SM 18 PDF
SM 18 PDF
Workshop Manual
Audi A3 2013 ➤ ,
Audi A3 Cabriolet 2015 ➤ ,
Audi A3 Limousine 2014 ➤ ,
Audi A3 Limousine China 2014 ➤ ,
Audi A3 Sportback 2013 ➤ ,
Audi A3 Sportback China 2014 ➤
Running gear, axles, steering
Edition 02.2019
Repair Group
00 - Technical data
40 - Front suspension
42 - Rear suspension
43 - Self-levelling suspension
44 - Wheels, tyres, vehicle geometry
48 - Steering
Technical information should always be available to the foremen and mechanics, because their
careful and constant adherence to the instructions is essential to ensure vehicle road-worthiness and
safety. In addition, the normal basic safety precautions for working on motor vehicles must, as a
matter of course, be observed.
Contents
00 - Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1 General notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.1 Running gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.2 Steering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.3 Types of tyre . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2 Safety precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
2.1 Safety precautions when working on vehicles with high-voltage system . . . . . . . . . . . . . . 2
2.2 Safety precautions when working in the vicinity of high-voltage components . . . . . . . . . . 2
2.3 Safety precautions when working on vehicles with start/stop system . . . . . . . . . . . . . . . . 3
2.4 Safety precautions when using testers and measuring instruments during a road test . . . . 3
3 Repair notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
3.1 Leaks at shock absorbers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
3.2 Noises from shock absorbers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
3.3 Checking shock absorbers when removed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
3.4 Checking shock absorbers on shock tester . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
3.5 Maximum values "a" in mm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
3.6 Rules for cleanliness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
3.7 General notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
3.8 General repair instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
3.9 Contact corrosion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
3.10 Steering rack . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
3.11 Gaskets and seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
3.12 Bolts and nuts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
3.13 Electrical components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
3.14 Repair notes for drive shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
3.15 Repairing damaged threads in longitudinal member (subframe to body) . . . . . . . . . . . . . . 10
3.16 Lifting suspension to unladen position - vehicles with coil springs . . . . . . . . . . . . . . . . . . . . 10
4 Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
4.1 Running gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
4.2 Steering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
5 Disposal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
5.1 Releasing gas and draining front gas-filled shock absorbers . . . . . . . . . . . . . . . . . . . . . . . . 14
5.2 Releasing gas and draining rear gas-filled shock absorbers . . . . . . . . . . . . . . . . . . . . . . . . 15
40 - Front suspension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
1 Front axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
1.1 Overview of fitting locations - front axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
2 Subframe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
2.1 Exploded view - subframe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
2.2 Fixing position of subframe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
2.3 Lowering subframe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
2.4 Removing and installing subframe without steering rack . . . . . . . . . . . . . . . . . . . . . . . . . . 33
2.5 Removing and installing subframe with steering rack . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
2.6 Servicing subframe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
2.7 Removing and installing anti-roll bar . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
2.8 Removing and installing coupling rod . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
3 Suspension strut, upper wishbone . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
3.1 Exploded view - suspension strut, upper wishbone . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
3.2 Removing and installing suspension strut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
3.3 Servicing suspension strut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
3.4 Lowering suspension strut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
4 Lower wishbone, swivel joint . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
Contents i
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ii Contents
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48 - Steering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 349
1 Steering wheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 349
1.1 Exploded view - steering wheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 349
1.2 Removing and installing steering wheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 350
2 Steering column . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 352
2.1 Exploded view - steering column . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 352
2.2 Handling and transporting steering column . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 353
2.3 Checking steering column for damage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 354
2.4 Removing and installing steering column . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 355
2.5 Removing and installing control unit for electronic steering column lock J764 . . . . . . . . . . 359
3 Steering rack . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 361
3.1 Exploded view - steering rack . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 361
3.2 Servicing steering rack . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 363
3.3 Handling and transporting steering rack . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 364
3.4 Removing and installing steering rack . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 364
3.5 Removing and installing boot . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 366
Contents iii
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iv Contents
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Running gear, axles, steering - Edition 02.2019
00 – Technical data
1 General notes
(ARL006290; Edition 02.2019)
⇒ “1.1 Running gear”, page 1
⇒ “1.2 Steering”, page 1
⇒ “1.3 Types of tyre”, page 1
1.2 Steering
Front-wheel drive and four-wheel drive
Steering Electro-mechanically assisted, maintenance-free rack-and-pinion steering
rack
1. General notes 1
Audi A3 2013 ➤ , Audi A3 Cabriolet 2015 ➤ , Audi A3 Limousine 2014 ➤ , A ...
Running gear, axles, steering - Edition 02.2019
2 Safety precautions
⇒ “2.1 Safety precautions when working on vehicles with high-
voltage system”, page 2
⇒ “2.2 Safety precautions when working in the vicinity of high-
voltage components”, page 2
⇒ “2.3 Safety precautions when working on vehicles with start/
stop system”, page 3
⇒ “2.4 Safety precautions when using testers and measuring in‐
struments during a road test”, page 3
2.4 Safety precautions when using testers and measuring instruments during
a road test
Risk of injury if test equipment is not secured
If an accident occurs and the front passenger's airbag is triggered,
test equipment which is not secured adequately may be catapul‐
ted through the vehicle with potentially serious consequences.
– Secure test equipment to the rear seat.
Or
– Have another person operate the test equipment from the rear
seat.
2. Safety precautions 3
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3 Repair notes
⇒ “3.1 Leaks at shock absorbers”, page 4
⇒ “3.2 Noises from shock absorbers”, page 5
⇒ “3.3 Checking shock absorbers when removed”, page 5
⇒ “3.4 Checking shock absorbers on shock tester”, page 6
⇒ “3.5 Maximum values "a" in mm”, page 7
⇒ “3.6 Rules for cleanliness”, page 7
⇒ “3.7 General notes”, page 7
⇒ “3.8 General repair instructions”, page 8
⇒ “3.9 Contact corrosion”, page 8
⇒ “3.10 Steering rack”, page 9
⇒ “3.11 Gaskets and seals”, page 9
⇒ “3.12 Bolts and nuts”, page 9
⇒ “3.13 Electrical components”, page 10
⇒ “3.14 Repair notes for drive shaft”, page 10
⇒ “3.15 Repairing damaged threads in longitudinal member (sub‐
frame to body)”, page 10
⇒ “3.16 Lifting suspension to unladen position - vehicles with coil
springs”, page 10
Note
Note
These noises are only very rarely caused by the shock absorbers.
Note
3. Repair notes 5
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Running gear, axles, steering - Edition 02.2019
Note
♦ If this is not the case, the shock absorber does not necessarily
need to be renewed. Provided there has been no major loss
of fluid, it will still be as effective as a conventional shock ab‐
sorber.
♦ Even without gas pressure, the shock absorber will provide full
damping effect as long as there has been no major loss of fluid.
However, it may produce more noise.
Note
Example:
Maximum value = 70
♦ a = higher than 70: unsatisfactory damping effect
♦ a = lower than 70: satisfactory damping effect
The damper combinations fitted in the vehicle are indicated by the
corresponding PR number on the vehicle data sticker.
Explanatory notes on production control numbers (PR numbers)
⇒ page 313
Note
3. Repair notes 7
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Running gear, axles, steering - Edition 02.2019
3. Repair notes 9
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Running gear, axles, steering - Edition 02.2019
♦ Support - T10149-
Note
3. Repair notes 11
Audi A3 2013 ➤ , Audi A3 Cabriolet 2015 ➤ , Audi A3 Limousine 2014 ➤ , A ...
Running gear, axles, steering - Edition 02.2019
Note
Note
– Turn wheel hub until one of the wheel bolt holes is at the top.
– Attach support - T10149- to wheel hub using wheel bolt.
WARNING
4 Technical data
⇒ “4.1 Running gear”, page 13
⇒ “4.2 Steering”, page 13
1) Front/rear track width only applicable to standard running gear with standard
tyre size 205/55/R16 on 7.0Jx16 ET40 rims (ET= rim offset)
4.2 Steering
Front-wheel drive and four-wheel drive
Maximum wheel lock angle Approx. 40°
4. Technical data 13
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Running gear, axles, steering - Edition 02.2019
5 Disposal
⇒ “5.1 Releasing gas and draining front gas-filled shock absorb‐
ers”, page 14
⇒ “5.2 Releasing gas and draining rear gas-filled shock absorb‐
ers”, page 15
WARNING
Note
WARNING
Note
Note
5. Disposal 15
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Running gear, axles, steering - Edition 02.2019
Procedure
– Clamp gas-filled shock absorber vertically in vice, with piston
rod pointing downwards.
WARNING
Note
40 – Front suspension
1 Front axle
⇒ “1.1 Overview of fitting locations - front axle”, page 17
I - ⇒ “2 Subframe”, page 18
II -
⇒ “3 Suspension strut, upper
wishbone”, page 67
III -
⇒ “4 Lower wishbone, swivel
joint”, page 77
IV -
⇒ “5 Wheel bearing”,
page 90
V-
⇒ “6 Drive shaft”, page 99
1. Front axle 17
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Running gear, axles, steering - Edition 02.2019
2 Subframe
⇒ “2.1 Exploded view - subframe”, page 18
⇒ “2.2 Fixing position of subframe”, page 20
⇒ “2.3 Lowering subframe”, page 23
⇒ “2.4 Removing and installing subframe without steering rack”,
page 33
⇒ “2.5 Removing and installing subframe with steering rack”, page
43
⇒ “2.6 Servicing subframe”, page 54
⇒ “2.7 Removing and installing anti-roll bar”, page 64
⇒ “2.8 Removing and installing coupling rod”, page 65
Caution
1 - Bolt
❑ Tightening torque: Ex‐
ploded view - assembly
mountings ⇒ Removing
and installing engine;
Rep. gr. 10 ; Assembly
mountings; Exploded
view - assembly mount‐
ings
2 - Bonded rubber bush (bot‐
tom) for pendulum support
❑ Renewing ⇒ page 54
3 - Bolt
❑ Always renew if re‐
moved
❑ 20 Nm +180°
4 - Subframe
❑ Different versions; for
correct version refer to
⇒ Electronic parts cata‐
logue
❑ Fixing position
⇒ page 20
❑ Lowering ⇒ page 23
❑ Removing and installing
without steering rack
⇒ page 33
❑ Removing and installing
with steering rack
⇒ page 43
5 - Bolt
❑ Always renew if re‐
moved
❑ 70 Nm +180°
6 - Clip
❑ For A3 g-tron only
7 - Nut
❑ When tightening, counterhold multi-point socket of joint pin
❑ Always renew if removed
❑ 65 Nm
8 - Bonded rubber bush (top) for pendulum support
❑ Renewing ⇒ page 54
9 - Anti-roll bar with rubber bush
❑ Removing and installing ⇒ page 64
10 - Nut
❑ When tightening, counterhold multi-point socket of joint pin
❑ Always renew if removed
❑ 65 Nm
11 - Suspension strut
❑ Removing and installing ⇒ page 68
12 - Coupling rod
❑ Removing and installing ⇒ page 65
2. Subframe 19
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Running gear, axles, steering - Edition 02.2019
13 - Intermediate plate
❑ For correct version refer to ⇒ Electronic parts catalogue “ETKA”
14 - Support
❑ Different versions; for correct version refer to ⇒ Electronic parts catalogue “ETKA”
15 - Bolt
❑ Always renew if removed
❑ 20 Nm +90°
16 - Bolt
❑ Always renew if removed
❑ 70 Nm +180°
Note
Procedure
– Remove noise insulation (front and rear) ⇒ General body re‐
pairs, exterior; Rep. gr. 66 ; Noise insulation; Exploded view
- noise insulation .
Audi A3 Cabriolet:
– Remove underbody trim (left and right) ⇒ General body re‐
pairs, exterior; Rep. gr. 66 ; Underbody trim; Exploded view -
underbody trim .
– Remove bolts -arrows- on both sides and detach diagonal strut
-1-.
Vehicles with high-voltage system:
– Unfasten and lower underbody trim (left and right) towards
centre of vehicle ⇒ General body repairs, exterior; Rep. gr.
66 ; Underbody trim; Exploded view - underbody trim .
2. Subframe 21
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Running gear, axles, steering - Edition 02.2019
Caution
Note
Procedure
– Turn steering wheel to straight-ahead position and remove ig‐
nition key so that the steering lock engages.
Vehicles with keyless entry system
– Switch off ignition and open driver's door so that steering lock
engages.
2. Subframe 23
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Note
– Unscrew bolt -1- for universal joint -2- and pull universal joint
off steering rack -arrow-.
– Remove noise insulation (front and rear) ⇒ General body re‐
pairs, exterior; Rep. gr. 66 ; Noise insulation; Exploded view
- noise insulation .
2. Subframe 25
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Running gear, axles, steering - Edition 02.2019
Note
– Pull out expanding clip -arrow- and move cable guide clear at
subframe.
Note
Note
2. Subframe 27
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Running gear, axles, steering - Edition 02.2019
Procedure
DANGER!
Note
– Unscrew bolt -1- for universal joint -2- and pull universal joint
off steering rack -arrow-.
– Remove noise insulation (front and rear) ⇒ General body re‐
pairs, exterior; Rep. gr. 66 ; Noise insulation; Exploded view
- noise insulation .
2. Subframe 29
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Running gear, axles, steering - Edition 02.2019
Note
– Pull out expanding clip -arrow- and move cable guide clear at
subframe.
