shield

SUBFRAME, STABILIZER BAR AND CONTROL ARM ASSEMBLY OVERVIEW

Note. If it should be necessary to move a vehicle whose drive axle has been removed, before doing so, install an outer joint in place of the drive axle and tighten it to 50 Nm, or else wheel bearing will be damaged. Welding and straightening work on supporting or wheel bearing components of the suspension is not permitted. Always replace self-locking nuts. Always replace corroded bolts/nuts.

Scheme 5

Scheme 5: SUBFRAME, STABILIZER BAR AND CONTROL ARM ASSEMBLY OVERVIEW
Scheme 5: SUBFRAME, STABILIZER BAR AND CONTROL ARM ASSEMBLY OVERVIEW
  1. Subframe retaining bracket Caged nut cannot be reworked. If nut is damaged, mount must be replaced as a complete unit.
  2. Weld nut in mount Thread can be repaired using helicoil thread insert when thread of weld nut is damaged. Repair thread in longitudinal «LONGITUDINAL MEMBER THREADS, SERVICING»(ref-492757-S34126222322012080600000).
  3. Bonded rubber bushing Removing and installing «SUBFRAME BONDED RUBBER BUSHINGS»(ref-492757-S27016585782012080600000).
  4. Self-locking nut Always replace after removal
  5. Hex bolt M 14 x 1.5 x 63 Tightening specification, «Subframe»(ref-492757-S13642190772012080600000). Always replace
  6. Rear bearing for control arm Installed position see scheme 28 Pressing out and in see scheme 29
  7. Hex bolt M 12 x 1.5 x 70 Tightening specification, «Control Arm»(ref-492757-S29714625692012080600000). Always replace
  8. Plate with nuts
  9. Self-locking nut M12 x 1.5 Tightening specification «FRONT SUSPENSION TIGHTENING SPECIFICATIONS»(ref-492757-S05725060902012080600000). Always replace
  10. Ball joint Checking «BALL JOINT, CHECKING»(ref-492757-S35558224852012080600000). Removing and installing «BALL JOINT»(ref-492757-S15110728762012080600000).
  11. Hex bolt M10 x 26 Tightening specification, «Control Arm»(ref-492757-S29714625692012080600000). Always replace after removal
  12. Control arm
  13. Coupling link Different versions
  14. Hex bolt M10 x 50 Tightening specification, «Stabilizer Bar»(ref-492757-S12353646832012080600000). Always replace after removal
  15. Hex nut Self-locking Tightening specification, «Wheel Bearing Housing»(ref-492757-S28860473962012080600000). Always replace after removal
  16. Stabilizer bar Subframe must be lowered for removal and installation. Different versions
  17. Socket head bolt
  18. Hex bolt M 14 x 1.5 x 95 Tightening specification, «Subframe»(ref-492757-S13642190772012080600000). Always replace after removal
  19. Front bearing for control arm Pressing out see scheme 26 Pressing in see scheme 27
  20. Hex bolt M 12 x 1.5 x 82 Tightening specification, «Control Arm»(ref-492757-S29714625692012080600000). Always replace
  21. Hex bolt M10 x 70 Tightening specification, «Pendulum Support»(ref-492757-S37248026062012080600000). Always replace after removal
  22. Hex bolt M10 x 30 Tightening specification, «Pendulum Support»(ref-492757-S37248026062012080600000). Always replace after removal
  23. Pendulum supports Different versions
  24. Hex bolt M8 x 45 Tightening specification, «Pendulum Support»(ref-492757-S37248026062012080600000).
  25. Rubber bushing
  26. Clamp
  27. Hex bolt M8 x 18 Tightening specification, «Stabilizer Bar»(ref-492757-S12353646832012080600000).
  28. Subframe Repair to threads for front control arm threaded connection is not permitted!

WHEEL BEARING AND HOUSING ASSEMBLY OVERVIEW

Note. If it should be necessary to move a vehicle whose drive axle has been removed, then before doing so install an outer joint in place of the drive axle and tighten it to 50 Nm, or else wheel bearing will be damaged. Welding and straightening work on supporting or wheel bearing components of the front suspension is not permitted. Always replace self-locking nuts. Always replace corroded bolts/nuts.

