Service

Workshop Manual
Audi A6 2019 ➤
Audi A6 China 2019 ➤
Audi A7 Sportback 2018 ➤
Running gear, front-wheel drive and four-wheel drive
Edition 04.2019

Service Department. Technical Information

 Service
List of Workshop Manual Repair Groups

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.

All rights reserved.

No reproduction without prior agreement from publisher.

Copyright © 2019 Audi AG, Ingolstadt D4B807FAEEB

 Audi A6 2019 ➤ , Audi A6 China 2019 ➤ , Audi A7 Sportback 2018 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 04.2019

Contents

00 - Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1 General notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.1 Running gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.2 Steering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.3 Types of tyre . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.4 General notes on drive shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2 Safety precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
2.1 Safety precautions when working on vehicles with start/stop system . . . . . . . . . . . . . . . . 2
2.2 Safety precautions when working on subframe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
2.3 Safety precautions when using testers and measuring instruments during a road test . . . . 2
3 Repair notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
3.1 General repair instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
3.2 Leaks at shock absorbers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
3.3 Checking shock absorbers when removed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
3.4 Checking shock absorbers on shock tester . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
3.5 Maximum values "a" in mm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
3.6 Rules for cleanliness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
3.7 General notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
3.8 Contact corrosion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
3.9 Gaskets and seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
3.10 Bolts and nuts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
3.11 Use of impact wrenches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
3.12 Electrical components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
3.13 Routing and attaching lines and wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
3.14 Repairing damaged threads in longitudinal member (subframe to body) . . . . . . . . . . . . . . 9
3.15 Lifting suspension to unladen position - vehicles with coil springs . . . . . . . . . . . . . . . . . . . . 9
3.16 Lifting suspension to normal level - vehicles with air suspension . . . . . . . . . . . . . . . . . . . . 12
4 Disposal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
4.1 Releasing gas and draining front gas-filled shock absorbers . . . . . . . . . . . . . . . . . . . . . . . . 15
4.2 Releasing gas and draining rear gas-filled shock absorbers . . . . . . . . . . . . . . . . . . . . . . . . 15
4.3 Discharging suspension strut (air suspension) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
4.4 Discharging accumulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

40 - Front suspension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
1 Front axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
1.1 Overview - front axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
2 Subframe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
2.1 Exploded view - subframe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
2.2 Fixing position of subframe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
2.3 Lowering subframe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
2.4 Removing and installing subframe with steering rack . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
2.5 Lowering subframe cross brace . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
2.6 Removing and installing subframe cross brace . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
2.7 Removing and installing subframe shield . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
3 Anti-roll bar . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
3.1 Exploded view - anti-roll bar . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
3.2 Removing and installing anti-roll bar . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
3.3 Removing and installing coupling rod . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
4 Suspension strut, upper links . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
4.1 Exploded view - suspension strut, upper links . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
4.2 Exploded view - body brace . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
4.3 Removing and installing suspension strut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64

Contents i
 Audi A6 2019 ➤ , Audi A6 China 2019 ➤ , Audi A7 Sportback 2018 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 04.2019

4.4 Servicing suspension strut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66

4.5 Removing and installing upper links . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
4.6 Renewing bush for upper link . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
4.7 Charging suspension strut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
4.8 Removing and installing shock absorber fork . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
4.9 Removing and installing body brace . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
5 Lower suspension links, swivel joint . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
5.1 Exploded view - lower suspension links, swivel joint . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
5.2 Removing and installing track control link . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
5.3 Removing and installing guide link . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
5.4 Renewing bush for track control link . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
5.5 Removing and installing swivel joint . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
5.6 Removing and installing bonded rubber bush for guide link . . . . . . . . . . . . . . . . . . . . . . . . 91
6 Wheel bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
6.1 Exploded view - wheel bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
6.2 Removing and installing wheel bearing housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
6.3 Removing and installing wheel bearing unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
6.4 Servicing wheel bearing unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
7 Drive shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
7.1 Exploded view - drive shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
7.2 Removing and installing drive shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
7.3 Removing and installing heat shield for drive shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
7.4 Loosening and tightening bolt securing drive shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106
7.5 Dismantling and assembling drive shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
7.6 Servicing constant velocity joint . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119
7.7 Checking outer constant velocity joint . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120
7.8 Tightening hose clip on triple roller joint and outer joint . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121

42 - Rear suspension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123

1 Rear axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123
1.1 Overview - rear axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123
2 Subframe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124
2.1 Exploded view - subframe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124
2.2 Fixing position of subframe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125
2.3 Removing and installing subframe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129
2.4 Servicing subframe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132
3 Anti-roll bar . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143
3.1 Exploded view - anti-roll bar . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143
3.2 Removing and installing anti-roll bar . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143
3.3 Removing and installing coupling rod . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145
4 Suspension links, track rod . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 146
4.1 Exploded view - transverse links . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 146
4.2 Removing and installing upper transverse links . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149
4.3 Removing and installing wind deflector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 153
4.4 Removing and installing lower transverse links . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 154
4.5 Removing and installing track rod . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 158
5 Suspension strut/shock absorber, spring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 161
5.1 Exploded view - suspension strut/shock absorber, spring . . . . . . . . . . . . . . . . . . . . . . . . . . 161
5.2 Removing and installing shock absorber . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 165
5.3 Removing and installing spring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 167
6 Wheel bearing, trailing arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 177
6.1 Exploded view - wheel bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 177
6.2 Removing and installing wheel bearing housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 179
6.3 Removing and installing wheel bearing unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 182

ii Contents
 Audi A6 2019 ➤ , Audi A6 China 2019 ➤ , Audi A7 Sportback 2018 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 04.2019

6.4 Servicing wheel bearing unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 186

7 Drive shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 190
7.1 Exploded view - drive shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 190
7.2 Removing and installing drive shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 192
7.3 Loosening and tightening bolt securing drive shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 194
7.4 Dismantling and assembling drive shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 195
7.5 Checking outer constant velocity joint . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
7.6 Checking inner constant velocity joint . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 202

43 - Self-levelling suspension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 204

1 Electronic damping control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 204
1.1 Overview of fitting locations - electronic damping control . . . . . . . . . . . . . . . . . . . . . . . . . . 204
1.2 Basic setting of electronic damper control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 205
1.3 Removing and installing running gear control unit J775 . . . . . . . . . . . . . . . . . . . . . . . . . . 206
2 Vehicle level senders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 208
2.1 Exploded view - front vehicle level senders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 208
2.2 Exploded view - rear vehicle level senders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 209
2.3 Removing and installing front vehicle level senders G78 / G289 . . . . . . . . . . . . . . . . . . . . 209
2.4 Removing and installing rear vehicle level senders G76 / G77 . . . . . . . . . . . . . . . . . . . . . . 210
3 Air suspension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 212
3.1 Overview of fitting locations - electrical components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 212
3.2 Overview of fitting locations - air suspension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 214
3.3 Exploded view - air pipes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 215
3.4 Exploded view - pressure accumulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 217
3.5 Exploded view - air supply unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 218
3.6 Setting normal level and permanently disabling control . . . . . . . . . . . . . . . . . . . . . . . . . . . . 219
3.7 Re-adapting normal level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 219
3.8 Bleeding and charging air spring system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 220
3.9 Checking air suspension for leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 221
3.10 Removing and installing adaptive suspension compressor electronics J1135 . . . . . . . . . . 223
3.11 Servicing air pipe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 224
3.12 Renewing connection piece . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 226
3.13 Removing and installing air supply unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 228
3.14 Removing and installing filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 231
3.15 Removing and installing solenoid valve block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 232
3.16 Removing and installing accumulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 233

44 - Wheels, tyres, vehicle geometry . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 234

1 Wheels, tyres . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 234
2 Wheel alignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 235
2.1 Notes on wheel alignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 235
2.2 Test requirements for wheel alignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 235
2.3 Preparations for measurement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 236
2.4 When does wheel alignment have to be checked? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 238
2.5 Wheel alignment procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 240
2.6 Explanatory notes on production control numbers (PR numbers) . . . . . . . . . . . . . . . . . . . . 241
2.7 Wheel runout compensation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 241
2.8 Checking full steering lock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 242
2.9 Checking unladen position for wheel alignment - vehicles with coil springs . . . . . . . . . . . . 242
2.10 Checking normal level for wheel alignment - vehicles with air suspension . . . . . . . . . . . . 244
2.11 Wheel alignment specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 245
2.12 Adjusting camber at rear wheels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 249
2.13 Adjusting toe setting at rear wheels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 249
2.14 Centralising camber at front wheels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 250
2.15 Adjusting toe setting at front wheels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 252

Contents iii
 Audi A6 2019 ➤ , Audi A6 China 2019 ➤ , Audi A7 Sportback 2018 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 04.2019

2.16 Basic setting for steering angle sender G85 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 253

3 Dynamic steering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 255
3.1 Exploded view - dynamic steering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 255
3.2 Removing and installing active steering control unit J792 . . . . . . . . . . . . . . . . . . . . . . . . . . 256
3.3 Basic setting for dynamic steering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 256
4 Adaptive cruise control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 258
4.1 Adjusting adaptive cruise control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 258
5 Front camera for driver assist systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 259
5.1 Calibrating front camera for driver assist systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 259
6 Night vision system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 260
6.1 Calibrating night vision system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 260

48 - Steering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 261
1 Steering wheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 261
1.1 Exploded view - steering wheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 261
1.2 Removing and installing steering wheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 262
2 Steering column . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 264
2.1 Exploded view - steering column . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 264
2.2 Checking steering column for damage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 267
2.3 Handling and transporting steering column . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 267
2.4 Removing and installing steering column . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 268
2.5 Removing and installing safety lock for active steering (locking solenoid) . . . . . . . . . . . . . . 271
2.6 Removing and installing intermediate steering shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 272
2.7 Removing and installing control unit for electronic steering column lock J764 . . . . . . . . . . 274
2.8 Removing and installing control unit for electrically adjustable steering column J866 . . . . 275
3 Steering rack . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 277
3.1 Exploded view - steering rack . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 277
3.2 Handling and transporting steering rack . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 280
3.3 Removing and installing steering rack . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 281
3.4 Removing and installing boot . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 284
3.5 Removing and installing track rod . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 286
3.6 Removing and installing track rod ball joint . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 288
3.7 Re-adapting end stops of steering rack . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 290
4 Rear wheel steering rack . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 291
4.1 Exploded view - rear wheel steering rack . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 291
4.2 Aligning rear wheel steering rack . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 291
4.3 Bringing rear wheel steering rack into zero position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 293
4.4 Removing and installing rear wheel steering rack . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 293

iv Contents
 Audi A6 2019 ➤ , Audi A6 China 2019 ➤ , Audi A7 Sportback 2018 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 04.2019

00 – Technical data
1 General notes
(ARL006379; Edition 04.2019)
⇒ “1.1 Running gear”, page 1
⇒ “1.2 Steering”, page 1
⇒ “1.3 Types of tyre”, page 1
⇒ “1.4 General notes on drive shaft”, page 1

1.1 Running gear

Front axle Multi-link suspension, anti-roll bar
Coil springs: twin-tube gas-filled shock absorbers, coil springs, or shock absorbers
with variable damper characteristics (option)
Air suspension: air spring struts with variable level settings and damping charac‐
teristics
Rear axle Multi-link suspension with separate spring/shock absorber layout and anti-roll bar
Coil springs: twin-tube gas-filled shock absorbers, coil springs, or shock absorbers
with variable damper characteristics (option)
Air suspension: air spring struts with variable level settings and damping charac‐
teristics

1.2 Steering
Steering rack Electro-mechanically assisted, maintenance-free rack-and-pinion steering

1.3 Types of tyre

For general information on wheel/tyre combinations, winter tyres,
snow chains and recommended tyre makes, refer to ⇒ Wheel/
Tyre Guide .