Note
2. Subframe 31
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Running gear, axles, steering - Edition 02.2019
Note
Note
DANGER!
Removing
Note
2. Subframe 33
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Running gear, axles, steering - Edition 02.2019
Note
2. Subframe 35
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Running gear, axles, steering - Edition 02.2019
Note
– Pull out expanding clip -arrow- and move cable guide clear at
subframe.
– Secure steering rack to body.
Caution
2. Subframe 37
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Running gear, axles, steering - Edition 02.2019
Removing
Note
DANGER!
2. Subframe 39
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Running gear, axles, steering - Edition 02.2019
Note
Note
– Pull out expanding clip -arrow- and move cable guide clear at
subframe.
Note
2. Subframe 41
Audi A3 2013 ➤ , Audi A3 Cabriolet 2015 ➤ , Audi A3 Limousine 2014 ➤ , A ...
Running gear, axles, steering - Edition 02.2019
Caution
DANGER!
Removing
– Turn steering wheel to straight-ahead position and remove ig‐
nition key so that the steering lock engages.
Vehicles with keyless entry system
– Switch off ignition and open driver's door so that steering lock
engages.
2. Subframe 43
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Running gear, axles, steering - Edition 02.2019
Note
– Unscrew bolt -1- for universal joint -2- and pull universal joint
off steering rack -arrow-.
– Remove front wheels ⇒ page 309 .
– Remove noise insulation (front and rear) ⇒ General body re‐
pairs, exterior; Rep. gr. 66 ; Noise insulation; Exploded view
- noise insulation .
2. Subframe 45
Audi A3 2013 ➤ , Audi A3 Cabriolet 2015 ➤ , Audi A3 Limousine 2014 ➤ , A ...
Running gear, axles, steering - Edition 02.2019
Note
– Pull out expanding clip -arrow- and move cable guide clear at
subframe.
Note
2. Subframe 47
Audi A3 2013 ➤ , Audi A3 Cabriolet 2015 ➤ , Audi A3 Limousine 2014 ➤ , A ...
Running gear, axles, steering - Edition 02.2019
Note
Removing
DANGER!
Note
2. Subframe 49
Audi A3 2013 ➤ , Audi A3 Cabriolet 2015 ➤ , Audi A3 Limousine 2014 ➤ , A ...
Running gear, axles, steering - Edition 02.2019
– Unscrew bolt -1- for universal joint -2- and pull universal joint
off steering rack -arrow-.
– Remove front wheels ⇒ page 309 .
– Remove noise insulation (front and rear) ⇒ General body re‐
pairs, exterior; Rep. gr. 66 ; Noise insulation; Exploded view
- noise insulation .
2. Subframe 51
Audi A3 2013 ➤ , Audi A3 Cabriolet 2015 ➤ , Audi A3 Limousine 2014 ➤ , A ...
Running gear, axles, steering - Edition 02.2019
Note
– Pull out expanding clip -arrow- and move cable guide clear at
subframe.
Note
Note
2. Subframe 53
Audi A3 2013 ➤ , Audi A3 Cabriolet 2015 ➤ , Audi A3 Limousine 2014 ➤ , A ...
Running gear, axles, steering - Edition 02.2019
Note
2. Subframe 55
Audi A3 2013 ➤ , Audi A3 Cabriolet 2015 ➤ , Audi A3 Limousine 2014 ➤ , A ...
Running gear, axles, steering - Edition 02.2019
Note
This step is necessary to prevent the outer ring of the upper bon‐
ded rubber bush from tilting sideways and catching in the aperture
for the pendulum support in the subframe.
2. Subframe 57
Audi A3 2013 ➤ , Audi A3 Cabriolet 2015 ➤ , Audi A3 Limousine 2014 ➤ , A ...
Running gear, axles, steering - Edition 02.2019
2. Subframe 59
Audi A3 2013 ➤ , Audi A3 Cabriolet 2015 ➤ , Audi A3 Limousine 2014 ➤ , A ...
Running gear, axles, steering - Edition 02.2019
2. Subframe 61
Audi A3 2013 ➤ , Audi A3 Cabriolet 2015 ➤ , Audi A3 Limousine 2014 ➤ , A ...
Running gear, axles, steering - Edition 02.2019
Note
This step is necessary to prevent the outer ring of the upper bon‐
ded rubber bush from tilting sideways and catching in the aperture
for the pendulum support in the subframe.
2. Subframe 63
Audi A3 2013 ➤ , Audi A3 Cabriolet 2015 ➤ , Audi A3 Limousine 2014 ➤ , A ...
Running gear, axles, steering - Edition 02.2019
Removing
– Lower subframe ⇒ page 23 .
– Remove bolts -2- and detach anti-roll bar from subframe.
2. Subframe 65
Audi A3 2013 ➤ , Audi A3 Cabriolet 2015 ➤ , Audi A3 Limousine 2014 ➤ , A ...
Running gear, axles, steering - Edition 02.2019
Removing
– Remove wheel ⇒ page 309 .
– Unscrew nuts -arrows- from coupling rod -1- (if necessary,
counterhold stud -2- with multi-point socket).
– Pull coupling rod -1- out of anti-roll bar and suspension strut
and detach coupling rod.
Installing
Install in reverse sequence, paying attention to the following:
– Tighten nuts -arrows- securing coupling rod to suspension
strut and anti-roll bar (counterhold stud -2- with multi-point
socket).
Note
Tightening torques
♦ ⇒ “2.1 Exploded view - subframe”, page 18
♦ ⇒ “1 Wheels, tyres”, page 309
1 - Trim cap
❑ Part of shock absorber
2 - Spring seat
❑ Note correct installation
position
3 - Shock absorber with bottom
spring plate
❑ Different versions avail‐
able ⇒ Electronic parts
catalogue “ETKA”
❑ Removing and installing
⇒ page 72
❑ If shock absorber is re‐
newed due to a bent pis‐
ton rod, track rod ball
joint must also be re‐
newed on same side of
vehicle
❑ Because of the different
shock absorber valve
systems, shock absorb‐
ers on both sides of an
axle should always be
from the same manufac‐
turer whenever possible
4 - Electrical connection
❑ Fitted on shock absorb‐
ers with electronic
damping control (Audi
magnetic ride)
5 - Bolt
❑ Renew after removing
❑ 70 Nm +180°
6 - Wheel bearing housing
❑ Different versions available ⇒ Electronic parts catalogue “ETKA”
7 - Nut
❑ Renew after removing
8 - Protective sleeve
❑ Different versions available ⇒ Electronic parts catalogue “ETKA”
9 - Coil spring
❑ Different versions available ⇒ Electronic parts catalogue “ETKA”
❑ Removing and installing ⇒ page 72
❑ Surface of spring coil must not be damaged
10 - Deep groove ball thrust bearing
11 - Bump stop
❑ Different versions available ⇒ Electronic parts catalogue “ETKA”
12 - Suspension strut mounting
❑ Note installation position; one of the two markings -arrows- on the spring plate must point in the direction
of travel ⇒ page 72 .
13 - Nut
❑ Always renew if removed
❑ 60 Nm
14 - Suspension turret
15 - Bolt
❑ Always renew if removed
❑ 15 Nm +90°
16 - Cover
♦ Support - T10149-
Removing
– Loosen drive shaft bolt at wheel hub ⇒ page 111 .
– Remove wheel ⇒ page 309 .
– If fitted, unscrew nut -4- and detach coupling rod of vehicle
level sender from wishbone.
Note
Do not let the drive shaft hang down under its own weight, as
otherwise excessive bending could damage the inner CV joint.
– Use wheel bolt to attach engine and gearbox jack - VAS 6931-
with support - T10149- to wheel hub.
Note
Use both hands to remove the connector: open the catch with one
hand whilst pressing off the connector with the other; do not use
any tools.
– If the suspension strut was not lowered, unscrew bolts -1- for
spring plate and take out suspension strut.
Installing
Install in reverse sequence, paying attention to the following:
• One of the two arrows -1- on the spring plate -2- must point in
the direction of travel.
– Fit wheel hub onto outer joint of drive shaft.
– Insert wheel bearing housing with swivel joint into wishbone.
• On vehicles with electronic damping control (Audi magnetic
ride), perform function “Re-adapt reference (default) position”
⇒ Vehicle diagnostic tester.
• If the reference position has been re-adapted, the front camera
for driver assist systems must be calibrated on vehicles with
lane departure warning function ⇒ page 343 .
• Perform basic setting of headlights ⇒ Electrical system; Rep.
gr. 94 ; Headlights; Adjusting headlights .
– Overview table: when does wheel alignment have to be
checked? ⇒ page 311
Tightening torques
♦ ⇒ “3.1 Exploded view - suspension strut, upper wishbone”,
page 67
♦ ⇒ “4.1 Exploded view - lower wishbone, swivel joint”,
page 77
♦ ⇒ “2.1 Exploded view - subframe”, page 18
♦ ⇒ “2.1 Exploded view - front vehicle level senders”,
page 302
♦ ⇒ “6.2 Exploded view - drive shaft”, page 100
♦ ⇒ “6.3 Loosening and tightening bolt securing drive shaft”,
page 111
♦ ⇒ “1 Wheels, tyres”, page 309
Procedure
• Suspension strut removed ⇒ page 68 .
– Compress coil spring with spring compressor - V.A.G 1752/1-
until thrust bearing is free at top.
– Unscrew hexagon nut from piston rod.
WARNING
First compress spring far enough to ensure that top spring plate
is free.
Note
Procedure
– Remove plenum chamber cover ⇒ General body repairs, ex‐
terior; Rep. gr. 50 ; Bulkhead; Removing and installing plenum
chamber cover .
– Remove cover for plenum chamber partition panel ⇒ General
body repairs, exterior; Rep. gr. 50 ; Bulkhead; Exploded view
- bulkhead .
– Detach cover from suspension turret.
– Place protective cover for suspension turret -T40295/2- on
suspension turret.
– Screw assembly aid -T40295/1- onto piston rod and tighten to
20 Nm.
– Loosen and remove bolts -arrows- securing suspension strut
mounting (counterhold suspension strut).
Note
Removing
– Before starting work, measure distance from centre of wheel
to lower edge of wheel housing ⇒ page 10 .
– Remove wheel ⇒ page 309 .
– Remove noise insulation ⇒ General body repairs, exterior;
Rep. gr. 66 ; Noise insulation; Exploded view - noise insula‐
tion .
– Detach wheel housing liner on underbody trim and swivel
wheel housing liner slightly to side.
– Depending on equipment version: Cut through cable ties
-arrows- and detach air duct -2- from wishbone -1-.
– If fitted, remove nut -4- and move coupling rod clear of vehicle
level sender -3-.
Note
When removing and installing, take care not to damage the rubber
boot of the swivel joint. The boot should be protected against
damage if necessary.
Note
Installing
– Insert rear of wishbone into subframe and swivel forwards.
– Install bolts -arrows- and tighten hand-tight.
– Install subframe ⇒ page 33 .
♦ Drift - T10219/2-
Note
The bush will move temporarily out of line at the start of the press‐
ing-in process, but will straighten up when it is pressed in further.
Additional guiding is not necessary.
– Press in bonded rubber bush until core of bush -1- and hole in
wishbone -2- are on a level.
Note
Note
Greasing the bushes will prevent possible noise while they are
bedding in.
Removing
– Loosen drive shaft bolt at wheel hub ⇒ page 111 .
– Remove wheel ⇒ page 309 .
– If fitted, remove nut -4- and move coupling rod clear of vehicle
level sender -3-.
Note
WARNING
5 Wheel bearing
⇒ “5.1 Exploded view - wheel bearing”, page 90
⇒ “5.2 Removing and installing wheel bearing housing”,
page 91
⇒ “5.3 Removing and installing wheel bearing unit”, page 96
Caution
Avoid
• dirtying or damag‐
ing the seal when picking
it up, laying it down or
placing it in storage
⇒ page 98
4 - Bolt
❑ Always renew if re‐
moved
❑ Before securing, clean
the threads in the CV
joint using a thread tap
❑ Loosening and tightening ⇒ “6.3 Loosening and tightening bolt securing drive shaft”, page 111
❑ -WHT.002.795- / 200 Nm + turn 180° further
❑ -WHT.005.437- / black = 200 Nm + turn 180° further
❑ -WHT.005.437.A- / silver = 200 Nm + turn 90° further
5 - Bolt
❑ Tightening torque ⇒ Brake system; Rep. gr. 45 ; Sensors; Exploded view - front wheel speed sensor
6 - Speed sensor
❑ Front right speed sensor - G45- , front left speed sensor - G47-
❑ Removing and installing ⇒ Brake system; Rep. gr. 45 ; Sensors; Removing and installing front speed
sensors -G45- / -G47-
♦ Spreader - 3424-
5. Wheel bearing 91
Audi A3 2013 ➤ , Audi A3 Cabriolet 2015 ➤ , Audi A3 Limousine 2014 ➤ , A ...
Running gear, axles, steering - Edition 02.2019
Removing
– Loosen bolt securing drive shaft at wheel hub ⇒ page 111 .
– Remove brake disc ⇒ Brake system; Rep. gr. 46 ; Front
brakes; Removing and installing brake disc .
– Remove ABS speed sensor ⇒ Brake system; Rep. gr. 45 ;
Sensors; Exploded view - front wheel speed sensor .
– Remove bolt -1-, detach bracket -2- with brake hose from
wheel bearing housing and tie up one side.