Scheme 6

Scheme 6: WHEEL BEARING AND HOUSING ASSEMBLY OVERVIEW
Scheme 6: WHEEL BEARING AND HOUSING ASSEMBLY OVERVIEW
  1. Drive axle Pressing drive axle out and in from wheel hub «DRIVE AXLE WITH CV JOINT AND TRIPLE ROLLER JOINTS AAR 2000 AND AAR 2900»(ref-492757-S18730490772012080600000).
  2. ABS wheel speed sensor
  3. Socket head bolt M6 x 16 Tightening specification, «Wheel Bearing Housing»(ref-492757-S28860473962012080600000).
  4. Strut
  5. Hex bolt Always replace after removal Hex bolt point must face in direction of travel
  6. Tie rod end
  7. Self-locking nut M12 x 15 Tightening specification, «Wheel Bearing Housing»(ref-492757-S28860473962012080600000). Never less than 90 degrees Torque angle tolerance 90 degrees to 120 degrees Always replace
  8. Self-locking nut Always replace Tightening specification, «Wheel Bearing Housing»(ref-492757-S28860473962012080600000).
  9. Wheel bearing housing For vehicles: With gasoline engine up to and including 85 kW With TDI engine
  10. Ball joint Removing and installing «BALL JOINT»(ref-492757-S15110728762012080600000).
  11. Self-locking nut M12 x 15 Tightening specification «FRONT SUSPENSION TIGHTENING SPECIFICATIONS»(ref-492757-S05725060902012080600000). Always replace after removal
  12. Cover plate
  13. Hex bolt M6 x 10 Tightening specification, «Wheel Bearing Housing»(ref-492757-S28860473962012080600000).
  14. Self-locking 12 point nut Tightening, «TIGHTENING SPECIFICATIONS»(ref-492757-S05562034462012080600000). Always replace
  15. Phillips-head screw
  16. Vented brake rotor
  17. Wheel hub with rotor for speed sensor Rotor is welded to wheel hub Removing and installing with wheel bearing housing installed «FRONT WHEEL BEARING, HUB AND INNER RACE, WITH WHEEL BEARING HOUSING INSTALLED»(ref-492757-S00804295912012080600000).
  18. Circlip Check for proper seating
  19. Wheel bearing Pressing out see scheme 83 Replace, destroyed during pressing out Pressing in see scheme 85 Removing and installing with wheel bearing housing installed «FRONT WHEEL BEARING, HUB AND INNER RACE, WITH WHEEL BEARING HOUSING INSTALLED»(ref-492757-S00804295912012080600000).
  20. Wheel bearing housing For vehicles: With gasoline engine from 110 kW

Scheme 7

Scheme 7: STRUT ASSEMBLY OVERVIEW
Scheme 7: STRUT ASSEMBLY OVERVIEW
  1. Self-locking hex nut M14 x 1.5 Tightening specification, «Strut»(ref-492757-S28775099732012080600000) .
  2. Stop plate
  3. Strut dome
  4. Hex nut M14 x 1.5 Tightening specification, «Strut»(ref-492757-S28775099732012080600000) .
  5. Suspension strut bearing
  6. Axial groove ball bearing
  7. Socket Only available in Mexico vehicles
  8. Spring plate
  9. Coil spring Note color code Surface of spring coil may not be damaged
  10. Hex bolt Tightening specification, «Strut»(ref-492757-S28775099732012080600000) .
  11. Bracket
  12. Heat shield
  13. Hex bolt Always replace Hex bolt point must face in direction of travel
  14. Clip
  15. Wheel bearing housing
  16. Self-locking nut M14 x 1.5 Tightening specification, «Strut»(ref-492757-S28775099732012080600000) . Always replace
  17. Clamp
  18. Shock absorber Can be replaced individually
  19. Buffer stop
  20. Protective sleeve