1.4 General notes on 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 .
Do not let drive shaft hang down under its own weight when per‐
forming repair work, as otherwise excessive bending could dam‐
age inner CV joint.
Wheel bearings must not be subjected to load after loosening bolt
securing drive shaft at wheel hub.
If the wheel bearings are subjected to the full weight of the vehicle
they will be overloaded, resulting in reduced service life. For this
reason please note the following points:
♦ Procedure for slackening bolt securing drive shaft to wheel
hub ⇒ page 106
Do not attempt to move the vehicle without the drive shafts fitted;
this would result in wheel bearing damage. If moving the vehicle
is unavoidable, note the following points:
– Fit an outer joint in place of the drive shaft.
– Tighten outer joint to 200 Nm.

1. General notes 1
 Audi A6 2019 ➤ , Audi A6 China 2019 ➤ , Audi A7 Sportback 2018 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 04.2019

2 Safety precautions
⇒ “2.1 Safety precautions when working on vehicles with start/
stop system”, page 2
⇒ “2.2 Safety precautions when working on subframe”,
page 2
⇒ “2.3 Safety precautions when using testers and measuring in‐
struments during a road test”, page 2

2.1 Safety precautions when working on vehicles with start/stop system

Risk of injury - engine may start unexpectedly
The engine can start unexpectedly if the vehicle's start/stop sys‐
tem is activated. A message in the instrument cluster indicates
whether the start/stop system is activated.
– To deactivate the start/stop system, switch off the ignition.

2.2 Safety precautions when working on subframe

Risk of damage to components
Lowering the vehicle onto its wheels can damage components if
the assembly mountings, steering rack or subframe cross brace
are not properly fitted.
– Never lower vehicle onto its wheels with suspension compo‐
nents unfastened or detached.
– Never support weight of vehicle on subframe or subframe
cross brace with suspension components unfastened or de‐
tached.

2.3 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 on the rear seat with a strap.
Or
– Have another person operate the test equipment from the rear
seat.

2 Rep. gr.00 - Technical data

 Audi A6 2019 ➤ , Audi A6 China 2019 ➤ , Audi A7 Sportback 2018 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 04.2019

3 Repair notes
⇒ “3.1 General repair instructions”, page 3
⇒ “3.2 Leaks at shock absorbers”, page 3
⇒ “3.3 Checking shock absorbers when removed”, page 4
⇒ “3.4 Checking shock absorbers on shock tester”, page 5
⇒ “3.5 Maximum values "a" in mm”, page 6
⇒ “3.6 Rules for cleanliness”, page 6
⇒ “3.7 General notes”, page 7
⇒ “3.8 Contact corrosion”, page 7
⇒ “3.9 Gaskets and seals”, page 8
⇒ “3.10 Bolts and nuts”, page 8
⇒ “3.11 Use of impact wrenches”, page 8
⇒ “3.12 Electrical components”, page 9
⇒ “3.13 Routing and attaching lines and wiring”, page 9
⇒ “3.14 Repairing damaged threads in longitudinal member (sub‐
frame to body)”, page 9
⇒ “3.15 Lifting suspension to unladen position - vehicles with coil
springs”, page 9
⇒ “3.16 Lifting suspension to normal level - vehicles with air sus‐
pension”, page 12

3.1 General repair instructions

To avoid repetition, a number of notes that are generally applica‐
ble to the individual procedures described in this manual are
summarised here. They apply for this individual Workshop Man‐
ual.
• If a component has a defective bonded rubber bush, the bon‐
ded rubber bush must be renewed individually if it is available
as a replacement part.
• Full renewal of a component with bonded rubber bush is only
permissible if, for example, its basic structure or joint is dam‐
aged.

3.2 Leaks at shock absorbers

Equipment version with coil springs
Shock absorbers are often replaced because of externally visible
leakage. Inspections on the test rig and in the vehicle have shown
that in the majority of cases this renewal is not justified.

3. Repair notes 3
 Audi A6 2019 ➤ , Audi A6 China 2019 ➤ , Audi A7 Sportback 2018 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 04.2019

Slight loss of fluid (“sweating”) at the piston rod seal is not a rea‐
son for renewing a shock absorber. A shock absorber with slight
fluid leakage can be accepted as OK under the following condi‐
tions:
Note:
Slight fluid leakage is actually beneficial, as it lubricates the piston
rod seal and thus extends the life of the shock absorber. This
applies to shock absorbers on both the front and rear axles.
♦ Fluid seepage (as shown in the shaded part of the illustration
-arrow-) is visible, but the fluid is dull and possibly dried by
dust.
♦ A thin film of fluid or dirt has formed on one side; no drips.

A shock absorber cannot be accepted as "OK" if the following

occurs:
♦ Drips running down the side -arrow-; large area wet with fluid.
♦ If the shock absorber has a wet film of fluid running down the
side of the tube, it is leaking and must be renewed.

3.3 Checking shock absorbers when re‐

moved
Equipment version with coil springs
Defective shock absorbers can be identified by loud rumbling
noises when driving, caused by wheel hopping, especially on bad
roads. Heavy fluid leakage is an additional visual indication.
Note:
Shock absorbers are maintenance-free; shock absorber fluid can‐
not be topped up.
After removal, a shock absorber can be checked by hand as fol‐
lows:
– Compress shock absorber by hand.
• The piston rod should move smoothly over the entire stroke
with uniform resistance and without jolts.
– Release piston rod.
• If the shock absorber has sufficient gas pressure the piston
rod will return by itself to its original position.

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Running gear, front-wheel drive and four-wheel drive - Edition 04.2019

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.

3.4 Checking shock absorbers on shock

tester
The shock tester allows shock absorbers to be tested without re‐
moving them from the vehicle. The damping effect can be as‐
sessed on the basis of the pointer deflection or the print-out.
Special tools and workshop equipment required
♦ Maha shock absorber tester - VAS 1990S-
♦ Suspension strut test stand - VAS 6636-
♦ Suspension strut test stand - VAS 6640-
Test requirements
• Temperature: +10...+40 ℃.
• Driver in vehicle
• Tyre pressures OK.
• Wheels of vehicle in a central and straight position on the tyre
contact plates
• Front wheels in straight-ahead position
• Electromechanical parking brake not applied, brake pedal not
depressed.
Test results
The condition of the shock absorbers can only be evaluated as
follows:
♦ Satisfactory damping effect
Or
♦ Unsatisfactory damping effect
• It is not possible to obtain intermediate readings specifying the
exact degree of impairment of damping effect.
• A forecast of the remaining service life is not permissible.
• Test results will be falsified if the suspension contacts the
bump stops when the readings are taken.
The following values apply only to tests conducted on the test
equipment listed above. If the maximum values listed below are
exceeded, the effectiveness of the shock absorber has deterio‐
rated significantly and renewal is recommended.

3. Repair notes 5
 Audi A6 2019 ➤ , Audi A6 China 2019 ➤ , Audi A7 Sportback 2018 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 04.2019

Example:
Maximum value = 70
♦ a = higher than 70: unsatisfactory damping effect
♦ a = lower than 70: satisfactory damping effect
Maximum values -a- in mm
⇒ “3.5 Maximum values "a" in mm”, page 6
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 241

3.5 Maximum values "a" in mm

• If the reading is higher than the maximum value “a” listed in
the table, the damping effect is unsatisfactory ⇒ renew the
suspension strut.
• If the reading is lower than the maximum value “a” listed in the
table, the damping effect is satisfactory ⇒ the suspension strut
does not have to be renewed.
• On vehicles with air suspension, the vehicle level setting has
no influence on this test.
Running gear Front axle Rear axle Remarks
1BA 44 49 ♦ Unladen
1BB 44 49 ♦ Tank full
1BE 42 48 ♦ Tyre pressure “Partially
1BL 69 75 laden”
1BQ 53 66 ♦ Measurement in drive
1BR 44 49 select mode “auto”
1BK 66 71 ♦ Measurement with igni‐
tion on or engine run‐
1BY 66 71 ning

3.6 Rules for cleanliness

♦ Thoroughly clean all joints and connections and the surround‐
ing areas before disconnecting.
♦ Place removed parts on a clean surface and cover them up to
keep them clean. Use plastic sheeting or paper for this pur‐
pose. Only use lint-free cloths.
♦ Only install clean components; replacement parts should only
be unpacked immediately prior to installation.
♦ Use only the grease and sealants with the part number stated.
♦ Carefully cover or seal open components if repairs cannot be
carried out immediately.
Air suspension
♦ Make sure that no dirt enters the compressed air system.
♦ Clean the affected area before detaching connection pieces,
air pipes or components of the compressed air system.
♦ Cover or seal off open compressed air lines and connections
of the compressed air system immediately with a plug.

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Running gear, front-wheel drive and four-wheel drive - Edition 04.2019

3.7 General notes

NOTICE
Risk of damage to threads in body due to improper handling.
– Never use an impact wrench to loosen or tighten.
– Fit bolts by hand only; make the first few turns by hand.

♦ All contact surfaces must be cleaned when installing wax-

coated components. The contact surfaces must be free of wax
and grease.
♦ Load-bearing components and other suspension parts must
not be welded or straightened.
♦ Do not perform welding or cutting operations (using power
grinders) near the suspension struts. Cover suspension struts
if necessary.
♦ Any cable ties, brackets or fasteners removed during repair
work must be re-attached at their original standard locations.
♦ 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 .
♦ When working on the vehicle, do not allow the drive shafts to
hang down under their own weight and never let the joints
bend to such an extent that they contact the end stop.
♦ Do not attempt to move the vehicle without the drive shafts
fitted; this would result in wheel bearing damage. If moving the
vehicle is unavoidable, note the following points:
♦ Fit an outer joint in place of the drive shaft.
♦ Tighten outer joint to 200 Nm.
♦ Bonded rubber bushes can only be turned to a limited extent.
The suspension mountings must therefore only be tightened
when the suspension is in the unladen position or at normal
level.
♦ Lift suspension to unladen position ⇒ page 9 or normal level
⇒ page 12 .
♦ Always renew bonded rubber bushes on both sides of vehicle.
♦ If the wheel alignment has to be checked and adjusted at a
later stage, all bolts and nuts which need to be slackened to
make adjustments should initially only be tightened to the
specified torque figure. After wheel alignment has been
checked and adjusted, bolts and nuts must then be fully tight‐
ened by turning them through the specified angle.

CAUTION
Risk of accident if bolts/nuts are not tightened as specified.
– Always tighten bolts/nuts as specified before driving the ve‐
hicle on public roads.

3.8 Contact corrosion

Contact corrosion can occur if unsuitable fasteners are used (e.g.
bolts, nuts, washers, etc.).
For this reason, only fasteners with a special surface coating are
fitted.
In addition, rubber parts, plastic parts and adhesives are made of
non-conductive material.