– Detach bracket for brake line and electrical wiring from wheel
bearing housing and move clear.
– Position engine and gearbox jack - VAS 6931- with support
plate under wheel bearing housing.
– Slacken off nut on track rod ball joint (but do not remove yet).
– Press track rod ball joint off wheel bearing housing using ball
joint puller - 3287 A- -1- and then unscrew nut.
– If fitted, remove nut -4- and move coupling rod clear of vehicle
level sender -3-.
Note
Use both hands to remove the connector: open the catch with one
hand whilst pressing off the connector with the other; do not use
any tools.
5. Wheel bearing 93
Audi A3 2013 ➤ , Audi A3 Cabriolet 2015 ➤ , Audi A3 Limousine 2014 ➤ , A ...
Running gear, axles, steering - Edition 02.2019
Note
♦ Do not let the drive shaft hang down under its own weight, as
otherwise excessive bending could damage the inner CV joint.
♦ Tie up drive shaft to body with wire.
5. Wheel bearing 95
Audi A3 2013 ➤ , Audi A3 Cabriolet 2015 ➤ , Audi A3 Limousine 2014 ➤ , A ...
Running gear, axles, steering - Edition 02.2019
Removing
– Loosen bolt securing drive shaft at wheel hub ⇒ page 111 .
– If fitted, remove nut -4- and move coupling rod clear of vehicle
level sender -3-.
– Remove brake disc ⇒ Brake system; Rep. gr. 46 ; Front
brakes; Removing and installing brake disc .
– Remove nut -1-, pull coupling rod -3- out of anti-roll bar -2- and
pivot to one side.
5. Wheel bearing 97
Audi A3 2013 ➤ , Audi A3 Cabriolet 2015 ➤ , Audi A3 Limousine 2014 ➤ , A ...
Running gear, axles, steering - Edition 02.2019
Caution
• The wheel bearing -1- must always face upwards when laying
down the wheel bearing unit.
• Always put down the wheel bearing unit with the wheel hub
-2- facing downwards.
• Do not touch the inside of the wheel bearing when you pick it
up.
• Always take hold of the outside of the wheel bearing.
Installing
Installation is carried out in reverse sequence. Note the following:
• On vehicles with electronic damping control (Audi magnetic
ride), perform function “Re-adapt reference (default) position”
using ⇒ Vehicle diagnostic tester.
• If the reference position has been re-adapted, the front camera
for driver assist systems must be recalibrated on vehicles with
lane departure warning function ⇒ page 343 .
• On vehicles with vehicle level sender, carry out basic adjust‐
ment of headlights ⇒ Electrical system; Rep. gr. 94 ; Head‐
lights; Adjusting headlights .
– Overview table: when does wheel alignment have to be
checked? ⇒ page 311
Tightening torques
♦ ⇒ “2.1 Exploded view - subframe”, page 18
♦ ⇒ “5.1 Exploded view - wheel bearing”, page 90
♦ ⇒ “3.1 Exploded view - suspension strut, upper wishbone”,
page 67
♦ ⇒ “4.1 Exploded view - lower wishbone, swivel joint”,
page 77
♦ ⇒ “2.1 Exploded view - front vehicle level senders”,
page 302
♦ ⇒ “6.3 Loosening and tightening bolt securing drive shaft”,
page 111
♦ ⇒ Brake system; Rep. gr. 46 ; Front brakes; Exploded view -
front brake
♦ ⇒ “1 Wheels, tyres”, page 309
6 Drive shaft
⇒ “6.1 Overview - drive shaft”, page 99
⇒ “6.2 Exploded view - drive shaft”, page 100
⇒ “6.3 Loosening and tightening bolt securing drive shaft”,
page 111
⇒ “6.4 Removing and installing heat shield for drive shaft”,
page 112
⇒ “6.5 Removing and installing drive shaft”, page 113
⇒ “6.6 Dismantling and assembling drive shaft”, page 136
⇒ “6.7 Checking outer constant velocity joint”, page 166
⇒ “6.8 Checking inner constant velocity joint”, page 167
I-
⇒ “6.2.1 Exploded view - drive
shaft with inner constant veloc‐
ity joint (108 mm dia., version
with bolted flange)”,
page 100
II -
⇒ “6.2.2 Exploded view - drive
shaft with inner constant veloc‐
ity joint (100 mm dia., version
with bolted flange)”,
page 102
III -
⇒ “6.2.3 Exploded view - drive
shaft with triple roller joint
AAR2600i/AAR3300i (with ex‐
ternal splines for insertion in
gearbox)”, page 105
IV -
⇒ “6.2.4 Exploded view - drive
shaft with triple roller joint
AAR2600i/AAR3300i (with in‐
ternal splines for gearbox stub
shaft)”, page 106
V-
⇒ “6.2.5 Exploded view - drive
shaft with sliding constant ve‐
locity joint (with internal splines
for gearbox stub shaft)”,
page 108
VI -
⇒ “6.2.6 Exploded view - drive
shaft with triple roller joint
AAR 2600i (version with bolted
flange)”, page 109
6. Drive shaft 99
Audi A3 2013 ➤ , Audi A3 Cabriolet 2015 ➤ , Audi A3 Limousine 2014 ➤ , A ...
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1 - Bolt
❑ Always renew if re‐
moved
❑ Loosening and tighten‐
ing ⇒ page 111
❑ Before securing, clean
the threads in the CV
joint using a thread tap
❑ -WHT.002.795- /
200 Nm + turn 180° fur‐
ther
❑ -WHT.005.437- / black =
200 Nm + turn 180° fur‐
ther
❑ -WHT.005.437.A- / sil‐
ver = 200 Nm + turn 90°
further
2 - Outer constant velocity joint
❑ Checking ⇒ page 166
❑ Removing ⇒ page 138
❑ Installing ⇒ page 138
❑ Grease splines on drive
shaft lightly with grease
used in joint when fitting
joint onto drive shaft
3 - Circlip
❑ Always renew if re‐
moved
❑ Insert in groove on shaft
4 - Hose clip
❑ Always renew if re‐
moved
❑ Tightening ⇒ page 141
5 - Boot for outer constant velocity joint
❑ Check for splits and chafing
6 - Hose clip
❑ Always renew if removed
❑ Tightening ⇒ page 141
7 - Profile shaft
8 - Hose clip
❑ Always renew if removed
❑ Tightening ⇒ page 141
9 - Boot for inner constant velocity joint
❑ Check for splits and chafing
10 - Hose clip
❑ Always renew if removed
❑ Tightening ⇒ page 141
11 - Lock plate
12 - Cap
❑ Always renew if removed
❑ Drive off constant velocity joint with a drift
❑ Apply sealant between joint and cover ⇒ page 140
chafing
6 - Hose clip
❑ Always renew if removed
❑ Tightening ⇒ page 146
7 - Dished spring
❑ Installation position ⇒ page 144
8 - Spacer ring (plastic)
❑ Installation position ⇒ page 144
9 - Circlip
❑ Always renew if removed
❑ Insert in groove on shaft
10 - Boot for inner constant velocity joint
❑ Check for splits and chafing
❑ Drive off constant velocity joint with a drift
❑ Before fitting on constant velocity joint, coat sealing surface with sealant
11 - Hose clip
❑ Always renew if removed
❑ Tightening ⇒ page 146
12 - Lock plate
13 - Multi-point socket head bolt
❑ Always renew if removed
❑ Initial tightening torque: 10 Nm in diagonal sequence
❑ Tightening torque, M8: 40 Nm in diagonal sequence
❑ Tightening torque, M10: 70 Nm in diagonal sequence
14 - Circlip
❑ Always renew if removed
❑ Removing and installing with -VW 161 A- ⇒ page 143
15 - Gasket
❑ Adhesive surface on constant velocity joint must be free of oil and grease
16 - Inner constant velocity joint
❑ Renew only as complete unit
❑ Checking ⇒ page 167
❑ Pressing off ⇒ page 145
❑ Pressing on ⇒ page 145
❑ Grease splines on drive shaft lightly with grease used in joint when fitting joint onto drive shaft
17 - Dished spring
❑ Installation position ⇒ page 144
8 - Hose clip
❑ Always renew if removed
❑ Tightening ⇒ page 151
9 - Drive shaft
10 - Hose clip
❑ Always renew if removed
❑ Tightening ⇒ page 151
11 - Boot for triple roller joint
❑ Check for splits and chafing
12 - Hose clip
❑ Always renew if removed
❑ Tightening ⇒ page 151
13 - Triple roller spider with rollers
Chamfer -arrow- faces towards drive shaft splines
14 - Circlip
❑ Always renew if removed
❑ Insert in groove on shaft
15 - Joint body
16 - Circlip
❑ Always renew if removed
12 - Circlip
❑ Always renew if removed
❑ Insert in groove on shaft
13 - Adapter
14 - Joint body
15 - Protective cap
❑ Detaching ⇒ page 157
❑ Driving on ⇒ page 157
6.2.5 Exploded view - drive shaft with sliding constant velocity joint (with internal
splines for gearbox stub shaft)
1 - Bolt
❑ Always renew if re‐
moved
❑ Loosening and tighten‐
ing ⇒ page 111
❑ Before securing, clean
the threads in the CV
joint using a thread tap
❑ 200 Nm +180°
2 - Outer constant velocity joint
❑ Renew only as com‐
plete unit
❑ Distribute grease filling
through ball races
❑ Removing ⇒ page 159
❑ Installing: drive onto
shaft as far as stop us‐
ing plastic hammer
❑ Checking ⇒ page 166
3 - Circlip
❑ Always renew if re‐
moved
❑ Insert in groove on shaft
4 - Hose clip
❑ Always renew if re‐
moved
❑ Tightening ⇒ page 161
5 - Boot
❑ Check for splits and
chafing
6 - Hose clip
❑ Always renew if re‐
moved
❑ Tightening ⇒ page 161
7 - Drive shaft
8 - Hose clip
❑ Always renew if removed
❑ Tightening ⇒ page 161
9 - Boot for sliding constant velocity joint
❑ Check for splits and chafing
10 - Circlip
❑ Always renew if removed
❑ Insert in groove on shaft
11 - Hose clip
❑ Always renew if removed
❑ Tightening ⇒ page 161
12 - Sliding constant velocity joint
❑ Renew only as complete unit
❑ Removing ⇒ page 159
❑ Distribute grease filling through ball races
❑ Installing: drive onto shaft as far as stop using plastic hammer
13 - Protective cap
❑ Detaching ⇒ page 162
❑ Driving on ⇒ page 162
Note
1 - Bolt
❑ Always renew if re‐
moved
❑ Loosening and tighten‐
ing ⇒ page 111
❑ Before securing, clean
the threads in the CV
joint using a thread tap
❑ -WHT.005.437- / black =
200 Nm + turn 180° fur‐
ther
❑ -WHT.005.437.A- / sil‐
ver = 200 Nm + turn 90°
further
2 - Outer constant velocity joint
❑ Renew only as com‐
plete unit
❑ Removing ⇒ page 164
❑ Installing ⇒ page 164
❑ Checking ⇒ page 166
❑ Grease splines on drive
shaft lightly with grease
used in joint when fitting
joint onto drive shaft
3 - Circlip
❑ Always renew if re‐
moved
❑ Insert in groove on shaft
4 - Spacer ring (plastic)
❑ Installation position
⇒ page 164
5 - Spring plate
❑ Installation position
⇒ page 164
6 - Hose clip
❑ Always renew if removed
❑ Tightening ⇒ page 165
7 - Boot for constant velocity joint
❑ Check for splits and chafing
8 - Hose clip
❑ Always renew if removed
❑ Tightening ⇒ page 165
9 - Profile shaft
10 - Triple roller spider with rollers
❑ Chamfer -arrow- faces towards drive shaft splines
❑ Grease splines on drive shaft lightly with grease used in joint when fitting triple roller spider onto drive
shaft
11 - Circlip
❑ Always renew if removed
❑ Insert in groove on shaft
12 - Hose clip
❑ Always renew if removed
♦ Socket, 24 mm - T10361A-
Note
Note
The wheels must not be in contact with the ground when initially
tightening the drive shaft bolt; otherwise the wheel bearing can
be damaged.
Four-wheel drive:
Component Tightening torque
Nuts -1- 20 Nm
♦ Pre-tighten all nuts to 10
Nm
♦ Assembly lever
Removing
– Loosen bolt securing drive shaft at wheel hub -arrow-
⇒ page 111 .
– Remove wheel ⇒ page 309 .
– Remove noise insulation ⇒ General body repairs, exterior;
Rep. gr. 66 ; Noise insulation; Exploded view - noise insula‐
tion .
– Remove coupling rod ⇒ page 65 .
Note
Do not allow the drive shaft to hang down under its own weight;
this would bend the inner joint too far and damage it.
Installing
Install in reverse sequence, paying attention to the following:
– Circlip on drive shaft must always be renewed following re‐
moval.
– If fitted: Renew O-ring for drive shaft.
– On gearboxes not sealed with internally splined sleeve: Re‐
new oil seal on gearbox ⇒ Gearbox; Rep. gr. 39 ; Oil seals;
Overview of fitting locations - oil seals .
– Grease pin on end of joint in area -A- all round with approx.
0.5 g of grease ⇒ Electronic parts catalogue “ETKA” .
• Install drive shaft at gearbox end first.
– Mesh outer and inner splines of joint body and gearbox.
– Take hold of drive shaft and slide it into joint body as far as it
will go.