Scheme 8

Scheme 8: DRIVE AXLE WITH CV JOINT ASSEMBLY OVERVIEW
Scheme 8: DRIVE AXLE WITH CV JOINT ASSEMBLY OVERVIEW
  1. Self-locking 12 point nut Tightening, «TIGHTENING SPECIFICATIONS»(ref-492757-S05562034462012080600000). Remove any paint residue and/or corrosion in threads of outer joint before removing nut.
  2. Right axle shaft (tubular)
  3. Socket head bolt Tightening specification, «Drive Axle»(ref-492757-S39378720062012080600000).
  4. Backing plate
  5. Clamp Replace Tensioning see scheme 95
  6. CV boot for inner Constant Velocity (CV) joint Material: Hytrel (Polyelastomere) Without ventilation bore Check for tears and scuffing Drive off Constant Velocity (CV) joint using a drift Before mounting on Constant Velocity (CV) joint, spread D 454 300 A2 on sealing surface
  7. CV boot for inner Constant Velocity (CV) joint Material: rubber With ventilation bore Check for tears and scuffing Drive off Constant Velocity (CV) joint using a drift Installation position for left shaft see scheme 92 Installation position for right shaft see scheme 93 Before mounting on Constant Velocity (CV) joint, spread D 454 300 A2 on sealing surface
  8. Dished washer Installed position see scheme 89
  9. Inner Constant Velocity (CV) joint Replace only as complete unit Pressing off see scheme 88 Pressing on see scheme 91 Greasing, «GREASE QUANTITIES AND TYPES»(ref-492757-S32944029502012080600000) Checking «INNER CV JOINT»(ref-492757-S13989826132012080600000).
  10. Gasket Bonding surface on CV joint must be free of grease and oil! Replace Pull off protective foil and bond into joint.
  11. Circlip Remove and install using VW 161 A
  12. Left axle shaft (full shaft) Replace Tensioning see scheme 95
  13. Clamp
  14. CV boot Check for tears and scuffing Material: Hytrel (Polyelastomere)
  15. Vibration damper
  16. Clamp Replace Tension using CV joint boot clamp tool V.A.G 1682 see scheme 94
  17. Dished washer Installed position see scheme 90
  18. Hex bolt M10 x 28 Tightening specification, «Drive Axle»(ref-492757-S39378720062012080600000).
  19. Protective cap
  20. Thrust washer Installed position see scheme 90
  21. Circlip Replace insert in groove on shaft
  22. Outer CV joint Replace only as complete unit Removing see scheme 87 Installing: Install on shaft using plastic hammer until impact Greasing, «GREASE QUANTITIES AND TYPES»(ref-492757-S32944029502012080600000) Checking «OUTER CV JOINT»(ref-492757-S08906525712012080600000).

Scheme 9

Scheme 9: DRIVE AXLE WITH TRIPLE ROLLER JOINT AAR 2000 ASSEMBLY OVERVIEW
Scheme 9: DRIVE AXLE WITH TRIPLE ROLLER JOINT AAR 2000 ASSEMBLY OVERVIEW
  1. Self-locking 12 point nut Tightening, «TIGHTENING SPECIFICATIONS»(ref-492757-S05562034462012080600000). Remove any corrosion in the threads of outer joint before threading nut on.
  2. Outer CV joint Replace only as complete unit Removing see scheme 87 Installing: Drive onto shaft using plastic hammer, until expanded securing ring contracts Checking «OUTER CV JOINT»(ref-492757-S08906525712012080600000). Greasing, «GREASE QUANTITIES AND TYPES»(ref-492757-S10003099692012080600000)
  3. Circlip insert in groove on shaft
  4. Thrust washer Installed position see scheme 90
  5. Dished washer Large dia. (concave side) rests against thrust washer
  6. Clamp Always replace after removal Tension using CV joint boot clamp tool V.A.G 1682 see scheme 94
  7. CV boot Check for tears and scuffing
  8. Clamp Always replace after removal Tightening see scheme 95
  9. Axle shaft
  10. CV boot for triple roller joint Check for tears and scuffing
  11. Clamp For triple roller joint Always replace after removal Tensioning, «TIGHTEN CLAMP USING HOSE CLAMP PLIERS V.A.G 1275»(ref-492757-S03796552952012091700000).
  12. Socket head bolt Tightening specification, «Drive Axle»(ref-492757-S39378720062012080600000).
  13. Backing plate Only installed on joints with dia. 108 mm
  14. Joint piece
  15. Triple roller star with rollers Chamfer -arrow- faces splines of axle shaft
  16. Circlip Always replace
  17. Sealing ring Always replace
  18. Cover Always replace