3. Repair notes 7
 Audi A6 2019 ➤ , Audi A6 China 2019 ➤ , Audi A7 Sportback 2018 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 04.2019

Always install new parts as listed in the Electronic parts catalogue

if you are not sure whether used parts can be refitted.
Please note:
♦ We recommend using only genuine replacement parts: these
have been fully tested and are compatible with aluminium.
♦ We recommend using Audi Genuine Accessories.
♦ Damage caused by contact corrosion is not covered by the
warranty.

3.9 Gaskets and seals

♦ Always renew gaskets and seals.
♦ Check contact surface on housing or shafts for burrs and dam‐
age after removing the seals, and repair as required.
♦ Remove residues of liquid gaskets completely from sealing
surfaces.

3.10 Bolts and nuts

♦ Loosen and tighten bolts and nuts securing covers and hous‐
ings in diagonal sequence.
♦ Take care not to tilt particularly sensitive components such as
the servo motor with control unit; slacken off and tighten pro‐
gressively in diagonal sequence.
♦ Tightening torques refer to unoiled bolts and nuts.
♦ Always renew self-locking bolts/nuts.
♦ Always renew bolts and nuts which are tightened by turning
through a specified angle.

3.11 Use of impact wrenches

In general, it is permitted to use an impact wrench to unscrew
bolts and nuts. An exception to this is when work is performed
inside an open high-voltage battery. For this work, it is not per‐
mitted to use an impact wrench.
An impact wrench may be used to screw in bolts and nuts when
performing repair work if the following requirements are observed.
In general, electric and compressed-air impact wrenches should
be used.
Requirements:
• Only screw in bolts with locking fluid or self-locking nuts at low
speed.
• Use a suitable impact wrench with variable speed and adjust‐
able torque range.
• Use suitable bits when working in the vicinity of sensitive sur‐
faces, e.g. plastic-coated bits for aluminium rims.
• When working in the vicinity of natural gas systems, observe
the information in the Workshop Manual “Natural gas engines
- General information”.
Use:
• Fit bolts/nuts by hand.
• Only use an impact wrench to screw in bolts/nuts until the head
of the bolt/nut makes contact and then continue tightening with
a torque wrench.
• Clean threaded pins before unscrewing the bolt/nut.

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Running gear, front-wheel drive and four-wheel drive - Edition 04.2019

3.12 Electrical components

You have certainly experienced light electric shocks when touch‐
ing metal objects. This is due to the electrostatic charge accumu‐
lated by the human body. This charge can cause malfunctions if
you touch the electric steering rack components.
– Before working on electrical components, touch an earthed
object (e.g. water pipe or lifting platform). Do not touch the
contact pins of the electrical connectors.

3.13 Routing and attaching lines and wiring

♦ Mark fuel lines, hydraulic lines, vacuum lines, lines for activa‐
ted charcoal filter and electrical wiring etc. before removal so
they can be re-installed in the original positions and correctly
connected. Make sketches or take photographs if necessary.
♦ To avoid damaging pipes, hoses and wiring, ensure sufficient
clearance from all moving or hot components in engine com‐
partment (limited space in engine compartment).

3.14 Repairing damaged threads in longitu‐

dinal member (subframe to body)
Instructions for repairing damaged threads ⇒ Body Repairs; Rep.
gr. 50 .

3.15 Lifting suspension to unladen position -

vehicles with coil springs
• All bolts on running gear components with bonded rubber
bushes must always be tightened with the suspension in the
unladen position ⇒ page 242 .
♦ Bonded rubber bushes can only be turned to a limited extent.
Therefore, before tightening the bolts, suspension compo‐
nents with bonded rubber bushes must be brought into a
position corresponding to the normal position while driving
(unladen position).
♦ Otherwise, the bush would be subject to torsion loading and
its service life would be shortened.
♦ This position can be simulated on the lifting platform by raising
the appropriate part of the suspension with the engine and
gearbox jack - VAS 6931- and support - T10149- .
Special tools and workshop equipment required

3. Repair notes 9
 Audi A6 2019 ➤ , Audi A6 China 2019 ➤ , Audi A7 Sportback 2018 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 04.2019

♦ Engine and gearbox jack - VAS 6931-

♦ Tensioning strap - T10038-

♦ Support - T10149-

10 Rep. gr.00 - Technical data

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Running gear, front-wheel drive and four-wheel drive - Edition 04.2019

Procedure
– Before commencing work, use measuring tape or similar to
measure dimension -a- from wheel centre to lower edge of
wing/wheel housing.
• Dimension -a- = unladen position; depends on the running
gear installed on the vehicle ⇒ page 242 .
• This measurement must be taken with the suspension in the
unladen position.
– Make a note of the measured value. This will be needed when
tightening the bolts and/or nuts.

CAUTION
Risk of accident if vehicle slips off lifting platform due to spring
force of suspension.
– Make sure vehicle is secured before lifting suspension to
unladen position.

• Before raising wheel unit to unladen position, secure vehicle

to engine and gearbox jack - T10038- using tensioning strap
- VAS 6931- .

– Remove wheel ⇒ page 234 .

– Turn wheel hub until one of the wheel bolt holes is at the top.
– Attach support - T10149- to wheel hub using wheel bolt -2-.
• The bolts/nuts on the relevant suspension mountings must not
be tightened until the distance between the wheel centre and
the lower edge of the wing/wheel arch is the same as the dis‐
tance measured before commencing work.

3. Repair notes 11
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– Insert support - T10149- in engine/gearbox jack - VAS 6931-

and lift wheel bearing housing until dimension -a- is attained.

CAUTION
Risk of accident if vehicle is lowered or raised when engine and
gearbox jack is positioned underneath.
– Never raise or lower the vehicle when the engine and gear‐
box jack is underneath it.
– Never leave the engine and gearbox jack under the vehicle
for longer than necessary.

– Tighten relevant nuts and bolts.

– Lower wheel bearing housing.
– Move engine and gearbox jack - VAS 6931- aside.
– Detach support - T10149- .
Tightening torques
♦ ⇒ “1 Wheels, tyres”, page 234

3.16 Lifting suspension to normal level - ve‐

hicles with air suspension
• All bolts on running gear components with bonded rubber
bushes must always be tightened with the suspension at the
normal level ⇒ page 244 .
♦ Bonded rubber bushes can only be turned to a limited extent.
Therefore, before tightening the bolts, suspension compo‐
nents with bonded rubber bushes must be brought into a
position corresponding to the normal position of the unladen
vehicle while driving (normal level).
♦ Otherwise, the bush would be subject to torsion loading and
its service life shortened.
♦ This position can be simulated on the lifting platform by raising
the appropriate part of the suspension with the engine and
gearbox jack - VAS 6931- and support - T10149- .
Special tools and workshop equipment required
♦ Engine and gearbox jack - VAS 6931-

12 Rep. gr.00 - Technical data

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Running gear, front-wheel drive and four-wheel drive - Edition 04.2019

♦ Tensioning strap - T10038-

♦ Support - T10149-

Procedure
– Before commencing work, use measuring tape or similar to
measure dimension -a- from wheel centre to lower edge of
wing/wheel housing.
• This measurement must be taken with the suspension at the
normal level ⇒ page 244 .
– Make a note of the measured value. This will be needed when
tightening the bolts and/or nuts.

CAUTION
Risk of accident if vehicle slips off lifting platform due to spring
force of air suspension.
The spring force of the air suspension remains unchanged
when the vehicle is lifted onto the lifting platform.
– Before lifting the suspension to the normal level, dissipate
the spring force of the air suspension by bleeding the system
completely.

• Before raising wheel unit, secure vehicle to arms of lifting plat‐

form using tensioning straps - T10038- .

3. Repair notes 13
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– Bleed air spring system ⇒ page 220 .

– Remove wheel ⇒ page 234 .
– Turn wheel hub until one of the wheel bolt holes is at the top.
– Attach support - T10149- to wheel hub using wheel bolt -2-.
• The bolts/nuts on the relevant suspension mountings must not
be tightened until the distance between the wheel centre and
the lower edge of the wing/wheel arch is the same as the dis‐
tance measured before commencing work.

– Insert support - T10149- in engine/gearbox jack - VAS 6931-

and lift wheel bearing housing until dimension -a- is attained.

CAUTION
Risk of accident if vehicle is lowered or raised when engine and
gearbox jack is positioned underneath.
– Never raise or lower the vehicle when the engine and gear‐
box jack is underneath it.
– Never leave the engine and gearbox jack under the vehicle
for longer than necessary.

– Tighten relevant nuts and bolts.

– Lower wheel bearing housing.
– Move engine and gearbox jack - VAS 6931- aside.
– Detach support - T10149- .
– Charge air spring system ⇒ page 220 .
• The vehicle must not be lowered from the lifting platform until
the system has been recharged.

14 Rep. gr.00 - Technical data

 Audi A6 2019 ➤ , Audi A6 China 2019 ➤ , Audi A7 Sportback 2018 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 04.2019

4 Disposal
⇒ “4.1 Releasing gas and draining front gas-filled shock absorb‐
ers”, page 15
⇒ “4.2 Releasing gas and draining rear gas-filled shock absorb‐
ers”, page 15
⇒ “4.3 Discharging suspension strut (air suspension)”,
page 17
⇒ “4.4 Discharging accumulator”, page 17

4.1 Releasing gas and draining front gas-fil‐

led shock absorbers
Special tools and workshop equipment required
♦ Hand-held drill
♦ Drill bit, ∅ 3 mm
♦ Drill bit, ∅ 6 mm
♦ Drip tray
♦ Safety goggles
♦ Protective gloves
Procedure
– Clamp gas-filled shock absorber vertically in vice, with piston
rod pointing downwards.

CAUTION
Risk of injury caused by flying metal shavings.
Eyes and skin can suffer irritation or injuries.
– Put on safety goggles.
– Put on protective gloves.

– Drill a 3 mm ∅ hole -item A- through outer tube of shock ab‐

sorber.
Note:
♦ Gas will escape during drilling.
♦ The shock absorber shown serves as an example only.
– Continue drilling until inner tube is fully penetrated (approx.
25 mm deep).
– Drill a second hole (6 mm ∅) -item B- through outer and inner
tubes of shock absorber.
– Hold shock absorber over a drip tray and move piston rod up
and down several times through entire stroke until no more
fluid comes out.

4.2 Releasing gas and draining rear gas-fil‐

led shock absorbers
Special tools and workshop equipment required

4. Disposal 15
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Running gear, front-wheel drive and four-wheel drive - Edition 04.2019

♦ Hand-held drill
♦ Drill bit, ∅ 3 mm
♦ Drill bit, ∅ 6 mm
♦ Drip tray
♦ Safety goggles
♦ Protective gloves
Procedure
– Clamp gas-filled shock absorber vertically in vice, with piston
rod pointing downwards.

CAUTION
Risk of injury caused by flying metal shavings.
Eyes and skin can suffer irritation or injuries.
– Put on safety goggles.
– Put on protective gloves.

– Drill a 3 mm ∅ hole -item A- through outer tube of shock ab‐

sorber.
Note:
♦ Gas will escape during drilling.
♦ The shock absorber shown serves as an example only.
– Continue drilling until inner tube is fully penetrated (approx.
25 mm deep).
– Drill a second hole (6 mm ∅) -item B- through outer and inner
tubes of shock absorber.
– Hold shock absorber over a drip tray and move piston rod up
and down several times through entire stroke until no more
fluid comes out.