– Then push joint body firmly into gearbox with a sudden, hard
push so that circlip engages.
Note
– Check that the joint body is fitted securely by pulling the joint
against the resistance of the circlip.
Caution
When making this check, only pull on the joint body. Do not pull
the drive shaft.
• Before fitting the outer joint in the wheel hub, apply a thin coat
of assembly paste to the splines on the outer joint ⇒ Electronic
parts catalogue “ETKA” .
• On vehicles with electronic damping control (Audi magnetic
ride), perform function “Re-adapt reference (default) position”
using ⇒ Vehicle diagnostic tester.
• If the reference position has been re-adapted, the front camera
for driver assist systems must be recalibrated on vehicles with
lane departure warning function ⇒ page 343 .
• On vehicles with vehicle level sender, carry out basic adjust‐
ment of headlights ⇒ Electrical system; Rep. gr. 94 ; Head‐
lights; Adjusting headlights .
Tightening torques
♦ ⇒ “6.3 Loosening and tightening bolt securing drive shaft”,
page 111
♦ ⇒ “2.1 Exploded view - front vehicle level senders”,
page 302
♦ ⇒ “2.1 Exploded view - subframe”, page 18
♦ ⇒ “4.1 Exploded view - lower wishbone, swivel joint”,
page 77
♦ Puller - T10382-
Removing
– Loosen bolt securing drive shaft at wheel hub -arrow-
⇒ page 111 .
– Remove wheel ⇒ page 309 .
– Remove noise insulation ⇒ General body repairs, exterior;
Rep. gr. 66 ; Noise insulation; Exploded view - noise insula‐
tion .
Note
Do not allow the drive shaft to hang down under its own weight;
this would bend the inner joint too far and damage it.
Note
Caution
Note
– Check that the joint body is fitted correctly by pulling the joint
against the resistance of the circlip.
Caution
When making this check, only pull on the joint body. Do not pull
the drive shaft.
– Before fitting the outer joint in the wheel hub, apply a thin coat
of assembly paste to the splines on the outer joint ⇒ Electronic
parts catalogue “ETKA” .
• On vehicles with electronic damping control (Audi magnetic
ride), perform function “Re-adapt reference (default) position”
using ⇒ Vehicle diagnostic tester.
• If the reference position has been re-adapted, the front camera
for driver assist systems must be recalibrated on vehicles with
lane departure warning function ⇒ page 343 .
♦ Puller - T10382-
Removing
– Loosen bolt securing drive shaft at wheel hub -arrow-
⇒ page 111 .
– Remove wheel ⇒ page 309 .
– Remove noise insulation ⇒ General body repairs, exterior;
Rep. gr. 66 ; Noise insulation; Exploded view - noise insula‐
tion .
Note
– Fit new seal -1- and circlip -2- in groove of stub shaft on gear‐
box.
– Apply approx. 2 g of grease all round splines on end of gearbox
shaft ⇒ Electronic parts catalogue “ETKA” .
– Mesh outer and inner splines of gearbox shaft and sliding con‐
stant velocity joint.
– Take hold of drive shaft and slide it into constant velocity joint
as far as it will go.
– Then push constant velocity joint onto stub shaft on gearbox
with a sudden, hard push.
Note
Caution
When making this check, only pull on the CV joint. Do not pull
the drive shaft.
Note
♦ Puller - T10382-
Removing
– Loosen bolt securing drive shaft at wheel hub -arrow-
⇒ page 111 .
– Remove wheel ⇒ page 309 .
– Remove noise insulation ⇒ General body repairs, exterior;
Rep. gr. 66 ; Noise insulation; Exploded view - noise insula‐
tion .
Note
Note
– Insert puller - T10382- and pull out drive shaft by striking multi-
purpose tool - VW 771- as required.
– Take drive shaft out of vehicle.
Installing
Install in reverse sequence, paying attention to the following:
• Remove any paint residue and/or corrosion on thread and
splines of outer joint.
Vehicles with four-wheel drive
– Strike end of stub shaft using a plastic hammer.
Caution
Note
Caution
When making this check, only pull on the CV joint. Do not pull
the drive shaft.
Note
♦ Thrust plate -
VW 401-
♦ Thrust plate -
VW 402-
♦ Press tool -
VW 408 A-
♦ Support sleeve - VW
522-
♦ Clamp - 40-204A-
♦ Clamp tensioner -
V.A.G 1682 A-
Detaching cover
– Drive off cover with a copper or brass drift.
Note
Note
6.6.2 Servicing drive shaft with 100 mm dia. inner constant velocity joint
Note
– Fit circlip.
Note
6.6.3 Servicing drive shaft with triple roller joint AAR3300i (with external splines
for insertion in gearbox)
♦ Puller - T10382-
– Remove circlip.
1 - Pliers (commercial type)
– Insert drive shaft in press.
Note
6.6.4 Servicing drive shaft with triple roller joint AAR2600i/AAR3300i (with inter‐
nal splines for gearbox stub shaft)
♦ Puller - T10382-
Dismantling
– Open hose clip at inner joint and push back boot from adapter.
– Pull joint body off drive shaft.
– Remove circlip.
1 - Pliers (commercial type)
– Insert drive shaft in press.
– Push joint boot onto adapter, making sure that boot engages
properly in groove on adapter -arrow-.
– Fit hose clip and tighten sufficiently to ensure reliable sealing.
Note
♦ Torque wrench -
V.A.G 1331-
♦ Clamp tensioner -
V.A.G 1682 A-
♦ Thrust piece -
T10243-
♦ Three-arm puller -
VAS 251 205- (previ‐
ously Kukko 45-2)
– If originally fitted, install dished spring -1- and spacer ring -2-
as shown in illustration.
– Push on small hose clip with joint boot and bring boot into po‐
sition on drive shaft.
Note
6.6.6 Servicing drive shaft with triple roller joint AAR 2600i (version with bolted
flange on inner joint)
♦ Assembly tool -
T10065-
Note
Removing
– Before dismantling, mark position of ball hub in relation to ball
cage and joint body with an electric scriber or oil stone
-arrow-.
– Swivel ball hub and ball cage and take out balls one after the
other.
– Turn cage until two cage openings -arrow- are level with joint
body.
– Lift out cage together with hub.
– Swivel one segment of the hub into one of the cage openings.
– Pivot hub out of cage.
Note
Installing
Install in reverse sequence, paying attention to the following:
– Fit cage with hub into joint body.
Note
– Press in balls one after the other from opposite sides, taking
care to re-establish original position of hub relative to cage and
joint body.
– Fit new circlip in shaft.
Note
Ball hub and joint body are paired. Mark position in relation to
each other with a waterproof felt-tip pen prior to removal.
Removing
– Swivel ball hub and ball cage.
– Push out joint body in direction of -arrow-.
– Push balls out of cage.
– Align ball hub with cage as shown -arrows- and pivot hub out
of cage.
– Check joint, ball hub, ball cage and balls for pitting and signs
of seizure.
Note
Installing
Install in reverse sequence, paying attention to the following:
– Insert hub into cage via the two chamfers. No specific instal‐
lation position is required. Push balls into cage.
– Insert hub with cage and balls at a right angle to the joint body.
Note
♦ When inserting, ensure that the wide spacing -a- on the joint
body is aligned with the narrow spacing -b- on the hub after
swivelling in.
♦ Chamfer on internal diameter of ball hub (splines) must face
large diameter of joint body.
♦ When reinstalling, you should also use felt-tip pen mark made
on removal as a guide.
– Swivel the hub into the joint body; at the same time the hub
must be swivelled out of the cage -arrows- far enough to allow
the balls to fit into the ball races.
42 – Rear suspension
1 Rear axle
⇒ “1.1 Overview - rear axle”, page 170
⇒ “1.2 Removing and installing rear axle”, page 172
1.1.1 Overview - rear axle (torsion beam axle), front-wheel drive vehicles
♦ Support - T10149-
Removing
– Before starting work, measure distance from centre of wheel
to lower edge of wheel housing ⇒ page 10 .
– Release handbrake.
– Remove rear wheels ⇒ page 309 .
– If fitted, remove underbody trim in area of axle beam ⇒ Gen‐
eral body repairs, exterior; Rep. gr. 66 ; Underbody trim;
Exploded view - underbody trim .
– Unplug electrical connectors (left and right) -1- for ABS speed
sensors and move electrical wiring clear.
– Unplug electrical connectors (left and right) -2- for electrome‐
chanical parking brake motor and move electrical wiring clear.
– Detach electrical wiring harness from retainers -arrows- and
move clear.
– Unclip electrical wire -1- from bracket -2- on axle beam (both
sides) -arrows- and move clear.
– Detach brake calipers on both sides and tie to body with wire
⇒ Brake system; Rep. gr. 46 ; Rear brakes; Exploded view -
rear brake .
Note
Caution
Installing
Installation is carried out in reverse sequence. Note the following:
• Tighten bolted connection -1- securing shock absorber to axle
beam with suspension in unladen position ⇒ page 10 .
– Check and adjust wheel alignment ⇒ page 310 .
Tightening torques
♦ ⇒ “2.1 Exploded view - axle beam”, page 188
♦ ⇒ “6.1.1 Exploded view - shock absorber, spring (torsion beam
axle)”, page 232
♦ ⇒ Brake system; Rep. gr. 46 ; Rear brakes; Exploded view -
rear brake
♦ ⇒ “1 Wheels, tyres”, page 309
Note
Note
WARNING
Note
WARNING
– Drain fuel tank ⇒ Fuel supply system; Rep. gr. 20 ; Fuel tank;
Draining fuel tank .
– Remove underbody trim (rear) for high-voltage battery unit ⇒
General body repairs, exterior; Rep. gr. 66 ; Underbody trim;
Removing and installing underbody trim .
– Fix position of subframe ⇒ page 200 .
– Remove wheel housing liners (both sides) ⇒ General body
repairs, exterior; Rep. gr. 66 ; Wheel housing liners; Removing
and installing wheel housing liner (rear) .
– Unplug electrical connector -1- from ABS speed sensor on
both sides and move clear.
– Unplug electrical connector -2- from electromechanical park‐
ing brake motor on brake caliper on both sides.
– Detach electrical wiring harness from retainers -arrows- and
move clear.
– Secure rear frame of fuel tank -1- using extension -2024 A /1-
-arrows-, as shown in illustration (tightening torque 20 Nm).
A - Left side of vehicle
B - Right side of vehicle
Note
Note
Note
Note
Note
Note
If the bolt securing the drive shaft has to be loosened for later
operations, remember that this must be done with the vehicle
standing on its wheels. Slacken bolt securing drive shaft to wheel
hub ⇒ page 283 .
Note
Note
Note
Note
2 Axle beam
⇒ “2.1 Exploded view - axle beam”, page 188
⇒ “2.2 Renewing bonded rubber bushes for axle beam”,
page 189
Caution
1 - Cover
2 - Bolt
❑ Always renew if re‐
moved
❑ 50 Nm +45°
3 - Bolt
❑ Always renew if re‐
moved
❑ Tighten in unladen posi‐
tion ⇒ page 10
❑ 70 Nm +360°
4 - Axle beam
❑ Removing and installing
⇒ page 172
5 - Bonded rubber bush
❑ Note correct installation
position
❑ Renewing ⇒ page 189
6 - Mounting bracket
Removing
– Release handbrake.
– Before commencing work, use measuring tape or similar to
measure dimension -a- from wheel centre to lower edge of
wheel housing.
• This measurement must be taken with the suspension in the
unladen position (vehicle unladen) ⇒ page 10 .
– Make a note of the measured value. This will be needed when
tightening the bolts and/or nuts.
– Raise vehicle to working height.
– Remove rear wheels ⇒ page 309 .
– If fitted, remove underbody trim in area of axle beam ⇒ Gen‐
eral body repairs, exterior; Rep. gr. 66 ; Underbody trim;
Exploded view - underbody trim .
Note
– Unclip electrical wire -1- from bracket -2- on axle beam (both
sides) -arrows-.
WARNING
– Carefully lower rear axle with engine and gearbox jack - VAS
6931- until bolt -1- can be taken out.
– Remove bolt -1-.
Installing
– Note correct position of bonded rubber bush -1- relative to axle
beam -2-.
Lug -arrow A- on bonded rubber bush -1- must point towards
notch -arrow B- on axle beam -2-.
