Replacement

Suspension strut, removing and installing

Special tools, testers and auxiliary items required

Engine/transmission jack V.A.G 1383 A:

^ Torque wrench V.A.G 1331
^ Torque wrench V.A.G 1332

Removing
- Remove wheel trim; pull trim cap off light-alloy wheels (using puller in vehicle tool kit).
- Remove wheel.
- Secure brake disc with wheel bolt.
- Before removing left suspension strut, remove headlight range control linkage from track control link by opening retaining clip.
- Unclip ABS wiring from retainer on brake caliper.

Vehicles with HP-2 brake caliper





- Remove hex bolt - 2 - and detach brake line bracket.
- Remove bolts - 1 - for brake caliper and remove brake caliper.
- install brake line bracket. Screw in and tighten hex bolt - 2 -.
- Secure brake caliper to body so the weight of brake caliper does not bend or damage brake line.

Continued for all vehicles
- Detach brake caliper and secure to body so that weight of brake caliper does not bend or damage brake hose or brake line.





- Remove clip - 1 - using pliers.

Note:
^ You do not need to re-insert this clip.

- Remove nut - 2 -, take out hex bolt and pull both links out and upward.
Never widen slots in wheel bearing housing using a chisel or similar.
- Use protective sleeve to prevent rubber boot on steering gear from being damaged.
For ease of illustration, steering gear is shown removed from vehicle.
The protective sleeve - 1 - can be ordered with No. 893 512 137.
- Cut a strip, dimension A (20 to 25 mm), out of protective sleeve - 1 -.
- Carefully deburr cut surfaces.
- Slide protective sleeve over steering gear boot. The open side with cut out strip must face downward.

Note:
^ To avoid damage to the joints of lower links, provide support (e.g. using Engine/transmission jack V.A.G 1383 A) to prevent the suspension from extending too far





- Remove hex bolt - arrow - securing suspension strut/track control link.
- Swing wheel bearing housing to one side.
- Unfasten connection to coolant reservoir
- Remove plenum chamber cover.





- Remove cover - arrow - for bolt.





- Remove hex bolts - 1 - in plenum chamber.
- Remove suspension strut with mounting bracket.
Take care not to damage drive axle boot.

Installing





- Insert suspension strut with mounting bracket into suspension strut dome. Tighten hex bolts - 1 -.

Note:
^ Make sure shims are correctly seated.

- Bonded rubber bushings can only be turned to a limited extent. The bolts of suspension links must only be tightened when the suspension is in the curb weight position.





- Insert fork head of suspension strut onto bottom link and tighten bolt connection - 1 -

Note:
^ Insert the bolt from front to rear





- Install both upper links joint pins in wheel bearing housing and press down as far as possible by clamping using pliers T40067.





- Install and tighten new bolt - 2 - and self-locking nut.
- Insert ABS wiring into retainer on brake caliper.
- Install brake disc, install brake caliper and secure.
- On vehicles with headlight range control, install coupling rod for vehicle level sensor on track control link.
- Install wheel and tighten.