16 Rep. gr.00 - Technical data

 Audi A6 2019 ➤ , Audi A6 China 2019 ➤ , Audi A7 Sportback 2018 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 04.2019

4.3 Discharging suspension strut (air sus‐

pension)
Procedure
– Remove air springs: front ⇒ page 64 , rear ⇒ page 165 .
– Release residual pressure valve -1- on air spring to dissipate
air pressure. (Shown installed in vehicle.)
– Dispose of air spring.
2, 3 - ignore

4.4 Discharging accumulator

Special tools and workshop equipment required
♦ Vehicle diagnostic tester
Procedure
• Observe rules for cleanliness ⇒ page 6 .
– Remove wheel on relevant side ⇒ page 234 .
– Remove relevant wheel housing liner (rear) ⇒ General body
repairs, exterior; Rep. gr. 66 ; Wheel housing liners; Exploded
view - wheel housing liner (rear) .
– Connect vehicle diagnostic tester .
– Switch on ignition.
– Select and start Diagnosis mode.
– Select Test plan tab.
– Choose Select own test and select following options one
after the other:
♦ Systems with diagnostic capability
♦ 0074 - Suspension control system J775
♦ 0074 - Suspension control system, functions
♦ 0074 - Basic setting
– Start selected program and follow instructions shown on dis‐
play of vehicle diagnostic tester.

4. Disposal 17
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– Slowly loosen air pipe -arrow- at corresponding accumulator

to dissipate air pressure. Unscrew air pipe when air pressure
has been dissipated; shown on accumulator (left-side).
– Remove and dispose of accumulator ⇒ page 233 .
• When unscrewing the air pipe from a component, check
whether the cutting ring is seated on the air pipe.

18 Rep. gr.00 - Technical data

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Running gear, front-wheel drive and four-wheel drive - Edition 04.2019

40 – Front suspension
1 Front axle
⇒ “1.1 Overview - front axle”, page 19

1.1 Overview - front axle

I - ⇒ “2 Subframe”, page 20
II -
⇒ “3 Anti-roll bar”, page 56
III -
⇒ “4 Suspension strut, upper
links”, page 60
IV -
⇒ “5 Lower suspension links,
swivel joint”, page 78
V-
⇒ “6 Wheel bearing”,
page 94
VI -
⇒ “7 Drive shaft”, page 103

1. Front axle 19
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Running gear, front-wheel drive and four-wheel drive - Edition 04.2019

2 Subframe
⇒ “2.1 Exploded view - subframe”, page 20
⇒ “2.2 Fixing position of subframe”, page 22
⇒ “2.3 Lowering subframe”, page 28
⇒ “2.4 Removing and installing subframe with steering rack”, page
32
⇒ “2.5 Lowering subframe cross brace”, page 40
⇒ “2.6 Removing and installing subframe cross brace”,
page 43
⇒ “2.7 Removing and installing subframe shield”, page 52

2.1 Exploded view - subframe

1 - Bolt
❑ Renew after removing
❑ 90 Nm +90°
2 - Bolt
❑ Renew after removing
❑ 20 Nm +90°
3 - Bolt
❑ Renew after removing
❑ 20 Nm +90°
4 - Bracket
❑ For electrical wiring har‐
ness
5 - Bolt
❑ 9 Nm
6 - Bolt
❑ Renew after removing
❑ Tightening sequence
⇒ page 22
❑ 115 Nm +90°
7 - Subframe (right-side)
❑ Fixing position
⇒ page 22
❑ Lowering ⇒ page 28
❑ Removing and installing
⇒ page 32
8 - Bolt
❑ 9 Nm
9 - Shield
❑ Removing and installing
⇒ page 52
10 - Nut
❑ 9 Nm

20 Rep. gr.40 - Front suspension

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Running gear, front-wheel drive and four-wheel drive - Edition 04.2019

11 - End piece
12 - Bolt
❑ Renew after removing
❑ 50 Nm +90°
13 - Nut
❑ Renew after removing
❑ 30 Nm
14 - Subframe cross brace
❑ Safety precautions ⇒ page 2
❑ Removing and installing ⇒ page 43
15 - Bolt
❑ Renew after removing
❑ Tightening sequence ⇒ page 21
❑ 115 Nm +90°
16 - Bolt
❑ Renew after removing
❑ 70 Nm +45°
17 - Bolt
❑ Renew after removing
❑ 70 Nm +90°

Subframe cross brace - tightening sequence

– Tighten bolts in stages:
Stage Bolts Tightening sequence
1. -arrows- Screw in by hand until contact is made
2. -arrows- Tighten in stages and in diagonal se‐
quence

2. Subframe 21
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Subframe with cross brace - tightening sequence

– Tighten bolts in stages in the sequence shown:
Stage Bolts Tightening sequence
1. -1 … 10- Screw in by hand until contact is made
2. -1 … 10- Tighten

2.2 Fixing position of subframe

Special tools and workshop equipment required
♦ Torque wrench - V.A.G 1331-

♦ Torque wrench - V.A.G 1332-

22 Rep. gr.40 - Front suspension

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Running gear, front-wheel drive and four-wheel drive - Edition 04.2019

♦ Engine and gearbox jack - VAS 6931-

♦ Rear axle support - T10552-

♦ Fastening device - T40327- (not illustrated)

♦ Adapter - T40386-

Preparing tool
– Loosen bolts -arrows-.
– Set to dimension -a-.
• Dimension -a- = 260 mm
– Tighten bolts to 10 Nm.

2. Subframe 23
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– Loosen bolt -right arrow-.

– Set to dimension -b-.

• Dimension -b- = 360 mm
– Tighten bolt -arrow- to 10 Nm.

– Loosen mounting pins -T10552/1- -item 3- at bottom left and

right.
– Set to dimension -c-.
• Dimension -c- = 155 mm.

– Turn threaded sleeves (left and right) on mounting pins -

T10552/1- -item 3- until dimension -d- is attained.
• Dimension -d- = 170 mm.

24 Rep. gr.40 - Front suspension

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Running gear, front-wheel drive and four-wheel drive - Edition 04.2019

– Fit adapter -T40386/1- and nut -T40386/2- on support -

T10552/2- and hand-tighten with bolt -arrow-.

– Fit rear axle support - T10552- -item 1- onto engine and gear‐
box jack - VAS 6931- -item 2-.

– Tighten bolt -right arrow-:

♦ M6: 5 Nm
♦ M8: 10 Nm
Procedure

CAUTION
Risk of accident if engine/gearbox assembly is not secured
properly.
– Support engine in installation position for following steps.

– Support engine in installation position ⇒ Rep. gr. 10 ; As‐

sembly mountings; Supporting engine in installation position .
– Remove front wheels ⇒ page 234 .
– Remove noise insulation ⇒ General body repairs, exterior;
Rep. gr. 66 ; Noise insulation; Exploded view - noise insula‐
tion .
– Remove wheel housing liner and wheel spoiler (both sides) ⇒
General body repairs, exterior; Rep. gr. 66 ; Wheel housing
liners; Exploded view - wheel housing liner (front) .
– Release front section of underbody trim panels on both sides
and lower slightly ⇒ General body repairs, exterior; Rep. gr.
66 ; Underbody trim; Exploded view - underbody trim .

2. Subframe 25
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– Move prepared rear axle support - T10552- with engine and

gearbox jack - VAS 6931- so that it makes contact with cross
brace.
• Mounting pins - T10552/1- engage in holes on rear of cross
brace.
– Secure cross brace with tensioning strap -arrow- of rear axle
support.

26 Rep. gr.40 - Front suspension

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Running gear, front-wheel drive and four-wheel drive - Edition 04.2019

• To fix position of subframe, a locating pin -T40327- must be

screwed in at position -1- on left and right sides.
• The locating pins must not be tightened to more than 20 Nm;
otherwise the threads of the pins will be damaged.
• The holes in the subframe are peened slightly from the ribbed
washers of the securing bolts; it may be necessary to de-burr
them.

NOTICE
Risk of damage to threads in body due to improper handling.
– Never use an impact wrench to loosen or tighten.
– Fit bolts by hand only; make the first few turns by hand.

– On both sides of vehicle, fit locating pin -T40327- in place of

bolt -1- and tighten to 20 Nm.
• The position of the subframe is now fixed.
– Remove bolts -arrows- on both sides.
Removing locating pins -T40327-
Removal is performed in reverse sequence; note the following:

NOTICE
Risk of damage to threads in body due to improper handling.
– Never use an impact wrench to loosen or tighten.
– Fit bolts by hand only; make the first few turns by hand.

• Subframe bolts tightened.

– Unscrew locating pins, fit new bolts in their place and tighten
(but do not tighten in diagonal sequence through specified an‐
gle yet).
– Remove support bracket - 10-222A- ⇒ Rep. gr. 10 ; Assembly
mountings; Supporting engine in installation position .

CAUTION
Risk of accident if bolts/nuts are not tightened as specified.
– Always tighten bolts/nuts as specified before driving the ve‐
hicle on public roads.

– Perform test drive after completing repair work.

• Wheel alignment must be checked and adjusted if the steering
wheel is not straight ⇒ page 235 .
• If wheel alignment does not need to be checked, tighten bolts
for subframe in diagonal sequence through specified angle.
Tightening torques
♦ ⇒ “2.1 Exploded view - subframe”, page 20
♦ ⇒ General body repairs, exterior; Rep. gr. 66 ; Noise insula‐
tion; Exploded view - noise insulation
♦ ⇒ General body repairs, exterior; Rep. gr. 66 ; Wheel housing
liners; Exploded view - wheel housing liner (front)
♦ ⇒ General body repairs, exterior; Rep. gr. 66 ; Underbody
trim; Exploded view - underbody trim
♦ ⇒ “1 Wheels, tyres”, page 234

2. Subframe 27
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2.3 Lowering subframe

Special tools and workshop equipment required
♦ Torque wrench - V.A.G 1331-

♦ Torque wrench - V.A.G 1332-

♦ Multi-point socket with jointed extension, 14 mm (commercial‐

ly available), for 3.0 ltr. TFSI engine
Procedure
• Re-install all cable ties in original positions.
Before commencing work:
– Equipment version with coil springs: ascertain unladen posi‐
tion ⇒ page 242 .
– Equipment version with air suspension: ascertain normal level
⇒ page 244 .
– Fix position of subframe ⇒ page 22 .
– Move wiring duct -4- clear at coolant pipe (right-side) and at
subframe.
– Remove nut -2- and bolt -3- and push coolant pipe on right of
subframe slightly towards rear.

28 Rep. gr.40 - Front suspension

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Running gear, front-wheel drive and four-wheel drive - Edition 04.2019

– Depending on equipment version: Remove bolts -arrows- and

push coolant pipe (left-side) to one side.

– Unscrew bolts -arrows- on closure plate.

– Depending on equipment version: Remove bolt -1- for support

mounting (both sides).

– Move electrical wiring harnesses clear at bracket -arrow-.

2. Subframe 29
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– Remove bolt -arrow- for subframe shield on both sides.

– Equipment version with 3.0 ltr. TDI engine: Unscrew nuts

-arrows- and move gearbox oil cooling valve - N509- clear.
– If necessary, move wiring harness and SCR supply line clear.

– On both sides, unscrew nut -3- and pull out bolt -1- for coupling
rod -2-.
– Detach intermediate steering shaft from steering rack and
slide shaft together ⇒ page 272 .
– Detach drive shafts (left and right) from gearbox
⇒ page 105 .

– Depending on equipment version: Unplug electrical connector

-3- for vehicle level sender on both sides and move electrical
wire clear.