3 Subframe
⇒ “3.1 Exploded view - subframe”, page 196
⇒ “3.2 Fixing position of subframe”, page 200
⇒ “3.3 Servicing subframe”, page 207
Caution
1 - Bolt
❑ Always renew if re‐
moved
❑ 70 Nm +180°
2 - Bolt
❑ Always renew if re‐
moved
❑ 50 Nm +45°
3 - Bolt
❑ Always renew if re‐
moved
❑ 70 Nm +180°
4 - Subframe
❑ Different versions; for
correct version refer to
⇒ Electronic parts cata‐
logue “ETKA”
❑ Removing and installing
subframe with attach‐
ments
♦ ⇒ “1.2.2 Removing and in‐
stalling rear axle (multi-link
suspension) - front-wheel
drive vehicles”, page 176
♦ ⇒ “1.2.3 Removing and in‐
stalling rear axle (multi-link
suspension) - vehicles with
high-voltage system”, page
179
5 - Bolt
❑ Always renew if re‐
moved
❑ 70 Nm +180°
6 - Bracket for subframe
❑ For Audi A3 Cabriolet only
7 - Bolt
❑ Tightening torque and tightening sequence ⇒ page 198
8 - Bolt
❑ Tightening torque and tightening sequence ⇒ page 198
9 - Nut
10 - Bolt
❑ Always renew if removed
❑ 50 Nm +45°
11 - Bolt
❑ Always renew if removed
❑ 70 Nm +180°
3. Subframe 197
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Running gear, axles, steering - Edition 02.2019
3.1.2 Exploded view - subframe (multi-link suspension with bonded rubber bush‐
es), front-wheel drive vehicles
Caution
1 - Subframe
❑ Removing and installing
subframe with attach‐
ments ⇒ page 176
2 - Bonded rubber bush (rear)
❑ Renewing ⇒ page 207
3 - Bonded rubber bush (front)
❑ Renewing ⇒ page 207
4 - Bolts
❑ Renew after removing
❑ 70 Nm +180°
3. Subframe 199
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Running gear, axles, steering - Edition 02.2019
Caution
1 - Cross piece
❑ For Audi Cabriolet
(quattro) only
2 - Bolt
❑ 40 Nm
3 - Rivet nut
4 - Bolt
❑ 40 Nm
5 - Rivet nut
6 - Subframe
❑ Removing and installing
subframe with attach‐
ments ⇒ page 183
7 - Bonded rubber bush (rear)
❑ Aluminium bushes on
A3 Cabriolet (cannot be
renewed)
❑ Renewing ⇒ page 207
8 - Bolt
❑ Always renew if re‐
moved
❑ 70 Nm +180°
9 - Bonded rubber bush (front)
❑ Aluminium bushes on
A3 Cabriolet (cannot be
renewed)
❑ Renewing ⇒ page 207
10 - Bolt
❑ Always renew if re‐
moved
❑ 70 Nm +180°
3. Subframe 201
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Running gear, axles, steering - Edition 02.2019
Preparing tool
– Loosen bolts -arrows-.
– Set to dimension -a-.
• Dimension -a- = 250 mm
– Tighten bolts to 10 Nm again.
– Fit rear axle support - T10552- -item 1- onto engine and gear‐
box jack - VAS 6931- -item 2-.
Audi A3 Cabriolet:
– Slacken bolts -3- securing bracket -2- for subframe and re‐
move bolt -1- (counterhold the nut).
3. Subframe 203
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Running gear, axles, steering - Edition 02.2019
Subframe version 1:
• To fix position of subframe, locating pins from locating pin set
- T10096- must be screwed in one after the other on both sides
at positions -1-.
Caution
– Screw in locating pin -1- from locating pin set - T10096- and
tighten to max. 20 Nm.
– Repeat procedure for second bolt (front) and bolts (rear) for
subframe.
♦ The position of the subframe is now fixed.
Subframe version 2:
Caution
3. Subframe 205
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Running gear, axles, steering - Edition 02.2019
– Screw in locating pin -1- from locating pin set - T10096- and
tighten to max. 20 Nm.
– Repeat procedure for second bolt (front) and bolts (rear) for
subframe.
♦ The position of the subframe is now fixed.
Removing locating pins -T10096-
Removal is performed in reverse sequence; note the following:
– Working in a diagonal sequence, unscrew only one locating
pin at a time and screw in a new bolt in its place.
Caution
WARNING
Risk of accident!
♦ All bolts and nuts must be fully tightened according to
specifications before the vehicle is driven on public roads.
Note
3. Subframe 207
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Running gear, axles, steering - Edition 02.2019
– Move brake line -1- clear on left side -arrow-. This will irrepar‐
ably damage the clip.
– Lower subframe approx. 100 mm with engine and gearbox
jack - VAS 6931- .
3. Subframe 209
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Running gear, axles, steering - Edition 02.2019
Installing
• To assist assembly, a mark -1- should be made on the new
bonded rubber bush.
– Coat outer edge of bonded rubber bush with assembly paste.
Note
3. Subframe 211
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Running gear, axles, steering - Edition 02.2019
Note
3. Subframe 213
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Running gear, axles, steering - Edition 02.2019
– Move brake line -1- clear on left side -arrow-. This will irrepar‐
ably damage the clip.
– Lower subframe approx. 100 mm with engine and gearbox
jack - VAS 6931- .
Note
♦ The collar on the outer ring of the bonded rubber bush will
shear off with a loud bang when the bush is removed.
♦ After it has been pulled out, the bonded rubber bush must be
removed from the tube - T10356/2- with light blows from a
hammer.
Installing
– To assist assembly, a mark -1- should be made on the new
bonded rubber bush.
– Coat outer edge of bonded rubber bush with assembly paste.
3. Subframe 215
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Running gear, axles, steering - Edition 02.2019
4 Anti-roll bar
⇒ “4.1 Exploded view - anti-roll bar”, page 217
⇒ “4.2 Removing and installing anti-roll bar”, page 217
⇒ “4.3 Removing and installing coupling rod”, page 221
1 - Anti-roll bar
❑ With rubber bushes
❑ Removing and installing
⇒ page 217
2 - Coupling rod
❑ Removing and installing
⇒ page 221
3 - Lower transverse link
4 - Nut
❑ Always renew if re‐
moved
❑ 20 Nm +180°
5 - Bolt
❑ Always renew if re‐
moved
6 - Bolt
❑ Tighten evenly
❑ Always renew if re‐
moved
❑ 20 Nm +90°
7 - Nut
❑ When tightening, coun‐
terhold at multi-point
socket of coupling rod
❑ 55 Nm
8 - Subframe
Note
Removing
– All A3 models except Cabriolet: Remove rear silencer or cen‐
tre silencer with rear silencer and move aside ⇒ Engine; Rep.
gr. 26 ; Exhaust pipes/silencers; Exploded view - silencers .
– Remove nut -1- from coupling rod -2-.
– Pull coupling rod -2- out of anti-roll bar -3-.
Installing
Install in reverse sequence, paying attention to the following:
– Tighten bolts -arrows- securing anti-roll bar -1- to subframe
-2- evenly.
Tightening torques
♦ ⇒ “4.1 Exploded view - anti-roll bar”, page 217
♦ ⇒ “7.1 Exploded view - wheel bearing”, page 246
♦ ⇒ Engine; Rep. gr. 26 ; Exhaust pipes/silencers; Exploded
view - silencers
♦ Support - T10149-
Note
Note
The following steps are described for the left side of the vehicle.
The procedure for the right side of the vehicle is identical.
Removing
– Remove rear silencer ⇒ Engine; Rep. gr. 26 ; Exhaust pipes/
silencers; Exploded view - silencers .
– Remove nut -1- from coupling rod -2-.
– Pull coupling rod -2- out of anti-roll bar -3-.
WARNING
Installing
Install in reverse sequence, paying attention to the following:
• Evenly tighten bolts -arrows- for anti-roll bar clamp.
Note
Tightening torques
♦ ⇒ “4.1 Exploded view - anti-roll bar”, page 217
♦ ⇒ Engine; Rep. gr. 26 ; Exhaust pipes/silencers; Exploded
view - silencers
♦ ⇒ “1 Wheels, tyres”, page 309
Note
Removing
– Before starting work, measure distance from centre of wheel
to lower edge of wheel housing ⇒ page 10 .
– Remove wheel ⇒ page 309 .
Vehicles with stone deflector
– Remove spreader rivets -1-.
– Unscrew bolts -2- and detach stone deflector -3-.
Installing
Install in reverse sequence, paying attention to the following:
– Insert coupling rod -2-, fit nuts -1 and 3- and tighten with sus‐
pension in unladen position ⇒ page 10 .
• When tightening nut -1-, counterhold at multi-point socket of
bolt.
Tightening torques
♦ ⇒ “4.1 Exploded view - anti-roll bar”, page 217
♦ ⇒ “1 Wheels, tyres”, page 309
Note
The illustration shows the transverse links on a vehicle with front-wheel drive; four-wheel drive is similar.
1 - Eccentric bolt
❑ After slackening off, per‐
form wheel alignment
⇒ page 310
❑ Do not turn more than
90° in either direction
(i.e. from minimum to
maximum adjustment
position)
2 - Subframe
3 - Eccentric washer
❑ With lug on inner bore
4 - Nut
❑ Always renew if re‐
moved
❑ Always tighten bolted
joints with suspension in
unladen position
⇒ page 10
❑ 95 Nm without insert
tool 18 mm - T10179-
❑ 80 Nm with insert tool 18
mm - T10179-
5 - Eccentric bolt
❑ After slackening off, per‐
form wheel alignment
⇒ page 310
❑ Do not turn more than
90° in either direction
(i.e. from minimum to
maximum adjustment
position)
6 - Eccentric washer
❑ With lug on inner bore
7 - Nut
❑ Always renew if removed
❑ Always tighten bolted joints with suspension in unladen position ⇒ page 10
❑ 95 Nm
Note
The illustration shows the track rod on a vehicle with four-wheel drive; front-wheel drive is similar.
1 - Subframe
2 - Bolt
❑ Always renew if re‐
moved
3 - Wheel bearing housing
❑ Different versions for
front-wheel drive and
four-wheel drive. Illus‐
tration shows wheel
bearing housing for
four-wheel drive vehi‐
cle.
4 - Track rod
❑ Removing and installing
⇒ page 230
5 - Bolt
❑ Always renew if re‐
moved
❑ Always tighten bolted
joints with suspension in
unladen position
⇒ page 10
❑ 70 Nm +180°
6 - Nut
❑ Always renew if re‐
moved
❑ 70 Nm +180°
Removing
– Before starting work, measure distance from centre of wheel
to lower edge of wheel housing ⇒ page 10 .
– Remove wheel ⇒ page 309 .
– Four-wheel drive vehicles: disengage wire -1- from bracket
-2- and move clear.
– Unscrew nut -6- and take off washer -5-.
– Remove bolt -3- and, if fitted, washer -4-.
Removing
– Before starting work, measure distance from centre of wheel
to lower edge of wheel housing ⇒ page 10 .
– Remove wheel ⇒ page 309 .
Vehicles with vehicle level senders
– Remove bolts -1- on linkage -2- for rear vehicle level sender
on both sides of vehicle.
– Unscrew nut -1- and pull out bolt -2- for coupling rod -3-.
– Unscrew nut -1- and pull out bolt -2- securing shock absorber.
– Unscrew nut -3- and pull out bolt -4- securing wheel bearing
housing.
Removing
– Before starting work, measure distance from centre of wheel
to lower edge of wheel housing ⇒ page 10 .
– Remove wheel ⇒ page 309 .
– Remove bolts -arrows- for anti-roll bar -1-.
Note
1 - Bolt
❑ Always renew if re‐
moved
❑ 50 Nm +45°
2 - Shock absorber
❑ Removing and installing
⇒ page 233
❑ Defective shock absorb‐
ers must always be de‐
gassed and drained be‐
fore disposal ⇒ page 15
3 - Axle beam
4 - Stone deflector
5 - Bolt
❑ Always renew if re‐
moved
❑ Always tighten bolted
connection with suspen‐
sion in unladen position
⇒ page 10
❑ 70 Nm +180°
6 - Bottom spring seat
❑ Turn end of spring
against stop
❑ When installing, fit pin in
aperture in spring
mounting on axle beam.
7 - Clamp ring
❑ After installing stone de‐
flector, press clamp ring
on so it is flush
8 - Coil spring
❑ Removing and installing ⇒ page 240
1 - Bolt
❑ Always renew if re‐
moved
❑ 50 Nm +45°
2 - Shock absorber
❑ Removing and installing
⇒ page 233
❑ Defective shock absorb‐
ers must always be de‐
gassed and drained be‐
fore disposal ⇒ page 15
3 - Bolt
❑ Always renew if re‐
moved
4 - Lower transverse link
5 - Clip
❑ Assists with installation
6 - Coil spring
❑ Removing and installing
⇒ page 243
7 - Top spring seat
❑ Fit on lug on body.
8 - Bottom spring seat
❑ Turn end of spring
against stop
❑ When installing, fit pin in
aperture in spring
mounting on lower
transverse link -arrow-.
9 - Nut
❑ Always renew if re‐
moved
❑ Always tighten bolted connection with suspension in unladen position ⇒ page 10
❑ 70 Nm +180°
♦ Support - T10149-
Removing
– Before starting work, measure distance from centre of wheel
to lower edge of wheel housing ⇒ page 10 .
– Remove wheel ⇒ page 309 .
– Use wheel bolt to attach engine and gearbox jack - VAS 6931-
with support - T10149- to wheel hub.
WARNING
1 - Shock absorber
❑ Removing and installing
⇒ page 233
❑ Defective shock absorb‐
ers must always be de‐
gassed and drained be‐
fore disposal ⇒ page 14
❑ Checking shock absorb‐
er following removal
⇒ page 4
2 - Protective tube
❑ Combined with -item 3-
as one unit
3 - Bump stop
❑ Combined with -item 2-
as one unit
4 - Shock absorber mounting
5 - Nut
❑ Always renew if re‐
moved
❑ 25 Nm
6 - Cover
1 - Shock absorber
❑ For correct version refer
to ⇒ Electronic parts
catalogue “ETKA”
❑ Removing and installing
⇒ page 233
❑ Defective shock absorb‐
ers must always be de‐
gassed and drained be‐
fore disposal ⇒ page 14
❑ Checking shock absorb‐
er following removal
⇒ page 4
2 - Protective tube
❑ Combined with -item 3-
as one unit
3 - Bump stop
❑ Combined with -item 2-
as one unit
4 - Shock absorber mounting
5 - Not fitted
6 - Nut
❑ Always renew if re‐
moved
❑ 25 Nm
7 - Wiring guide
8 - Cover
❑ With connector fasten‐
ing
Removing
– Remove wheel ⇒ page 309 .
