Volkswagen 2004 Golf User Manual

P
r
o
t
e
c
t
e
d
b
y
c
o
p
y
r
i
g
h
t
.
C
o
p
y
i
n
g
f
o
r
p
r
i
v
a
t
e
o
r
c
o
m
m
e
r
c
i
a
l
p
u
r
p
o
s
e
s
,
i
n
p
a
r
t
o
r
i
n
w
h
o
l
e
,
i
s
n
o
t
p
e
r
m
i
t
t
e
d
u
n
l
e
s
s
a
u
t
h
o
r
i
s
e
d
b
y
V
o
l
k
s
w
a
g
e
n
A
G
.
V
o
l
k
s
w
a
g
e
n
A
G
d
o
e
s
n
o
t
g
u
a
r
a
n
t
e
e
o
r
a
c
c
e
p
t
a
n
y
l
i
a
b
i
l
i
t
y
w
i
t
h
r
e
s
p
e
c
t
t
o
t
h
e
c
o
r
r
e
c
t
n
e
s
s
o
f
i
n
f
o
r
m
a
t
i
o
n
i
n
t
h
i
s
d
o
c
u
m
e
n
t
.
C
o
p
y
r
i
g
h
t
b
y
V
o
l
k
s
w
a
g
e
n
A
G
.
Workshop Manual
Golf 2004 ➤
Golf Plus 2005 ➤
Running gear, axles, steering
Edition 08.2009
Service
Service Department. Technical Information

Volkswagen 2004 Golf Specifications

General

Brand	Volkswagen
Model	2004 Golf
Category	Automobile
Language	English

Summary

00 - Technical Data

1 Checklist for evaluating running gear of accident vehicles

Checklist for assessing vehicle running gear after accidents.

2 General information

General information on wheels, tyres, and snow chains.

40 - Front Suspension

1 Appraisal of accident vehicles

Checklist for evaluating running gear of accident vehicles.

2 Repairing front suspension

Procedures for repairing front suspension components.

3 Subframe, anti-roll bar, suspension link

Assembly overview and component details for subframe, anti-roll bar, and suspension links.

4 Assembly overview - wheel bearing

Exploded view and component identification for wheel bearing.

5 Assembly overview: suspension strut

Exploded view and component identification for suspension strut.

6 Removing and installing drive shafts

Steps for removing and installing drive shafts.

8 Assembly overview - drive shaft with VL90 or VL100 constant velocity joint

Exploded view of drive shaft with VL90/VL100 CV joint.

42 - Rear Suspension

1 Appraisal of accident vehicles

Checklist for evaluating running gear of accident vehicles.

2 Repairing rear suspension (front-wheel drive)

Procedures for repairing rear suspension components for FWD.

3 Assembly overview: subframe, transverse link, track rod (front-wheel drive)

Exploded view and component details for subframe, links, and track rod.

4 Assembly overview: wheel bearing housing, trailing arm (front-wheel drive)

Exploded view and component details for wheel bearing housing and trailing arm.

5 Assembly overview: shock absorber, coil spring (front-wheel drive)

Exploded view and component details for shock absorber and coil spring.

8 Repairing rear suspension (four-wheel drive)

Procedures for repairing rear suspension components for 4WD.

9 Assembly overview - subframe made from aluminium, final drive (four-wheel drive)

Exploded view of aluminium subframe and final drive for 4WD.

10 Assembly overview - subframe made from steel, final drive (four-wheel drive)

Exploded view of steel subframe and final drive for 4WD.

11 Assembly overview - control arm, track rod (four-wheel drive, subframe made from aluminium and wheel bearing housing made from cast steel)

Exploded view of control arm, track rod, subframe, and housing.

12 Assembly overview - control arm, track rod (four-wheel drive, subframe made from steel and wheel bearing housing made from aluminium)

Exploded view of control arm, track rod, subframe, and housing.

13 Assembly overview - wheel bearing housing, trailing link (four-wheel drive, subframe made from aluminium and wheel bearing housing made from cast steel)

Exploded view of housing, trailing link, subframe, and housing.

14 Assembly overview - wheel bearing housing, trailing link (four-wheel drive, subframe made from steel and wheel bearing housing made from aluminium)

Exploded view of housing, trailing link, subframe, and housing.

15 Assembly overview - shock absorber, coil spring (four-wheel drive, subframe made from aluminium and wheel bearing housing made from cast steel)

Exploded view of shock absorber, spring, subframe, and housing.

16 Assembly overview - shock absorber, coil spring (four-wheel drive, subframe made from steel and wheel bearing housing made from aluminium)

Exploded view of shock absorber, spring, subframe, and housing.

17 Assembly overview - anti-roll bar (four-wheel drive, subframe made from aluminium and wheel bearing housing made from cast steel)

Exploded view of anti-roll bar, subframe, and housing.

18 Assembly overview - anti-roll bar (four-wheel drive, subframe made from steel and wheel bearing housing made from aluminium)

Exploded view of anti-roll bar, subframe, and housing.

19 Assembly overview - drive shaft

Exploded view and component identification for drive shaft.

44 - Wheels, Tyres, Vehicle Geometry

1 Appraisal of accident vehicles

Checklist for evaluating running gear of accident vehicles.

2 Torque settings for wheel bolts

Specifies torque values for wheel bolts.

3 Fitting wheel and tyre

Procedures for fitting wheels and tyres.

4 Removing and fitting tyres (wheels with tyre pressure monitoring)

Procedures for removing and fitting tyres with TPM.

5 Removing and fitting tyres with run-flat capability to wheel rims

Procedures for removing/fitting run-flat tyres.

6 Tyre monitor display

Information on the tyre pressure monitoring system display.

7 Tyre pressure monitor (TPM)

System description and functions of the tyre pressure monitor.

8 Wheel alignment

Comprehensive guide to checking and adjusting wheel alignment.

12 Rough running due to wheels/tyres - causes and rectification

Troubleshooting guide for wheel and tyre related rough running.

48 - Steering

1 Appraisal of accident vehicles

Checklist for evaluating steering system after accidents.

2 General repair instructions

Important general notes and safety rules for steering repairs.

3 Steering wheel

Procedures for steering wheel removal and installation.

4 Steering column, Golf

Overview and procedures for the Golf steering column.

5 Steering column, Golf Plus, CrossGolf

Overview and procedures for the Golf Plus/CrossGolf steering column.

6 Electromechanical steering box up to model year 2008

Overview and procedures for electromechanical steering boxes up to MY 2008.

7 Electromechanical steering box after model year 2009

Overview and procedures for electromechanical steering boxes after MY 2009.

8 Distinguishing between steering boxes (1st and 2nd generations), Golf

Guidance on identifying Golf steering boxes (1st vs 2nd gen).

11 Repairing electromechanical steering box (1st generation), Golf

Procedures for repairing 1st gen electromechanical steering box.

12 Repairing electromechanical steering box (2nd and 3rd generations)

Procedures for repairing 2nd/3rd gen electromechanical steering box.