30 Rep. gr.40 - Front suspension

 Audi A6 2019 ➤ , Audi A6 China 2019 ➤ , Audi A7 Sportback 2018 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 04.2019

Note:
To unscrew bolt for engine mounting (left-side) on equipment ver‐
sion with 3.0 ltr. TFSI engine, use a multi-point socket (14 mm)
-item 1- with jointed extension -2-.

– Depending on equipment version: Move SCR supply line -1-

clear at subframe.
– Remove bolts -2- (left and right) and lower subframe with en‐
gine and gearbox jack - VAS 6931- .
• When lowering subframe, make sure there is enough clear‐
ance for electrical wiring.
• If necessary for additional work, tie up subframe to body using
tensioning straps -T10038- and remove engine and gearbox
jack - VAS 6931- .
Installing
Installation is carried out in reverse order; note the following:
– Remove locating pins -T40327- ⇒ page 22 .
– Install intermediate steering shaft ⇒ page 272 .
• Bonded rubber bushes can only be turned to a limited extent.
The suspension mountings must therefore only be tightened
when the suspension is in the unladen position or normal level.
– Lift suspension to unladen position ⇒ page 9 or normal level
⇒ page 12 .

CAUTION
Risk of accident if bolts/nuts are not tightened as specified.
– Always tighten bolts/nuts as specified before driving the ve‐
hicle on public roads.

Tightening torques
♦ ⇒ “2.1 Exploded view - subframe”, page 20
♦ ⇒ “3.1 Exploded view - anti-roll bar”, page 56
♦ ⇒ “7.1 Exploded view - drive shaft”, page 103
♦ ⇒ Engine; Rep. gr. 10 ; Assembly mountings; Exploded view
- assembly mountings
♦ ⇒ Engine; Rep. gr. 19 ; Coolant pump/thermostat assembly;
Exploded view - coolant valves
♦ ⇒ Engine; Rep. gr. 19 ; Coolant pipes; Exploded view - coolant
pipes

2. Subframe 31
 Audi A6 2019 ➤ , Audi A6 China 2019 ➤ , Audi A7 Sportback 2018 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 04.2019

2.4 Removing and installing subframe with

steering rack
Special tools and workshop equipment required
♦ Hook - 10-222A/20-

♦ Torque wrench - V.A.G 1331-

♦ Torque wrench - V.A.G 1332-

♦ Hose clip pliers - VAS 6362-

32 Rep. gr.40 - Front suspension

 Audi A6 2019 ➤ , Audi A6 China 2019 ➤ , Audi A7 Sportback 2018 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 04.2019

♦ Ball joint ejector - VAS 251 805-

♦ Ball joint ejector - VAS 251 809- with -VAS 251 809/1-

♦ Tensioning strap - T10038-

♦ Multi-point socket with jointed extension, 14 mm (commercial‐

ly available), for 3.0 ltr. TFSI engine
Removing
• Re-install all cable ties in original positions.
Before commencing work:
– Equipment version with coil springs: ascertain unladen posi‐
tion ⇒ page 242 .
– Equipment version with air suspension: ascertain normal level
⇒ page 244 .
– Fix position of subframe ⇒ page 22 .

2. Subframe 33
 Audi A6 2019 ➤ , Audi A6 China 2019 ➤ , Audi A7 Sportback 2018 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 04.2019

– Move wiring duct -4- clear at coolant pipe (right-side) and at

subframe.
– Remove nut -2- and bolt -3- and push coolant pipe on right of
subframe slightly towards rear.

– Depending on equipment version: Remove bolts -arrows- and

push coolant pipe (left-side) to one side.

– Unscrew bolts -arrows- on closure plate.

– Remove bolt -1- and unplug electrical connector -2-.

34 Rep. gr.40 - Front suspension

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Running gear, front-wheel drive and four-wheel drive - Edition 04.2019

– Detach electrical connector -2- from bracket and unplug.

– Remove nut -1- and move earth wires clear.
– Move electrical wiring leading to subframe clear.

– Depending on equipment version: Remove bolt -1- for support

mounting (both sides).

– Remove bolt -arrow- for subframe shield on both sides.

– Equipment version with 3.0 ltr. TDI engine: Unscrew nuts

-arrows- and move gearbox oil cooling valve - N509- clear.
– If necessary, move wiring harness and SCR supply line clear.

2. Subframe 35
 Audi A6 2019 ➤ , Audi A6 China 2019 ➤ , Audi A7 Sportback 2018 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 04.2019

NOTICE
Risk of damage if joints of upper suspension links are over‐
strained.
– Support wheel bearing housing.

– On left and right, engage hooks - 10-222A/20- into vehicle

body and tie up wheel bearing housing using tensioning strap
- T10038- , as shown.

– To protect thread, unscrew nut -arrow- on joint pin of track rod

ball joint (on both sides) until nut is flush with thread of joint
pin.
• To prevent damage to ball joint puller, make sure the two lever
arms of the puller are parallel when maximum force is exerted.

CAUTION
Track rod ball joint is released abruptly when it is pressed out -
risk of injury.
Risk of contusions.
– Secure tools by placing engine and gearbox jack under‐
neath.

– Use ball joint ejector - VAS 251 805- to press track rod ball
joint off wheel bearing housing on both sides.
– Then unscrew nut; if necessary, counterhold at joint pin with
a 6 mm hexagon socket.

On relevant equipment versions:

– Unplug electrical connector -3- for vehicle level sender on both
sides and move electrical wire clear.
– Remove nut -2- and move coupling rod clear.

36 Rep. gr.40 - Front suspension

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Running gear, front-wheel drive and four-wheel drive - Edition 04.2019

All versions (continued):

– Clean steering rack and subframe in area of rubber boot.
– Release spring-type clip -3- using hose clip pliers - VAS 6362- .
– Detach hose clip -1- and pull boot -2- outwards off steering
rack.

– On both sides, separate bolted connections -1, 3- for track

control links.
– Swivel track control link to the front.
Note:
To remove bolt -1-, turn steering to full left/right lock.

– To protect thread, unscrew nut -arrow- on joint pin of guide link

(on both sides) until nut is flush with thread of joint pin.
• To prevent damage to ball joint puller, make sure the two lever
arms of the puller are parallel when maximum force is exerted.

CAUTION
Swivel joint is released abruptly when it is pressed out - risk of
injury.
Risk of contusions.
– Secure tools by placing engine and gearbox jack under‐
neath.

– Press joint pin of guide link out of tapered seat using ball joint
ejector - VAS 251 809- with -VAS 251 809/1- , taking care not
to damage boot.
– Unscrew nut; if necessary, counterhold at joint pin with a TX40
hexagon socket.
– Move guide link clear at wheel bearing housing.

– On both sides, unscrew nut -3- and pull out bolt -1- for coupling
rod -2-.
– Detach intermediate steering shaft from steering rack and
slide shaft together ⇒ page 272 .

2. Subframe 37
 Audi A6 2019 ➤ , Audi A6 China 2019 ➤ , Audi A7 Sportback 2018 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 04.2019

Note:
To unscrew bolt for engine mounting (left-side) on equipment ver‐
sion with 3.0 ltr. TFSI engine, use a multi-point socket (14 mm)
-item 1- with jointed extension -2-.

38 Rep. gr.40 - Front suspension

 Audi A6 2019 ➤ , Audi A6 China 2019 ➤ , Audi A7 Sportback 2018 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 04.2019

– Depending on equipment version: Move SCR supply line -1-

clear at subframe.
– Remove bolts -2- (left and right) and lower subframe with en‐
gine and gearbox jack - VAS 6931- .
• When lowering subframe, make sure there is enough clear‐
ance for electrical wiring and coolant hoses.
Installing
Installation is carried out in reverse order; note the following:
– Install intermediate steering shaft ⇒ page 272 .
• Bonded rubber bushes can only be turned to a limited extent.
The suspension mountings must therefore only be tightened
when the suspension is in the unladen position or normal level.
– Lift suspension to unladen position ⇒ page 9 or normal level
⇒ page 12 .

CAUTION
Risk of accident if bolts/nuts are not tightened as specified.
– Always tighten bolts/nuts as specified before driving the ve‐
hicle on public roads.

– Install boot for steering rack ⇒ page 284 .

• Overview table: when does wheel alignment have to be
checked? ⇒ page 238
• Equipment version with air suspension: Re-adapt normal level
⇒ page 219 .
• Equipment version with coil springs: Adjust headlights ⇒ Elec‐
trical system; Rep. gr. 94 ; Headlights; Adjusting headlights .
• Calibrate front camera for driver assist systems ⇒ Driver as‐
sist systems; Rep. gr. 98 ; Front camera for driver assist
systems; Calibrating front camera for driver assist systems .
Tightening torques
♦ ⇒ “2.1 Exploded view - subframe”, page 20
♦ ⇒ “3.1 Exploded view - anti-roll bar”, page 56
♦ ⇒ “4.1 Exploded view - suspension strut, upper links”,
page 60
♦ ⇒ “5.1 Exploded view - lower suspension links, swivel joint”,
page 78
♦ ⇒ “6.1 Exploded view - wheel bearing”, page 94
♦ ⇒ “2.1 Exploded view - front vehicle level senders”,
page 208
♦ ⇒ Engine; Rep. gr. 10 ; Assembly mountings; Exploded view
- assembly mountings
♦ ⇒ Engine; Rep. gr. 19 ; Coolant pump/thermostat assembly;
Exploded view - coolant valves
♦ ⇒ Engine; Rep. gr. 19 ; Coolant pipes; Exploded view - coolant
pipes
♦ Earth wires ⇒ Current flow diagrams, Electrical fault finding
and Fitting locations

2. Subframe 39
 Audi A6 2019 ➤ , Audi A6 China 2019 ➤ , Audi A7 Sportback 2018 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 04.2019

2.5 Lowering subframe cross brace

Special tools and workshop equipment required
♦ Torque wrench - V.A.G 1331-

♦ Engine and gearbox jack - VAS 6931-

♦ Brace - T40335-

40 Rep. gr.40 - Front suspension

 Audi A6 2019 ➤ , Audi A6 China 2019 ➤ , Audi A7 Sportback 2018 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 04.2019

Preparing brace - T40335-

• Noise insulation removed ⇒ General body repairs, exterior;
Rep. gr. 66 ; Noise insulation; Exploded view - noise insulation
– Measure diameter of hole in subframe.
a - 17.6 mm
b - 15.6 mm
– If necessary, loosen grub screw -1-.
– Insert pin -T40335/1- in brace - T40335- (ensure pin is right
way round).
– Re-tighten grub screw.
Procedure
• Re-install all cable ties in original positions.
– If not already removed, remove noise insulation ⇒ General
body repairs, exterior; Rep. gr. 66 ; Noise insulation; Exploded
view - noise insulation .
– Move electrical wiring on cross brace clear.
– If not already removed, unfasten rear section of front wheel
housing liner (both sides) ⇒ General body repairs, exterior;
Rep. gr. 66 ; Wheel housing liners; Exploded view - wheel
housing liner (front) .
– Release front section of underbody trim panels on both sides
and lower slightly ⇒ General body repairs, exterior; Rep. gr.
66 ; Underbody trim; Exploded view - underbody trim .
– Remove wheel spoilers (front) on both sides ⇒ General body
repairs, exterior; Rep. gr. 66 ; Wheel housing liners; Exploded
view - wheel housing liner (front) .