– Pull out clip -1- as far as it will go in direction of -arrow-.
Note
WARNING
Note
Installing
Install in reverse sequence, paying attention to the following:
– Check that spring seat is not damaged.
– Renew spring seat if necessary.
– Fit spring seat on bottom of coil spring.
• End of spring -arrow- must lie against stop on bottom spring
seat.
– Install spring together with spring seat.
– The bottom spring seat has a pin.
– Insert this pin in hole in lower spring mounting on axle beam.
Removing
– Remove wheel ⇒ page 309 .
– Press in lugs -arrows- of assembly tool -1-.
– Lift out assembly tool -1-.
WARNING
Note
– Remove spring.
WARNING
Installing
Install in reverse sequence, paying attention to the following:
End of spring -arrow- must lie against stop on bottom spring seat.
– Install spring together with spring seat.
– Insert assembly tool -1- and press down until lugs -arrows-
engage.
– Overview table: when does wheel alignment have to be
checked? ⇒ page 311
Tightening torques
♦ ⇒ “1 Wheels, tyres”, page 309
7.1.1 Exploded view - wheel bearing unit (torsion beam axle), front-wheel drive
vehicles
1 - Grease cap
❑ Always renew if re‐
moved
2 - Bolt
❑ Always renew if re‐
moved
❑ Loosening and tighten‐
ing ⇒ page 283
❑ Before securing, clean
threads in stub axle us‐
ing a thread tap
❑ 200 Nm + turn +180°
further
3 - Wheel bearing unit
❑ Removing and installing
⇒ page 260
❑ Wheel bearing and
wheel hub are com‐
bined in one housing.
❑ This wheel bearing unit
is maintenance-free and
has zero play. There is
no provision for adjust‐
ment or repair.
4 - Bolt
❑ Always renew if re‐
moved
❑ 30 Nm +90°
5 - Splash plate for brakes
❑ Removing and installing
⇒ Brake system; Rep.
gr. 46 ; Rear brakes;
Exploded view - rear
brake
6 - Stub axle
7 - Axle beam
7.1.2 Exploded view - wheel bearing housing, wheel bearing unit (multi-link sus‐
pension), front-wheel drive vehicles
1 - Bolt
❑ Tightening torque: ⇒
Brake system; Rep. gr.
45 ; Overview of fitting
locations; Overview of
fitting locations - ABS/
ESP
2 - Rear speed sensor
❑ Removing and installing
⇒ Brake system; Rep.
gr. 45 ; Overview of fit‐
ting locations; Overview
of fitting locations - ABS/
ESP
3 - Wheel bearing housing
❑ Removing and installing
⇒ page 251
4 - Bonded rubber bush
❑ Renewing ⇒ page 268
5 - Bolt
❑ Tightening torque ⇒
Brake system; Rep. gr.
46 ; Rear brakes; Explo‐
ded view - rear brake
6 - Brake disc
❑ Removing and installing
⇒ Brake system; Rep.
gr. 46 ; Rear brakes;
Removing and installing
brake disc
7 - Bolt
❑ Tightening torque ⇒
Brake system; Rep. gr.
46 ; Rear brakes; Explo‐
ded view - rear brake
8 - Grease cap
❑ Always renew if removed
❑ Removing and installing ⇒ page 260
❑ Proper sealing can only be achieved by installing a new grease cap.
9 - Bolt
❑ Always renew if removed
❑ Loosening and tightening ⇒ page 283
❑ Before securing, clean threads in wheel bearing housing using a thread tap.
❑ 200 Nm + turn +180° further
10 - Wheel bearing unit
❑ Removing and installing ⇒ page 263
❑ Wheel bearing and wheel hub are combined in one housing.
❑ This wheel bearing unit is maintenance-free and has zero play. There is no provision for adjustment or
repair.
Caution
Avoid
• dirtying or damag‐
ing the seal when laying
it down or placing it in
storage ⇒ page 262 .
7.1.3 Exploded view - wheel bearing housing, wheel bearing unit (multi-link sus‐
pension), four-wheel drive vehicles
1 - Bolt
❑ Always renew if re‐
moved
❑ 80 Nm +90°
2 - Drive shaft
3 - Wheel bearing housing
❑ Removing and installing
⇒ page 255
4 - Rear speed sensor
❑ Removing and installing
⇒ Brake system; Rep.
gr. 45 ; Overview of fit‐
ting locations; Overview
of fitting locations - ABS/
ESP
5 - Bolt
❑ Tightening torque: ⇒
Brake system; Rep. gr.
45 ; Overview of fitting
locations; Overview of
fitting locations - ABS/
ESP
6 - Bonded rubber bush
❑ Renewing ⇒ page 268
7 - Bolt
❑ Tightening torque ⇒
Brake system; Rep. gr.
46 ; Rear brakes; Explo‐
ded view - rear brake
8 - Brake disc
❑ Removing and installing
⇒ Brake system; Rep.
gr. 46 ; Rear brakes;
Removing and installing brake disc
9 - Bolt
❑ Tightening torque ⇒ Brake system; Rep. gr. 46 ; Rear brakes; Exploded view - rear brake
10 - Bolt
❑ Always renew if removed
❑ Loosening and tightening ⇒ page 283
❑ Before securing, clean the threads in the CV joint using a thread tap
Caution
Avoid
• dirtying or damag‐
ing the seal when laying
it down or placing it in
storage ⇒ page 268 .
1 - Cover
2 - Mounting bracket
3 - Bolt
❑ Always renew if re‐
moved
❑ 50 Nm +45°
4 - Bolt
❑ Always renew if re‐
moved
❑ 90 Nm +90°
5 - Bolt
❑ Always renew if re‐
moved
❑ 70 Nm +90°
6 - Bolt
❑ Always renew if re‐
moved
❑ 70 Nm +90°
7 - Bolt
❑ Tightening torque: ⇒
Brake system; Rep. gr.
45 ; Overview of fitting
locations; Overview of
fitting locations - ABS/
ESP
8 - Rear speed sensor
❑ Removing and installing
⇒ Brake system; Rep.
gr. 45 ; Overview of fit‐
ting locations; Overview
of fitting locations - ABS/
ESP
Note
♦ Support - T10149-
Removing
– Before starting work, measure distance from centre of wheel
to lower edge of wheel housing ⇒ page 10 .
– Remove wheel ⇒ page 309 .
– Remove brake caliper ⇒ Brake system; Rep. gr. 46 ; Rear
brakes; Removing and installing brake caliper .
• If you are renewing the wheel bearing housing and intend to
re-install the old wheel bearing unit, you must remove the
wheel bearing unit.
– If necessary, remove wheel bearing unit ⇒ page 263 .
– If necessary, remove splash plate ⇒ Brake system; Rep. gr.
46 ; Rear brakes; Exploded view - rear brake .
Vehicles with vehicle level senders:
– Remove bolts -1- on linkage -2- for rear vehicle level sender
on both sides of vehicle.
Installing
Install in reverse sequence, paying attention to the following:
Do not tighten bolts securing trailing arm to wheel bearing housing
until all other suspension components (especially spring and
shock absorber) on that side are fitted. The suspension must be
in extended position before securing. The trailing arm and the
wheel bearing housing will only then move into the required po‐
sition -arrows-.
♦ Support - T10149-
Removing
– Before starting work, measure distance from centre of wheel
to lower edge of wheel housing ⇒ page 10 .
– Loosen bolt securing drive shaft at wheel hub ⇒ page 283 .
– Remove wheel ⇒ page 309 .
Vehicles with vehicle level senders
– Remove bolts -1- on linkage -2- for rear vehicle level sender
on both sides of vehicle.
Note
Installing
Install in reverse sequence, paying attention to the following:
Do not tighten bolts securing trailing arm to wheel bearing housing
until all other suspension components (especially spring and
shock absorber) on that side are fitted. The suspension must be
in extended position before securing. The trailing arm and the
wheel bearing housing will only then move into the required po‐
sition -arrows-.
WARNING
There is a risk that bit XZN 18 with tool number -T10162- with‐
out index “A” can break!
♦ Use ONLY bit XZN 18 - T10162 A- .
Removing
– Remove brake disc ⇒ Brake system; Rep. gr. 46 ; Rear
brakes; Removing and installing brake disc .
– Loosen grease cap from seat by tapping lightly on claw of hub
grease cap puller - VW 637/2- -1-.
– Lever off grease cap using hub grease cap puller - VW 637/2-
-item 1-.
Caution
Caution
– Use a new multi-point socket head bolt -1- and tighten it.
Caution
Note
Note
Tightening torques
♦ ⇒ “7.1.1 Exploded view - wheel bearing unit (torsion beam
axle), front-wheel drive vehicles”, page 246
♦ ⇒ Brake system; Rep. gr. 46 ; Rear brakes; Exploded view -
rear brake
♦ ⇒ “1 Wheels, tyres”, page 309
WARNING
There is a risk that bit XZN 18 with tool number -T10162- with‐
out index “A” can break!
♦ Use ONLY bit XZN 18 - T10162 A- .
Removing
– Remove brake disc ⇒ Brake system; Rep. gr. 46 ; Rear
brakes; Removing and installing brake disc .
– Loosen grease cap -3- from seat by tapping lightly on claw of
hub grease cap puller - VW 637/2- -2- with hammer -1-.
– Lever off grease cap using hub grease cap puller - VW 637/2-
-item 1-.
Caution
Caution
– Use a new multi-point socket head bolt -1- and tighten it.
Caution
Note
Note
Tightening torques
♦ ⇒ “7.1.2 Exploded view - wheel bearing housing, wheel bear‐
ing unit (multi-link suspension), front-wheel drive vehicles”,
page 248
♦ ⇒ Brake system; Rep. gr. 46 ; Rear brakes; Exploded view -
rear brake
Removing
– Before starting work, measure distance from centre of wheel
to lower edge of wheel housing ⇒ page 10 .
– Loosen bolt securing drive shaft at wheel hub ⇒ page 283 .
– Remove brake disc ⇒ Brake system; Rep. gr. 46 ; Rear
brakes; Removing and installing brake disc .
– Remove coil spring ⇒ page 240 .
– Remove drive shaft ⇒ page 284 .
– Remove bolts -arrows-.
– Pull wheel bearing unit out of wheel bearing housing.
Caution
• Do not touch the inside of the wheel bearing when you pick it
up.
• Always take hold of the outside of the wheel bearing.
The same procedure applies to the wheel bearing without wheel
hub.
Installing
Install in reverse sequence, paying attention to the following:
• The bolted connections on the wheel bearing housing may
only be tightened when the original distance between the
wheel hub centre and the lower edge of the wheel housing (as
measured before assembly) has been obtained ⇒ page 10 .
– Overview table: when does wheel alignment have to be
checked? ⇒ page 311
Tightening torques
♦ ⇒ “7.1.3 Exploded view - wheel bearing housing, wheel bear‐
ing unit (multi-link suspension), four-wheel drive vehicles”,
page 249
♦ ⇒ Brake system; Rep. gr. 46 ; Rear brakes; Exploded view -
rear brake
♦ ⇒ “8.3 Loosening and tightening bolt securing drive shaft”,
page 283
♦ Carrier - 3390-
Removing
– Before starting work, measure distance from centre of wheel
to lower edge of wheel housing ⇒ page 10 .
– Remove wheel ⇒ page 309 .
– Remove coil spring ⇒ page 240 .
Vehicles with vehicle level senders:
– Remove bolts -1- on linkage -2- for rear vehicle level sender
on both sides of vehicle.
– Unscrew nut -1- and pull out bolt -2- securing shock absorber.
– Unscrew nut -3- and pull out bolt -4- securing wheel bearing
housing.
Note
♦ Support - T10149-
Removing
– Remove wheel ⇒ page 309 .
– Remove coil spring ⇒ page 240 .
– Remove retainers -arrows- by pushing out inner pins of rivets.
– Move electrical wiring harness -3- clear.
– Remove bolts -1 and 2- from trailing arm.
– Remove underbody trim on relevant side ⇒ General body re‐
pairs, exterior; Rep. gr. 66 ; Underbody trim; Exploded view -
underbody trim .
Procedure
– Remove trailing arm with mounting bracket ⇒ page 273 .
– Clamp trailing arm -1- in vice using protective jaw covers.
– Unscrew bolt -2- and detach mounting bracket -3- from trailing
arm.