Scheme 10

Scheme 10: DRIVE AXLE WITH TRIPLE ROLLER JOINT AAR 2900 ASSEMBLY OVERVIEW
Scheme 10: DRIVE AXLE WITH TRIPLE ROLLER JOINT AAR 2900 ASSEMBLY OVERVIEW
  1. Self-locking 12 point nut Tightening, «TIGHTENING SPECIFICATIONS»(ref-492757-S05562034462012080600000). Remove any corrosion in the threads of outer joint before threading nut on. Always replace
  2. Outer CV joint Replace only as complete unit Removing see scheme 87 Installing: Drive onto shaft using plastic hammer, until expanded securing ring contracts Checking «OUTER CV JOINT»(ref-492757-S08906525712012080600000). Greasing, «GREASE QUANTITIES AND TYPES»(ref-492757-S21878942842012080600000)
  3. Circlip Always replace after removal Insert in groove on shaft
  4. Thrust washer Installed position see scheme 90
  5. Dished washer Installed position see scheme 90
  6. Clamp Always replace after removal Tighten using CV joint boot clamp tool V.A.G 1682 see scheme 94
  7. CV boot Check for tears and scuffing Material: Hytrel (Polyelastomere)
  8. Clamp Always replace after removal Tensioning see scheme 95
  9. Axle shaft
  10. Clamp Always replace after removal Tensioning, «TIGHTEN SMALL CLAMP USING HOSE CLAMP PLIERS V.A.G 1275»(ref-492757-S08028220512012091700000).
  11. CV boot for triple roller joint Check for tears and scuffing
  12. Clamp Always replace Tensioning, «TIGHTEN CLAMP USING HOSE CLAMP PLIERS V.A.G 1275»(ref-492757-S00571569992012091700000).
  13. Joint piece
  14. Socket head bolt M 8 x 18; Tightening specification, «Drive Axle»(ref-492757-S39378720062012080600000).
  15. Rollers
  16. Triple roller star Chamfer -arrow- faces splines of drive axle
  17. Circlip Replace Insert in groove on shaft
  18. Sealing ring Is no longer required for assembly.
  19. Rectangular seal This seal is provided in the repair kit. It was not installed during series production. It is no longer supplied as a replacement part, a new repair kit will be delivered instead.
  20. Cover Destroyed during removal. It is no longer required for assembly and is not supplied as a replacement part. A new cover is provided in repair kit.

Scheme 11

Scheme 11: DRIVE AXLE WITH TRIPLE ROLLER JOINT AAR 3300I ASSEMBLY OVERVIEW
Scheme 11: DRIVE AXLE WITH TRIPLE ROLLER JOINT AAR 3300I ASSEMBLY OVERVIEW
  1. Self-locking 12 point nut Tightening, «TIGHTEN 12 POINT NUT TO 200 Nm AND RELEASE A HALF A ROTATION»(ref-492757-S16893955142012091700000). Remove any corrosion in threads of outer joint before threading nut on. Always replace
  2. Outer CV joint Replace only as complete unit Removing see scheme 87 Installing: drive onto shaft using plastic hammer, until expanded securing ring contracts Greasing, «GREASE QUANTITIES AND TYPES»(ref-492757-S09032734242012080600000) Checking «OUTER CV JOINT»(ref-492757-S08906525712012080600000).
  3. Circlip Always replace after removal Insert in groove on shaft
  4. Thrust washer Installed position see scheme 90
  5. Dished washer Installed position see scheme 90
  6. Clamp Always replace after removal Tighten using CV joint boot clamp tool V.A.G 1682 see scheme 94
  7. CV boot Check for tears and scuffing Material: Hytrel (Polyelastomere)
  8. Clamp Always replace after removal Tightening see scheme 95
  9. Axle shaft
  10. Clamp Always replace Tensioning, «TIGHTEN LARGE CLAMP USING HOSE CLAMP PLIERS V.A.G 1275»(ref-492757-S38599731022012091400000).
  11. CV boot for triple roller joint Check for tears and scuffing
  12. Clamp Always replace after removal Tensioning, «TIGHTEN LARGE CLAMP USING HOSE CLAMP PLIERS V.A.G 1275»(ref-492757-S38599731022012091400000).
  13. Triple roller star with rollers Chamfer -arrow- faces splines of axle shaft
  14. Circlip Always replace after removal Insert in groove on shaft
  15. Joint piece
  16. Circlip Always replace after removal Insert into groove of joint piece

More articles — Front Suspension (Hatchback)