– Unscrew nut -2- and bolt -3-, and move coolant pipe (right-
side) clear at subframe.

– Remove bolt -arrow- for subframe shield on both sides.

2. Subframe 41
 Audi A6 2019 ➤ , Audi A6 China 2019 ➤ , Audi A7 Sportback 2018 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 04.2019

– Attach brace - T40335- to subframe on left and right. If nec‐

essary, adjust brace using knurled handle -1-.
– Secure brace using locking pins -arrows-.

– Equipment version with 3.0 ltr. TDI engine: Unscrew nuts

-arrows- and move gearbox oil cooling valve - N509- clear.
– If necessary, move wiring harness and SCR supply line clear.

– Unscrew bolts -arrows- on closure plate.

– Move engine and gearbox jack - VAS 6931- so that it makes
contact with cross brace.

42 Rep. gr.40 - Front suspension

 Audi A6 2019 ➤ , Audi A6 China 2019 ➤ , Audi A7 Sportback 2018 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 04.2019

NOTICE
Risk of damage to threads in body due to improper handling.
– Never use an impact wrench to loosen or tighten.
– Fit bolts by hand only; make the first few turns by hand.

– Remove bolts -arrows- and lower subframe cross brace -1-

with engine and gearbox jack - VAS 6931- .

NOTICE
Risk of damage to components due to improper handling.
Lowering the vehicle onto its wheels can damage components
if the assembly mountings, steering rack or subframe cross
brace are not fitted as specified.
– Never lower vehicle onto its wheels with suspension com‐
ponents unfastened or detached.
– Never support weight of vehicle on subframe or cross brace
with suspension components unfastened or detached.

• If vehicle is to be moved, fit subframe cross brace with old bolts

and tighten to specified torque without turning further through
specified angle.
Installing
Installation is carried out in reverse order; note the following:
– Move cross brace into installation position and secure
⇒ Fig. ““Subframe cross brace - tightening sequence”“ , page
21 .
Tightening torques
♦ ⇒ “2.1 Exploded view - subframe”, page 20
♦ ⇒ Engine; Rep. gr. 19 ; Coolant pump/thermostat assembly;
Exploded view - coolant valves
♦ ⇒ Engine; Rep. gr. 19 ; Coolant pipes; Exploded view - coolant
pipes
♦ ⇒ General body repairs, exterior; Rep. gr. 66 ; Noise insula‐
tion; Exploded view - noise insulation
♦ ⇒ General body repairs, exterior; Rep. gr. 66 ; Wheel housing
liners; Exploded view - wheel housing liner (front)
♦ ⇒ General body repairs, exterior; Rep. gr. 66 ; Underbody
trim; Exploded view - underbody trim

2.6 Removing and installing subframe cross

brace
Special tools and workshop equipment required

2. Subframe 43
 Audi A6 2019 ➤ , Audi A6 China 2019 ➤ , Audi A7 Sportback 2018 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 04.2019

♦ Torque wrench - V.A.G 1331-

♦ Engine and gearbox jack - VAS 6931-

♦ Ball joint ejector - VAS 251 805-

♦ Ball joint ejector - VAS 251 809- with -VAS 251 809/1-

44 Rep. gr.40 - Front suspension

 Audi A6 2019 ➤ , Audi A6 China 2019 ➤ , Audi A7 Sportback 2018 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 04.2019

♦ Rear axle support - T10552-

♦ Brace - T40335-

♦ Adapter - T40386-

Preparing rear axle support - T10552-

– Loosen bolts -arrows-.
– Set to dimension -a-.
• Dimension -a- = 250 mm
– Tighten bolts to 10 Nm.

2. Subframe 45
 Audi A6 2019 ➤ , Audi A6 China 2019 ➤ , Audi A7 Sportback 2018 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 04.2019

– Loosen bolt -right arrow-.

– Set to dimension -b-.

• Dimension -b- = 370 mm
– Tighten bolt -arrow- to 10 Nm.

– Loosen mounting pins -T10552/1- -item 3- at bottom left and

right.
– Set to dimension -c-.
• Dimension -c- = 155 mm.

– Turn threaded sleeves (left and right) on mounting pins -

T10552/1- -item 3- until dimension -d- is attained.
• Dimension -d- = 185 mm.

46 Rep. gr.40 - Front suspension

 Audi A6 2019 ➤ , Audi A6 China 2019 ➤ , Audi A7 Sportback 2018 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 04.2019

– Fit adapter -T40386/1- and nut -T40386/2- on support -

T10552/2- and hand-tighten with bolt -arrow-.

– Fit rear axle support - T10552- -item 1- onto engine and gear‐
box jack - VAS 6931- -item 2-.

– Tighten bolt -right arrow-:

♦ M6: 5 Nm
♦ M8: 10 Nm

2. Subframe 47
 Audi A6 2019 ➤ , Audi A6 China 2019 ➤ , Audi A7 Sportback 2018 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 04.2019

Preparing brace - T40335-

• Noise insulation removed ⇒ General body repairs, exterior;
Rep. gr. 66 ; Noise insulation; Exploded view - noise insulation
– Measure diameter of hole in subframe.
a - 17.6 mm
b - 15.6 mm
– If necessary, loosen grub screw -1-.
– Insert pin -T40335/1- in brace - T40335- (ensure pin is right
way round).
– Re-tighten grub screw.
Removing
• Re-install all cable ties in original positions.
– Remove noise insulation ⇒ General body repairs, exterior;
Rep. gr. 66 ; Noise insulation; Exploded view - noise insula‐
tion .
– Move electrical wiring on cross brace clear.
– Unfasten rear section of front wheel housing liner (both sides)
⇒ General body repairs, exterior; Rep. gr. 66 ; Wheel housing
liners; Exploded view - wheel housing liner (front) .
– Release front section of underbody trim panels on both sides
and lower slightly ⇒ General body repairs, exterior; Rep. gr.
66 ; Underbody trim; Exploded view - underbody trim .
– Remove wheel spoilers (front) on both sides ⇒ General body
repairs, exterior; Rep. gr. 66 ; Wheel housing liners; Exploded
view - wheel housing liner (front) .

– To protect thread, unscrew nut -arrow- on joint pin of guide link

(on both sides) until nut is flush with thread of joint pin.
• To prevent damage to ball joint puller, make sure the two lever
arms of the puller are parallel when maximum force is exerted.

CAUTION
Swivel joint is released abruptly when it is pressed out - risk of
injury.
Risk of contusions.
– Secure tools by placing engine and gearbox jack under‐
neath.

– Press joint pin of guide link out of tapered seat using ball joint
ejector - VAS 251 809- with -VAS 251 809/1- , taking care not
to damage boot.
– Unscrew nut; if necessary, counterhold at joint pin with a TX40
hexagon socket.
– Move guide link clear at wheel bearing housing.

48 Rep. gr.40 - Front suspension

 Audi A6 2019 ➤ , Audi A6 China 2019 ➤ , Audi A7 Sportback 2018 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 04.2019

– Unscrew nut -2- and bolt -3-, and move coolant pipe (right-
side) clear at subframe.

– Remove bolt -arrow- for subframe shield on both sides.

– Attach brace - T40335- to subframe on left and right. If nec‐

essary, adjust brace using knurled handle -1-.
– Secure brace using locking pins -arrows-.

– Equipment version with 3.0 ltr. TDI engine: Unscrew nuts

-arrows- and move gearbox oil cooling valve - N509- clear.
– If necessary, move wiring harness and SCR supply line clear.

2. Subframe 49
 Audi A6 2019 ➤ , Audi A6 China 2019 ➤ , Audi A7 Sportback 2018 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 04.2019

– Unscrew bolts -arrows- on closure plate.

– Move prepared rear axle support - T10552- with engine and

gearbox jack - VAS 6931- so that it makes contact with cross
brace.
• Mounting pins - T10552/1- engage in holes on rear of cross
brace.
– Secure cross brace with tensioning strap -arrow- of rear axle
support.

50 Rep. gr.40 - Front suspension

 Audi A6 2019 ➤ , Audi A6 China 2019 ➤ , Audi A7 Sportback 2018 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 04.2019

NOTICE
Risk of damage to threads in body due to improper handling.
– Never use an impact wrench to loosen or tighten.
– Fit bolts by hand only; make the first few turns by hand.

– Remove bolts -arrows-, lower subframe cross brace -1- with

engine and gearbox jack - VAS 6931- and remove.

NOTICE
Risk of damage to components due to improper handling.
Lowering the vehicle onto its wheels can damage components
if the assembly mountings, steering rack or subframe cross
brace are not fitted as specified.
– Never lower vehicle onto its wheels with suspension com‐
ponents unfastened or detached.
– Never support weight of vehicle on subframe or cross brace
with suspension components unfastened or detached.

• If vehicle is to be moved, fit subframe cross brace with old bolts

and tighten to specified torque without turning further through
specified angle.
Installing
Installation is carried out in reverse order; note the following:
– Move cross brace into installation position and secure
⇒ Fig. ““Subframe cross brace - tightening sequence”“ , page
21 .
Tightening torques
♦ ⇒ “2.1 Exploded view - subframe”, page 20
♦ ⇒ “5.1 Exploded view - lower suspension links, swivel joint”,
page 78
♦ ⇒ Engine; Rep. gr. 19 ; Coolant pump/thermostat assembly;
Exploded view - coolant valves
♦ ⇒ Engine; Rep. gr. 19 ; Coolant pipes; Exploded view - coolant
pipes
♦ ⇒ General body repairs, exterior; Rep. gr. 66 ; Noise insula‐
tion; Exploded view - noise insulation
♦ ⇒ General body repairs, exterior; Rep. gr. 66 ; Wheel housing
liners; Exploded view - wheel housing liner (front)
♦ ⇒ General body repairs, exterior; Rep. gr. 66 ; Underbody
trim; Exploded view - underbody trim

2. Subframe 51
 Audi A6 2019 ➤ , Audi A6 China 2019 ➤ , Audi A7 Sportback 2018 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 04.2019

2.7 Removing and installing subframe

shield
⇒ “2.7.1 Removing and installing subframe shield (left-side) -
equipment version with 3.0 ltr. TFSI engine”, page 52
⇒ “2.7.2 Removing and installing subframe shield (left-side) -
equipment version with 3.0 ltr. TDI engine”, page 52
⇒ “2.7.3 Removing and installing subframe shield (right-side)”,
page 53

2.7.1 Removing and installing subframe

shield (left-side) - equipment version
with 3.0 ltr. TFSI engine
Special tools and workshop equipment required
♦ Torque wrench - V.A.G 1410-

Removing
– Remove noise insulation ⇒ General body repairs, exterior;
Rep. gr. 66 ; Noise insulation; Exploded view - noise insula‐
tion .
– Remove bolts -arrows-.
– Detach subframe shield -1- downwards through cross brace.
Installing
Installation is carried out in reverse sequence.
Tightening torques
♦ ⇒ “2.1 Exploded view - subframe”, page 20
♦ ⇒ General body repairs, exterior; Rep. gr. 66 ; Noise insula‐
tion; Exploded view - noise insulation

2.7.2 Removing and installing subframe

shield (left-side) - equipment version
with 3.0 ltr. TDI engine
Special tools and workshop equipment required

52 Rep. gr.40 - Front suspension

 Audi A6 2019 ➤ , Audi A6 China 2019 ➤ , Audi A7 Sportback 2018 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 04.2019

♦ Torque wrench - V.A.G 1410-

Removing
– Remove noise insulation ⇒ General body repairs, exterior;
Rep. gr. 66 ; Noise insulation; Exploded view - noise insula‐
tion .
– Remove drive shaft cover ⇒ General body repairs, exterior;
Rep. gr. 66 ; Wheel housing liners; Exploded view - wheel
housing liner (front) .
On relevant equipment versions:
– Unplug electrical connector -3-.
– Unscrew bolt -1- and move vehicle level sender to one side.