Note
8 Drive shaft
⇒ “8.1 Overview - drive shaft”, page 279
⇒ “8.2 Exploded view - drive shaft”, page 280
⇒ “8.3 Loosening and tightening bolt securing drive shaft”,
page 283
⇒ “8.4 Removing and installing drive shaft”, page 284
⇒ “8.5 Dismantling and assembling drive shaft”, page 286
⇒ “8.6 Checking outer constant velocity joint”, page 296
⇒ “8.7 Checking inner constant velocity joint”, page 298
I-
⇒ “8.2.1 Exploded view - drive
shaft with 90 mm diameter out‐
er constant velocity joint”, page
280
II -
⇒ “8.2.2 Exploded view - drive
shaft with 82 mm diameter out‐
er constant velocity joint”, page
282
Note
or ⇒ page 292
5 - Boot for outer constant velocity joint
❑ Without vent hole
❑ Check for splits and chafing
6 - Hose clip
❑ Renew
❑ Tightening ⇒ page 292 or ⇒ page 292
7 - Dished spring
❑ Installation position ⇒ page 289
8 - Spacer ring (plastic)
❑ Installation position ⇒ page 289
9 - Circlip
❑ Renew
❑ Insert in groove on shaft
10 - Boot for inner constant velocity joint
❑ Without vent hole
❑ Check for splits and chafing
❑ Drive off constant velocity joint with a drift
❑ Before fitting on constant velocity joint, coat sealing surface with D 454 300 A2
11 - Hose clip
❑ Renew
❑ Tightening ⇒ page 292 or ⇒ page 292
12 - Lock plate
13 - Multi-point socket head bolt
❑ Always renew if removed
❑ Initial tightening torque: 10 Nm in diagonal sequence
❑ Tightening torque, M8: 20 Nm in diagonal sequence
❑ Final setting, M8: turn 180° further in diagonal sequence
14 - Circlip
❑ Renew
❑ Removing and installing with -VW 161 A- ⇒ page 289
15 - Gasket
❑ Adhesive surface on constant velocity joint must be free of oil and grease
16 - Inner constant velocity joint
❑ Renew only as complete unit
❑ Checking ⇒ page 298
❑ Pressing off ⇒ page 289
❑ Greasing ⇒ page 280
❑ Pressing on ⇒ page 290
❑ Grease splines on drive shaft lightly with grease used in joint when fitting joint onto drive shaft
17 - Dished spring
❑ Installation position ⇒ page 290
Note
The wheels must not be in contact with the ground when initially
tightening the drive shaft bolt; otherwise the wheel bearing can
be damaged.
Note
8.5.1 Servicing drive shaft with 90 mm dia. outer constant velocity joint
Note
– Fit circlip.
Note
8.5.2 Servicing drive shaft with 82 mm dia. outer constant velocity joint
Assembling
Installation position of dished spring at inner and outer joint
1- Dished spring
– Press on joint as far as stop.
– Engage circlip.
Note
Note
Removing
– Before dismantling, mark position of ball hub in relation to ball
cage and joint body with an electric scriber or oil stone
-arrow-.
– Swivel ball hub and ball cage and take out balls one after the
other.
– Turn cage until two cage openings -arrow- are level with joint
body.
– Lift out cage together with hub.
– Swivel one segment of the hub into one of the cage openings.
– Pivot hub out of cage.
Note
Installing
Install in reverse sequence, paying attention to the following:
– Pack required amount of grease into joint body (check table)
⇒ page 280 .
– Fit cage with hub into joint body.
Note
– Press in balls one after the other from opposite sides, taking
care to re-establish original position of hub relative to cage and
joint body.
– Fit new circlip in shaft.
– Distribute remaining grease in boot.
Note
Ball hub and joint body are paired. Mark position in relation to
each other with a waterproof felt-tip pen prior to removal.
Removing
– Swivel ball hub and ball cage.
– Push out joint body in direction of -arrow-.
– Push balls out of cage.
– Align ball hub with cage as shown -arrows- and pivot hub out
of cage.
– Check joint, ball hub, ball cage and balls for pitting and signs
of seizure.
Note
Installing
Install in reverse sequence, paying attention to the following:
– Insert hub into cage via the two chamfers. No specific instal‐
lation position is required. Push balls into cage.
– Insert hub with cage and balls at a right angle to the joint body.
Note
♦ When inserting, ensure that the wide spacing -a- on the joint
body is aligned with the narrow spacing -b- on the hub after
swivelling in.
♦ Chamfer on internal diameter of ball hub (splines) must face
large diameter of joint body.
♦ When reinstalling, you should also use felt-tip pen mark made
on removal as a guide.
– Swivel the hub into the joint body; at the same time the hub
must be swivelled out of the cage -arrows- far enough to allow
the balls to fit into the ball races.
43 – Self-levelling suspension
1 Electronic damping control
⇒ “1.1 Exploded view - electronic damping control”, page 300
⇒ “1.2 Removing and installing electronically controlled damping
control unit J250 ”, page 301
1 - Electronically controlled
damping control unit - J250-
❑ Removing and installing
⇒ page 301
❑ Fitting location: elec‐
tronically controlled
damping control unit -
J250- is located under
front right seat
❑ Function “Replace con‐
trol unit” must be per‐
formed with ⇒ Vehicle
diagnostic tester if elec‐
tronically controlled
damping control unit -
J250- is renewed.
❑ If the reference position
has been re-adapted,
the front camera for driv‐
er assist systems must
be recalibrated on vehi‐
cles with lane departure
warning function
⇒ page 343 .
2 - Shock absorber with rear
right shock absorber damper
adjustment valve - N339-
❑ Removing and installing
shock absorber
⇒ page 233
❑ Servicing shock absorb‐
er ⇒ page 236
3 - Shock absorber with rear
left shock absorber damper
adjustment valve - N338-
❑ Removing and installing
shock absorber
⇒ page 233
❑ Servicing shock absorber ⇒ page 236
4 - Rear left/right vehicle level senders - G76/G77-
❑ Removing and installing ⇒ page 306
5 - Shock absorber with front left shock absorber damper adjustment valve - N336-
❑ Removing and installing suspension strut ⇒ page 68
❑ Servicing suspension strut ⇒ page 72
6 - Front left vehicle level sender - G78-
❑ Removing and installing ⇒ page 305
7 - Shock absorber with front right shock absorber damper adjustment valve - N337-
❑ Removing and installing suspension strut ⇒ page 68
❑ Servicing suspension strut ⇒ page 72
Note
The front left/right vehicle level sender - G78/G289- is only available as a replacement part complete with
coupling rod and upper and lower retaining plates.
1 - Subframe
2 - Front left vehicle level send‐
er - G78- and front right vehicle
level sender - G289-
❑ Complete with mounting
parts
❑ Lever must face out‐
wards
❑ Removing and installing
⇒ page 305
❑ On vehicles with elec‐
tronic damping control
(Audi magnetic ride),
perform function “Re-
adapt reference posi‐
tion” using ⇒ Vehicle
diagnostic tester if you
have removed and in‐
stalled front left vehicle
level sender - G78- or
front right vehicle level
sender - G289- .
❑ If the reference position
has been re-adapted,
the front camera for driv‐
er assist systems must
be recalibrated on vehi‐
cles with lane departure
warning function
⇒ page 343 .
❑ Perform basic setting of
headlights ⇒ Electrical
system; Rep. gr. 94 ;
Headlights; Adjusting
headlights
3 - Electrical connector
4 - Bolt
❑ 8 Nm
5 - Wishbone
6 - Nut
❑ Always renew if removed
❑ 8 Nm
2.2.1 Exploded view - rear left vehicle level sender - G76- / rear right vehicle level
sender -G77- , vehicles with multi-link suspension
Note
The vehicle level sender is only available as a replacement part complete with coupling rod and upper and
lower retaining plates.
2.2.2 Exploded view - rear left vehicle level sender - G76- , vehicles with torsion
beam axle
1 - Electrical connector
2 - Bolt
❑ 5 Nm
3 - Rear left vehicle level send‐
er - G76-
❑ Removing and installing
⇒ page 306
❑ Perform basic setting of
headlights ⇒ Electrical
system; Rep. gr. 94 ;
Headlights; Adjusting
headlights
4 - Bolt
❑ 8 Nm
5 - Axle beam
6 - Mounting bracket
Removing
– Unplug connector -2-.
– Unscrew nut -4- and bolt -1-.
– Take out vehicle level sender -3-.
Installing
Installation is carried out in reverse sequence. Note the following:
Note
Removing
– Unplug connector -1-.
– Remove bolts -4 and 2-.
– Take out rear vehicle level sender -3-.
Installing
Installation is carried out in reverse sequence. Note the following:
The lever on the vehicle level sender must face towards rear of
vehicle.
• Perform basic setting of headlights ⇒ Electrical system; Rep.
gr. 94 ; Headlights; Adjusting headlights .
Tightening torques
♦ ⇒ “2.2.2 Exploded view - rear left vehicle level sender G76 ,
vehicles with torsion beam axle”, page 305
Removing
– Unplug connector -2-.
– Remove bolts -arrows-.
– Take out rear vehicle level sender -1-.
Installing
Installation is carried out in reverse sequence. Note the following:
The lever on the vehicle level sender must face outwards.
• On vehicles with electronic damping control (Audi magnetic
ride), perform function “Re-adapt reference (default) position”
using ⇒ Vehicle diagnostic tester.
• If the reference position has been re-adapted, the front camera
for driver assist systems must be recalibrated on vehicles with
lane departure warning function ⇒ page 343 .
• Perform basic setting of headlights ⇒ Electrical system; Rep.
gr. 94 ; Headlights; Adjusting headlights .
Tightening torques
♦ ⇒ “2.2.1 Exploded view - rear left vehicle level sender G76 /
rear right vehicle level sender G77 , vehicles with multi-link
suspension”, page 304
2 Wheel alignment
⇒ “2.1 Notes on wheel alignment”, page 310
⇒ “2.2 When does wheel alignment have to be checked?”,
page 311
⇒ “2.3 Test requirements”, page 312
⇒ “2.4 Preparations required before calibration of driver assist
systems”, page 313
⇒ “2.5 Explanatory notes on production control numbers (PR
numbers)”, page 313
⇒ “2.6 Preparations for measurement”, page 314
⇒ “2.7 Wheel runout compensation”, page 315
⇒ “2.8 Checking full steering lock”, page 315
⇒ “2.9 Wheel alignment procedure”, page 316
⇒ “2.10 Wheel alignment specifications”, page 317
⇒ “2.11 Adjusting camber at front wheels”, page 321
⇒ “2.12 Adjusting camber at rear wheels”, page 322
⇒ “2.13 Adjusting toe setting at rear wheels”, page 324
⇒ “2.14 Adjusting toe setting at front wheels”, page 325
Note
WARNING
WARNING
WARNING
.
2) "Unladen condition" means: the height of the vehicle ready for the road (with
full tank, spare wheel, vehicle tools and vehicle jack).
• Drive vehicle onto wheel alignment unit and ensure that sus‐
pension is not under stress, if necessary by moving vehicle
backwards and forwards several times.
• Before starting the initial measurement and before making any
adjustments, make sure that the steering is returned correctly
to the centre position by turning the steering wheel uniformly
in both directions using the steering wheel balance - VAS
6458- .
The following steps are required if one or more driver assist sys‐
tems on the vehicle are to be calibrated via the “Quick-start”
procedure (i.e. without first checking and adjusting the wheel
alignment):
• Before driving the vehicle onto the alignment platform, make
sure there is sufficient space between the vehicle and the cal‐
ibration unit. The distance between the calibration unit and the
vehicle must be 120 cm ± 2.5 cm.
• If the available space is not adequate, drive the vehicle back‐
wards onto the alignment platform as required.
• Before commencing calibration, interrogate event memory
and rectify any faults.
• Vehicle accurately aligned, suspension bounced and rocked
several times.
• Ensure that the sliding plates and turntables are not touching
the end stop when checking the alignment.
• Connect battery charger ⇒ Electrical system; Rep. gr. 27 ;
Battery; Disconnecting and connecting battery .
• Bring front wheels into straight-ahead position.
• Connect up ⇒ Vehicle diagnostic tester to vehicle and run di‐
agnostic cable out through open window.
• Exterior lighting switched off.
• All vehicle doors closed.
• Press button to select required calibration on wheel alignment
computer.
Note
Note
-Rear axle-
Total toe Multi-link suspen‐ 25′ ± 10′
sion
Torsion beam axle 20′ ± 12′
5)
Maximum permissible difference between left and right Multi-link suspen‐ max. 30′
sion
Torsion beam axle max. 30′
Maximum permissible deviation from direction of travel Multi-link suspen‐ max. 12′
sion
Torsion beam axle max. 20′
-Rear axle-
Total toe Multi-link suspen‐ 25′ ± 10′
sion
Torsion beam axle 24′ ± 12′
5)
Maximum permissible difference between left and right Multi-link suspen‐ max. 30′
sion
Torsion beam axle max. 30′
Maximum permissible deviation from direction of travel Multi-link suspen‐ max. 12′
sion
Torsion beam axle max. 20′
-Rear axle-
Total toe Multi-link suspen‐ 25′ ± 10′
sion
Torsion beam axle 16′ ± 12′
5)
Maximum permissible difference between left and right Multi-link suspen‐ max. 30′
sion
Torsion beam axle max. 30′
Maximum permissible deviation from direction of travel Multi-link suspen‐ max. 12′
sion
Torsion beam axle max. 20′
-Rear axle-
Total toe Multi-link suspen‐ 25′ ± 10′
sion
Toe setting at each wheel Multi-link suspen‐ 12.5′ ± 5′
sion
Camber Multi-link suspen‐ -1° 20′ ± 30′
Maximum permissible difference between left and right sion max. 30′
Maximum permissible deviation from direction of travel Multi-link suspen‐ max. 12′
sion
-Rear axle-
Total toe Multi-link suspen‐ 25′ ± 10′
sion
Torsion beam axle 27′ ± 12′
5)
Maximum permissible difference between left and right Multi-link suspen‐ max. 30′
sion
Torsion beam axle max. 30′
Maximum permissible deviation from direction of travel Multi-link suspen‐ max. 12′
sion
Torsion beam axle max. 20′
S3 sports running gear and S3 sports running gear with Audi magnetic ride 2UC and G05/G07/G26/G27/
G46/G47/G97
-Front axle-
Total toe 10′ ± 10′
Toe setting at each wheel 5′ ± 5′
Camber (in straight-ahead position) 3) -52′ ± 30′
Maximum permissible difference between left and right max. 30′
Toe-out on turns with 20° steering angle 4) 1° 40′ ± 20′
Caster 7° 51′ ± 30′
Maximum permissible difference between left and right max. 30′
Maximum steering angle at inner wheel 39°57′
-Rear axle-
Total toe 25′ ± 10′
Toe setting at each wheel 12.5′ ± 5′
Camber -1° 20′ ± 30′
Maximum permissible difference between left and right max. 30′
Maximum permissible deviation from direction of travel max. 12′
-Rear axle-
Total toe 10′ ± 10′
Toe setting at each wheel 5′ ± 5′
Camber -1° 20′ ± 30′
Maximum permissible difference between left and right max. 30′
Maximum permissible deviation from direction of travel max. 12′
– Unscrew bolts -1, 6, 7 and 8- one after the other and loosely
screw in new ones.