All versions (continued):

– Loosen bolts -arrows-.
– If installed, move bracket -3- clear together with SCR supply
line and move bracket -2- clear together with gearbox oil cool‐
ing valve - N509- .
– Remove subframe shield -1- towards left side.
Installing
Installation is carried out in reverse sequence.
Tightening torques
♦ ⇒ “2.1 Exploded view - subframe”, page 20
♦ ⇒ Engine; Rep. gr. 19 ; Coolant pump/thermostat assembly;
Exploded view - coolant valves
♦ ⇒ General body repairs, exterior; Rep. gr. 66 ; Noise insula‐
tion; Exploded view - noise insulation
♦ ⇒ General body repairs, exterior; Rep. gr. 66 ; Wheel housing
liners; Exploded view - wheel housing liner (front)

2.7.3 Removing and installing subframe

shield (right-side)
Special tools and workshop equipment required

2. Subframe 53
 Audi A6 2019 ➤ , Audi A6 China 2019 ➤ , Audi A7 Sportback 2018 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 04.2019

♦ Torque wrench - V.A.G 1410-

Removing
– Remove noise insulation ⇒ General body repairs, exterior;
Rep. gr. 66 ; Noise insulation; Exploded view - noise insula‐
tion .
– Remove drive shaft cover ⇒ General body repairs, exterior;
Rep. gr. 66 ; Wheel housing liners; Exploded view - wheel
housing liner (front) .
On relevant equipment versions:
– Unplug electrical connector -3-.
– Unscrew bolt -1- and move vehicle level sender to one side.
All versions (continued):
– Unfasten front section of front wheel housing liner ⇒ General
body repairs, exterior; Rep. gr. 66 ; Wheel housing liners; Ex‐
ploded view - wheel housing liner (front) .

– Move wiring duct -4- clear at coolant pipe (right-side) and at

subframe.
– Remove nut -2- and bolt -3- and push coolant pipe on right of
subframe slightly upwards.

54 Rep. gr.40 - Front suspension

 Audi A6 2019 ➤ , Audi A6 China 2019 ➤ , Audi A7 Sportback 2018 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 04.2019

– Loosen bolts -arrows-.

– Remove subframe shield -1- towards right side.
Installing
Installation is carried out in reverse sequence.
Tightening torques
♦ ⇒ “2.1 Exploded view - subframe”, page 20
♦ ⇒ “2.1 Exploded view - front vehicle level senders”,
page 208
♦ ⇒ Engine; Rep. gr. 19 ; Coolant pump/thermostat assembly;
Exploded view - coolant valves
♦ ⇒ Engine; Rep. gr. 19 ; Coolant pipes; Exploded view - coolant
pipes
♦ ⇒ General body repairs, exterior; Rep. gr. 66 ; Noise insula‐
tion; Exploded view - noise insulation
♦ ⇒ General body repairs, exterior; Rep. gr. 66 ; Wheel housing
liners; Exploded view - wheel housing liner (front)

2. Subframe 55
 Audi A6 2019 ➤ , Audi A6 China 2019 ➤ , Audi A7 Sportback 2018 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 04.2019

3 Anti-roll bar
⇒ “3.1 Exploded view - anti-roll bar”, page 56
⇒ “3.2 Removing and installing anti-roll bar”, page 56
⇒ “3.3 Removing and installing coupling rod”, page 58

3.1 Exploded view - anti-roll bar

1 - Nut
❑ Renew after removing
❑ Unscrew and tighten
evenly in stages
❑ 30 Nm
2 - Clamp
3 - Anti-roll bar
❑ With rubber bush
❑ Rubber bush cannot be
renewed separately
❑ Removing and installing
⇒ page 56
4 - Nut
❑ Renew after removing
❑ Tighten in unladen posi‐
tion ⇒ page 9 or at nor‐
mal level ⇒ page 12
❑ 40 Nm +90°
5 - Subframe
6 - Bolt
❑ Renew after removing
7 - Coupling rod
❑ Removing and installing
⇒ page 58
8 - Shock absorber fork
❑ Removing and installing
⇒ page 74
9 - Nut
❑ Renew after removing
❑ Tighten in unladen posi‐
tion ⇒ page 9 or at normal level ⇒ page 12
❑ 40 Nm +90°
10 - Bolt
❑ Renew after removing

3.2 Removing and installing anti-roll bar

Special tools and workshop equipment required

56 Rep. gr.40 - Front suspension

 Audi A6 2019 ➤ , Audi A6 China 2019 ➤ , Audi A7 Sportback 2018 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 04.2019

♦ Torque wrench - V.A.G 1331-

♦ Brace - T40335-

Preparing brace - T40335-

– Measure diameter of hole in subframe.
a - 17.6 mm
b - 15.6 mm
– If necessary, loosen grub screw -1-.
– Insert pin -T40335- in brace - T40335- (ensure pin is right way
round).
– Re-tighten grub screw.
Removing
Before commencing work:
– Equipment version with coil springs: ascertain unladen posi‐
tion ⇒ page 242 .
– Equipment version with air suspension: ascertain normal level
⇒ page 244 .
– Remove noise insulation ⇒ General body repairs, exterior;
Rep. gr. 66 ; Noise insulation; Exploded view - noise insula‐
tion .
– Remove wheel spoilers (front) on both sides ⇒ General body
repairs, exterior; Rep. gr. 66 ; Wheel housing liners; Exploded
view - wheel housing liner (front) .

3. Anti-roll bar 57
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Running gear, front-wheel drive and four-wheel drive - Edition 04.2019

– Attach brace - T40335- to subframe on left and right. If nec‐

essary, adjust brace using knurled handle -1-.
– Secure brace using locking pins -arrows-.

– Remove nuts -arrows- and -3- on both sides.

– Remove clamp -1- and bolt -4- on both sides.
– Detach anti-roll bar -2-.
Installing
Installation is carried out in reverse order; note the following:
• Anti-roll bar and rubber bushes must be free of grease.
• Tighten any loose studs for clamps as far as stop.
– Screw in bolts for anti-roll bar initially until they make contact,
but do not tighten to final torque yet.
• Bonded rubber bushes can only be turned to a limited extent.
The suspension mountings must therefore only be tightened
when the suspension is in the unladen position or normal level.
– Lift suspension to unladen position ⇒ page 9 or normal level
⇒ page 12 .
Tightening torques
♦ ⇒ “3.1 Exploded view - anti-roll bar”, page 56
♦ ⇒ General body repairs, exterior; Rep. gr. 66 ; Noise insula‐
tion; Exploded view - noise insulation
♦ ⇒ General body repairs, exterior; Rep. gr. 66 ; Wheel housing
liners; Exploded view - wheel housing liner (front)

3.3 Removing and installing coupling rod

Special tools and workshop equipment required
♦ Torque wrench - V.A.G 1332-

Removing
Before commencing work:

58 Rep. gr.40 - Front suspension

 Audi A6 2019 ➤ , Audi A6 China 2019 ➤ , Audi A7 Sportback 2018 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 04.2019

– Equipment version with coil springs: ascertain unladen posi‐

tion ⇒ page 242 .
– Equipment version with air suspension: ascertain normal level
⇒ page 244 .
– Remove drive shaft cover ⇒ General body repairs, exterior;
Rep. gr. 66 ; Wheel housing liners; Exploded view - wheel
housing liner (front) .
– Remove nuts -arrows-.
– Remove bolts -1, 3- and detach coupling rod -2-.
Note:
Turn front wheels to left or right as necessary to unscrew bottom
bolt.
Installing
Installation is carried out in reverse order; note the following:
– Screw in bolts for components with bonded rubber bushes in‐
itially until they make contact, but do not tighten to final torque
yet.
• Bonded rubber bushes can only be turned to a limited extent.
The suspension mountings must therefore only be tightened
when the suspension is in the unladen position or normal level.
– Lift suspension to unladen position ⇒ page 9 or normal level
⇒ page 12 .
Tightening torques
♦ ⇒ “3.1 Exploded view - anti-roll bar”, page 56
♦ ⇒ General body repairs, exterior; Rep. gr. 66 ; Wheel housing
liners; Exploded view - wheel housing liner (front)

3. Anti-roll bar 59
 Audi A6 2019 ➤ , Audi A6 China 2019 ➤ , Audi A7 Sportback 2018 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 04.2019

4 Suspension strut, upper links

⇒ “4.1 Exploded view - suspension strut, upper links”, page 60
⇒ “4.2 Exploded view - body brace”, page 64
⇒ “4.3 Removing and installing suspension strut”, page 64
⇒ “4.4 Servicing suspension strut”, page 66
⇒ “4.5 Removing and installing upper links”, page 68
⇒ “4.6 Renewing bush for upper link”, page 71
⇒ “4.7 Charging suspension strut”, page 72
⇒ “4.8 Removing and installing shock absorber fork”, page 74
⇒ “4.9 Removing and installing body brace”, page 77

4.1 Exploded view - suspension strut, upper

links
⇒ “4.1.1 Exploded view - suspension strut, upper links”,
page 60
⇒ “4.1.2 Exploded view - suspension strut (coil springs)”,
page 63

4.1.1 Exploded view - suspension strut, upper links

60 Rep. gr.40 - Front suspension

 Audi A6 2019 ➤ , Audi A6 China 2019 ➤ , Audi A7 Sportback 2018 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 04.2019

1 - Bolt
❑ Renew after removing
2 - Track control link
3 - Shock absorber fork
❑ Removing and installing
⇒ page 74
4 - Nut
❑ Renew after removing
❑ Tighten in unladen posi‐
tion ⇒ page 9 or at nor‐
mal level ⇒ page 12
❑ 40 Nm +180°
5 - Suspension strut
❑ Shown for equipment
version with air suspen‐
sion
❑ Exploded view: Suspen‐
sion strut (coil springs)
⇒ page 63
❑ Removing and installing
⇒ page 64
❑ Installation position
⇒ page 62
6 - Suspension turret
7 - Bolt
❑ Renew after removing
❑ 20 Nm +90°
8 - Trim cap
9 - O-ring
❑ Renew if leakage oc‐
curs and after removal
10 - Air pipe
❑ Do not loosen residual pressure valve
❑ Cutting ring must be fitted to ensure that air pipe is fitted securely
❑ Tightening torque ⇒ Item 3 (page 215)
11 - Bolts
❑ Renew after removing
❑ Tighten in unladen position ⇒ page 9 or at normal level ⇒ page 12
❑ 50 Nm +90°
12 - Bonded rubber bush
❑ Renewing ⇒ page 71
13 - Upper link (rear)
❑ Removing and installing ⇒ page 68
14 - Bolt
❑ Renew after removing
15 - Nut
❑ Renew after removing
❑ 40 Nm

4. Suspension strut, upper links 61

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16 - Wheel bearing housing

❑ Removing and installing ⇒ page 95
17 - Upper link (front)
❑ Removing and installing ⇒ page 68
18 - Bonded rubber bush
❑ Renewing ⇒ page 71
19 - Bolt
❑ Renew after removing
20 - Nut
❑ Renew after removing
❑ Tighten in unladen position ⇒ page 9 or at normal level ⇒ page 12
❑ 90 Nm +90°

Installation position of suspension strut (air springs)

• The locating pin -1- of the protective cap must engage in the
hole -2- in the suspension turret -arrow-.