– Move subframe -9- sideways until camber is the same on both
sides ⇒ page 317 .
– Tighten subframe bolts -1, 6, 7 and 8-.
Note
Note
Procedure
– Counterhold track rod ball joint -1- with a suitable tool when
loosening and tightening lock nut -2-.
– Loosen lock nut -2-.
– Adjust toe setting at left and right wheels via hexagon flats
-arrow-.
Note
Note
Note
Note
♦ Version II
– Release retaining tabs -1- -arrow-.
– Detach trim -2- from adaptive cruise control unit - J428-
-item 3-.
– Connect up vehicle diagnostic tester with appropriate diagno‐
sis lead.
♦ Version I
♦ Version II
Note
The remaining steps are now performed via the vehicle diagnostic
tester :
♦ Version I
– For adjustment in “Guided Fault Finding” routine, use screws
-1- and -2-.
• Use adjusting tool - VAS 6190/2- -item 3- to adjust sensor for
adaptive cruise control.
♦ Version II
– For adjustment in “Guided Fault Finding” routine, use screws
-1- and -2-.
• Use adjusting tool - VAS 6190/2- to adjust sensor for adaptive
cruise control.
WARNING
Note
Note
♦ Version II
– Release retaining tabs -1- -arrow-.
– Detach trim -2- from adaptive cruise control unit - J428-
-item 3-.
– Connect up vehicle diagnostic tester with appropriate diagno‐
sis lead.
– Remove any dirt from sensor lens and inside of radar cover.
– Position ACC setting device - VAS 6430- so that distance
-A- between sensor lens and surface of reflector is
120 cm ± 2,5 cm.
– In area -A-, align number -2- on rotary knob with mark on mirror
(number 2 on rotary knob must face vehicle).
– Use adjusting screws -1-, -2- and -3- to bring spirit levels -A-
and -B- on -VAS 6430- into horizontal position.
– Using crank handle -arrow- on -VAS 6430- , set mirror -4- so
that laser beam coincides with centre of sensor lens in vertical
plane.
– Set identical individual front axle toe values with fine adjust‐
ment screw -5-.
– Difference between individual toe values must be less than 6'
or equal.
♦ Version I
♦ Version II
Note
The remaining steps are now performed via the vehicle diagnostic
tester :
♦ Version I
– For adjustment in “Guided Fault Finding” routine, use screws
-1- and -2-.
• Use adjusting tool - VAS 6190/2- -item 3- to adjust sensor for
adaptive cruise control.
♦ Version II
– For adjustment in “Guided Fault Finding” routine, use screws
-1- and -2-.
• Use adjusting tool - VAS 6190/2- to adjust sensor for adaptive
cruise control.
WARNING
♦ The adaptive cruise control unit - J428- has been removed and
installed or renewed.
♦ The front lock carrier has been detached or moved.
♦ The front impact bar has been detached or moved.
♦ The front impact bar or lock carrier has been damaged.
♦ The misalignment angle is greater than –0.8° to +0.8°.
Full wheel alignment
This procedure (adjustment and wheel alignment) should be
selected in the following cases:
♦ The rear axle toe setting has been adjusted.
♦ The running gear of the vehicle has been modified in any way
– e.g. conversion from standard running gear to sports running
gear.
Note
Note
Note
♦ Check that the front camera for driver assist systems - R242-
is seated correctly in the bracket.
♦ Check that the camera vision is unobstructed (visual inspec‐
tion).
♦ Before commencing calibration, interrogate event memory
and rectify any faults.
Note
Note
Note
For the next step the wheel alignment platform must be set at the
lowest available position.
Note
Note
– Secure by tightening bolts -2- and -3- -VAS 6430- lightly. (This
will prevent the -VAS 6430- from rolling away).
Note
The remaining steps are now performed via the vehicle diagnostic
tester :
From this point you are guided through the calibration procedure
by the ⇒ Vehicle diagnostic tester.
Then follow the instructions on the screen to perform the calibra‐
tion.
Note
– Enter dimension -a- for the height of the body, as noted pre‐
viously.
48 – Steering
1 Steering wheel
⇒ “1.1 Exploded view - steering wheel”, page 349
⇒ “1.2 Removing and installing steering wheel”, page 350
1 - Locking bar
2 - Steering column electronics
control unit - J527-
❑ With airbag coil connec‐
tor and return ring with
slip ring - F138-
❑ Removing and installing
⇒ Electrical system;
Rep. gr. 94 ; Steering
column switch module;
Exploded view - steer‐
ing column switch mod‐
ule
3 - Airbag steering wheel (4-
spoke steering wheel)
❑ Different versions avail‐
able ⇒ Electronic parts
catalogue “ETKA”
❑ Removing and installing
⇒ page 350
4 - Wiring harness
❑ For airbag igniter on
driver side - N95-
5 - Airbag unit
❑ With driver side airbag
igniter - N95- and driver
side airbag igniter 2 -
N250-
WARNING
Observe safety precau‐
tions for working on air‐
bags ⇒ General body
repairs, interior; Rep. gr.
00 ; Safety precautions;
Safety precautions when
working with pyrotechnic
components .
❑ Removing and installing ⇒ General body repairs, interior; Rep. gr. 69 ; Airbag (driver side); Exploded
view - airbag (driver side)
6 - Bolt
❑ Always renew if removed
❑ 30 Nm +90°
7 - Airbag steering wheel (3-spoke steering wheel)
❑ Different versions available ⇒ Electronic parts catalogue “ETKA”
WARNING
Observe safety precau‐
tions for working on air‐
bags ⇒ General body
repairs, interior; Rep. gr.
00 ; Safety precautions;
Safety precautions when
working with pyrotechnic
components .
❑ Removing and installing ⇒ General body repairs, interior; Rep. gr. 69 ; Airbag (driver side); Exploded
view - airbag (driver side)
10 - Bolt
❑ Always renew if removed
❑ 30 Nm +90°
Removing
– Move steering wheel upwards and rearwards as far as possi‐
ble, using the full range of the steering column adjuster.
– Remove airbag unit ⇒ General body repairs, interior; Rep. gr.
69 ; Airbag (driver side); Exploded view - airbag (driver side) .
Note
2 Steering column
⇒ “2.1 Exploded view - steering column”, page 352
⇒ “2.2 Handling and transporting steering column”, page 353
⇒ “2.3 Checking steering column for damage”, page 354
⇒ “2.4 Removing and installing steering column”, page 355
⇒ “2.5 Removing and installing control unit for electronic steering
column lock J764 ”, page 359
Note
7 - Bolt
❑ Always renew if removed
❑ 20 Nm
8 - Bolt
❑ Always renew if removed
❑ Clean threaded hole (e.g. with a thread tap) before fitting new bolt
❑ 20 Nm +90°
WARNING
Note
Checking function
– Check that steering column turns easily and smoothly.
– Check that steering column can be adjusted for height and
reach.
Removing
The replacement steering column is only supplied as a complete
unit. Repair is not possible.
The steering lock housing can be transferred from the old unit ⇒
Electrical system; Rep. gr. 94 ; Steering column switch module;
Exploded view - steering column switch module .
The control unit for electronic steering column lock - J764- can be
transferred from the old unit ⇒ page 359 .
– Turn wheels to straight ahead position.
– Pull down lever beneath steering column.
– Push steering column down as far as possible and pull out.
– Remove steering wheel ⇒ page 350 .
WARNING
Caution
– Unscrew bolt -1- for universal joint -2- and pull universal joint
off steering rack -arrow-.
Caution
Installing
Install in reverse sequence, paying attention to the following:
– Hook steering column -2- into installation aids on mounting
bracket -1- at top and bottom.
– Align steering column with mounting bracket and fit in position.
• Before fitting new bolt -1-, clean threaded hole with a thread
tap or similar.
WARNING
With bolt -1- screwed into place, try to pull off universal joint to
check that it is correctly seated. Then tighten bolt.
Caution
– Release connector -1- and detach from control unit for elec‐
tronic steering column lock - J764- .
– Move electrical wiring clear at retaining bracket -arrow-.
Installing
Installation is carried out in reverse sequence. Note the following:
– Secure control unit for electronic steering column lock - J764-
with new shear bolts -arrows-.
– Tighten shear bolts -arrows- evenly until bolt heads shear off.
– If the control unit for electronic steering column lock - J764-
has been renewed it must be adapted; select “Replace” func‐
tion in “Guided Functions” on ⇒ vehicle diagnostic tester .
3 Steering rack
⇒ “3.1 Exploded view - steering rack”, page 361
⇒ “3.2 Servicing steering rack”, page 363
⇒ “3.3 Handling and transporting steering rack”, page 364
⇒ “3.4 Removing and installing steering rack”, page 364
⇒ “3.5 Removing and installing boot”, page 366
⇒ “3.6 Removing and installing track rod”, page 369
⇒ “3.7 Removing and installing track rod ball joint”, page 371
1 - Bolt
❑ Always renew if re‐
moved
❑ 70 Nm +90°
2 - Subframe
3 - Power steering rack
❑ Different versions avail‐
able ⇒ Electronic parts
catalogue “ETKA”
❑ Incorporates power
steering control unit -
J500- and steering an‐
gle sender - G85-
❑ Power steering control
unit - J500- and steering
angle sender - G85- can
be checked via Guided
Fault Finding ⇒ Vehi‐
cle diagnostic tester
❑ Power steering control
unit - J500- and steering
angle sender - G85-
cannot be renewed sep‐
arately. If defective, re‐
new steering rack
❑ Removing and installing
steering rack
⇒ page 364
4 - Nut
❑ Renew after removing
❑ When tightening, coun‐
terhold socket of track
rod ball joint
❑ 20 Nm +90°
5 - Wheel bearing housing (right-side)
6 - Heat shield
❑ Different versions possible depending on engine version. Refer to ⇒ Electronic parts catalogue “ETKA”
7 - Bolt
❑ Either 3x or 4x are fitted depending on engine version. Refer to ⇒ Electronic parts catalogue “ETKA”
❑ To secure electrical wiring.
❑ 6 Nm
8 - Threaded bush
❑ 2x
9 - Electrical wire
10 - Expanding clip
11 - Steering shaft with universal joint
12 - Bolt
❑ Tightening torque ⇒ Item 8 (page 353)
❑ Always renew if removed
❑ Clean threaded hole (e.g. with a thread tap) before fitting new bolt
13 - Seal
❑ Renew if damaged
10 - Spring-type clip
11 - Boot
❑ Removing and installing ⇒ page 366
❑ Check for damage
❑ Must not be twisted when toe setting has been adjusted
12 - Hose clip
❑ Always renew if removed
❑ Secure new hose clip using locking pliers for Phaeton steering rack - VAS 6199-
13 - Track rod
❑ If defective, also renew track rod ball joint
❑ Removing and installing ⇒ page 369
❑ 100 Nm
WARNING
WARNING
Removing
– Remove subframe with steering rack ⇒ page 43 .
– Remove bolts -1-.
– Detach steering rack from subframe.
Installing
Installation is carried out in reverse sequence. Note the following:
Note
Note
Removing
Caution
Caution
– Screw in track rod until the mark applied upon removal is just
visible.
– Tighten lock nut -2- to specified torque (counterhold track rod
ball joint -1- for this purpose).
– Lightly grease sealing point between rubber boot and track rod
with grease from repair kit.
– Push rubber boot -2- onto track rod -1- as shown in illustration.
– Secure spring-type hose clip onto rubber boot using hose clip
pliers - V.A.G 1275- .
– Lightly grease sealing point between rubber boot and steering
rack housing with grease from repair kit.
Removing
– Remove rubber boot ⇒ page 366 .
– Turn steering as follows:
- Turn steering to full right lock for left track rod.
- Turn steering to full left lock for right track rod.
– Unscrew track rod.
1- Open-end spanner attachment - V.A.G 1923-
2- Torque wrench - V.A.G 1332-
Caution
– Screw track rod into track rod ball joint until dimension -a- is
obtained.
Dimension -a- = 373 ± 1 mm
– Slacken off nut on track rod ball joint (but do not remove yet).
• Leave nut screwed on a few turns to protect threads on joint
pin.
– Press track rod ball joint off wheel bearing housing using ball
joint puller - 3287 A- -1- and then remove nut.
– Unscrew track rod ball joint -1- from track rod (counterhold at
hexagon flats on track rod -arrow-).