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4.1.2 Exploded view - suspension strut (coil springs)

1 - Protective sleeve
2 - Auxiliary spring
3 - Coil spring
❑ Installation position
⇒ page 63
4 - Spring seat
5 - Suspension strut mounting
6 - Nut
❑ Renew after removing
❑ 50 Nm
7 - Trim cap
❑ Can only be fitted in one
position
8 - Trim cap
❑ Not on all versions
9 - Protective cap
10 - Spring seat
11 - Bottom spring plate
12 - Shock absorber
❑ 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
❑ Removing and installing
⇒ page 66
❑ For equipment version
with electronic damping
control: Re-adapt reference position after renewing ⇒ Vehicle diagnostic tester

Installation position of suspension strut (coil springs)

• The locating pin -1- on the suspension strut mounting must
engage in the hole -2- in the suspension turret -arrow-.

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4.2 Exploded view - body brace

1 - Bolt
❑ 8 Nm
2 - Bulkhead
3 - Sealing pieces
4 - Body brace
❑ Removing and installing
⇒ page 77
5 - Bolt
❑ 25 Nm

4.3 Removing and installing suspension

strut
♦ Torque wrench - V.A.G 1331-

Removing
– Remove shock absorber fork ⇒ page 74 .

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Equipment version with air suspension:

• Observe rules for cleanliness ⇒ page 6 .
• Take care to prevent indentations forming in boot on air spring
during assembly work.
– Unscrew air pipe -2- from residual pressure valve -1-. This will
allow air to escape.
– Move air pipe clear at bracket -3-.
Note:
♦ The residual pressure valve cannot be removed separately.
♦ Renew the air spring strut if the residual pressure valve is
faulty.
– Close both connections.

Equipment version with electronic damping control:

– Detach cover -1-.
– Release catch -2- upwards -arrows- and unplug electrical con‐
nector.

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All versions (continued):

– Remove bolts -arrows- and detach suspension strut, taking
care not to damage protective boots on steering and drive
shaft or boot on suspension strut.
Installing
Installation is carried out in reverse order; note the following:
Note:
Cutting ring must be fitted to ensure that air pipe is fitted securely.
• Steps when installing a new air spring ⇒ page 72
– Note installation position
⇒ Fig. ““Installation position of suspension strut (air springs)”“ ,
page 62 /
⇒ Fig. ““Installation position of suspension strut (coil
springs)”“ , page 63 .
Equipment version with coil springs (after renewing springs):
• Adjust headlights ⇒ Electrical system; Rep. gr. 94 ; Head‐
lights; Adjusting headlights .
• Calibrate front camera for driver assist systems ⇒ Driver as‐
sist systems; Rep. gr. 98 ; Front camera for driver assist
systems; Calibrating front camera for driver assist systems .
Equipment version with air suspension:
– Charge air spring system ⇒ page 220 .
– Re-adapt reference position ⇒ page 219 .
Tightening torques
♦ ⇒ “4.1 Exploded view - suspension strut, upper links”,
page 60
♦ ⇒ “5.1 Exploded view - lower suspension links, swivel joint”,
page 78

4.4 Servicing suspension strut

Because of the different shock absorber valve systems, shock
absorbers on both sides of an axle should always be from the
same manufacturer whenever possible.
Special tools and workshop equipment required
♦ Torque wrench - V.A.G 1332-

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♦ Suspension strut spring compressor - V.A.G 1752-

♦ Shock absorber tool set - T10001-

Removing coil spring

• Suspension strut removed ⇒ page 64 .
– Clamp spring compressor - V.A.G 1752/1- -item 1- in a vice
using protective jaw covers.

CAUTION
Risk of injury if the coil spring is released abruptly.
Risk of contusions.
– Note the following instructions.

• Ensure that coil spring is correctly seated -arrow- in spring re‐

tainer - V.A.G 1752/6- .
1- Spring compressor - V.A.G 1752/1-
2- Spring retainer - V.A.G 1752/6-

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– Set up special tools as shown:

1- Spring compressor - V.A.G 1752/1-
2- Commercially available ratchet
3- -T10001/7-
4- -T10001/11-
5- -T10001/3-
6- Spring retainer - V.A.G 1752/6-
– Compress coil spring using spring compressor until top spring
plate with spring seat is free.
– Take off cover.
– Unscrew nut from piston rod.
– Take off suspension strut components and coil spring together
with spring compressor.

Renewing shock absorber

– Take off protective cap -4- and bottom spring seat -2-.
– Knock spring plate -1- loose using plastic-headed hammer
and lift it off shock absorber -3-.
Installing coil spring
– Using plastic-headed hammer, knock spring plate -1- onto
new shock absorber -3-.
– Install bottom spring seat -2- and protective cap -4-.
– Position compressed coil spring on bottom spring seat.
– Fit component parts of suspension strut.

– Install suspension strut mounting -1- with spring seat -2- on

compressed coil spring so that spring seat makes contact with
end of spring coil -arrow-.
• Maximum permissible clearance: 2 mm
– Release spring compressor - V.A.G 1752/1- .
• When releasing, make sure top end of spring contacts stop on
spring seat.
Tightening torques
♦ ⇒ “4.1.2 Exploded view - suspension strut (coil springs)”, page
63

4.5 Removing and installing upper links

Special tools and workshop equipment required
♦ Vehicle diagnostic tester

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♦ Torque wrench - V.A.G 1331-

♦ Ring spanner insert AF 16 - V.A.G 1331/12-

♦ Torque wrench - V.A.G 1332-

♦ Engine and gearbox jack - VAS 6931-

4. Suspension strut, upper links 69

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♦ Support - T10149-

Removing
Before commencing work:
– Equipment version with coil springs: ascertain unladen posi‐
tion ⇒ page 242 .
– Equipment version with air suspension: ascertain normal level
⇒ page 244 .
– Remove front wheel ⇒ page 234 .
– Turn wheel hub until one of the wheel bolt holes is at the top.
– Attach support - T10149- to wheel hub using wheel bolt -2-.
– Support wheel bearing housing using support - T10149- with
engine and gearbox jack - VAS 6931- .

CAUTION
Risk of accident if vehicle is lowered or raised when engine and
gearbox jack is positioned underneath.
– Never raise or lower the vehicle when the engine and gear‐
box jack is underneath it.
– Never leave the engine and gearbox jack under the vehicle
for longer than necessary.

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– Unscrew bolt -2-.

NOTICE
Risk of damage to wheel bearing housing due to deformation.
– Do not enlarge the slots in the wheel bearing housing.

– Pull appropriate joint pins of upper links -3- out of wheel bear‐
ing housing.
– Unscrew bolt -1- or -4- and detach appropriate upper link.
Installing
Installation is carried out in reverse order; note the following:
– Screw in bolts for components with bonded rubber bushes in‐
itially until they make contact, but do not tighten to final torque
yet.
• Bonded rubber bushes can only be turned to a limited extent.
The suspension mountings must therefore only be tightened
when the suspension is at the normal level.
– Lift suspension to unladen position ⇒ page 9 or normal level
⇒ page 12 .
Tightening torques
♦ ⇒ “4.1 Exploded view - suspension strut, upper links”,
page 60
♦ ⇒ “1 Wheels, tyres”, page 234

4.6 Renewing bush for upper link

Special tools and workshop equipment required
♦ Assembly tool - 3301-

♦ Assembly tool - 3348-

4. Suspension strut, upper links 71

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Procedure
• Upper links removed ⇒ page 68 .
– Mark installation depth of bonded rubber bush using a water‐
proof felt-tip pen or similar.
Extracting bonded rubber bush
– Clamp suspension link in jaws of vice. Use protective jaw cov‐
ers.
– Set up workshop tools, as shown in illustration.
– Extract bonded rubber bush -A- by turning nut -arrow-.

Installing bonded rubber bush

• Do not use lubricant.
– Transfer marking for installation depth from old bonded rubber
bush to new bush.
– Set up workshop tools, as shown in illustration.
– Install bonded rubber bush -A- by turning nut -arrow-, using
the installation depth marking made earlier as a guide.

– Check installation depth of bonded rubber bush -1- in suspen‐

sion link -2-.
• Specification: Dimension -a- = dimension -b-
– Increase depth of bonded rubber bush if dimensions are not
equal.

4.7 Charging suspension strut

Replacement air springs are supplied with a minimum gas filling.
After a period of storage, they may lose some of this initial pres‐
sure (in the same way as a tyre). The minimum pressure must
therefore be checked, and if necessary »recharged« to the re‐
quired level before the air springs are taken out of their packaging.
If the spring is taken out of its packaging without checking and
recharging the pressure, this can cause indentations or kinks to
form in the U-bellows before it reaches its normal shape. This can
damage the bellows and cause premature failure of the air spring.
Special tools and workshop equipment required

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♦ Filler unit for air suspension strut - VAS 6231-

♦ Adapters - T10157-

♦ Gas cylinder: Argon or Corgon

Legal regulations and guidelines
Country-specific laws, regulations and guidelines apply to work
with industrial gases.
Some examples of the regulations which apply in Germany are:
♦ Technical regulations for technical gases (pressurised gases)
= TRG
♦ Technical Rules for Hazardous Substances = TRGS
♦ Technical workplace safety regulations = TRBS
Procedure
– Remove sealing plug -arrow- from residual pressure valve.
– Close valve on gas cylinder.

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– Connect filler unit for air suspension strut - VAS 6231- and
adapter - T10157- .
1- Air spring (in its packaging)
2- Gas cylinder for argon or Corgon with fittings
• To stop “unfiltered” air entering the air spring system, the air
spring may only be »recharged« with the gases listed above.

– Set restrictor valve to 2.0 ltr./min -arrow-.

– Charge the air spring with gas up to approx. 5.0 bar, using
several separate bursts of pressure.

– Disconnect filler unit for air suspension strut - VAS 6231- from
adapter - T10157- ; gas pressure in excess of 3.5 bar
-arrow- will then be released.
• The minimum pressure has now been restored. You can take
the air spring out of the packaging.
– After installation, set the suspension to the raised level setting
and then back to the normal level.
– Repeat the procedure.
• Most of the gas will be replaced with the filtered and dried air
from the air supply unit once the suspension has twice moved
up and down to these settings.
– Install air spring ⇒ page 66 .

4.8 Removing and installing shock absorber

fork
Special tools and workshop equipment required

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♦ Spreader - 3424-

♦ Torque wrench - V.A.G 1331-

♦ Torque wrench - V.A.G 1332-

Removing
Before commencing work:
– Equipment version with coil springs: ascertain unladen posi‐
tion ⇒ page 242 .
– Equipment version with air suspension: ascertain normal level
⇒ page 244 .
– Remove front wheel ⇒ page 234 .
– Remove coupling rod ⇒ page 58 .

4. Suspension strut, upper links 75

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– Detach bolt connections -1, 2- for shock absorber fork.

– Insert spreader - 3424- in slot in shock absorber fork -arrow-.

NOTICE
Risk of damage to swivel joints if force is applied.
– Never force the joints of the upper links beyond their maxi‐
mum articulation point.

– Pull shock absorber fork downwards off shock absorber tube

and remove; at the same time, carefully push wheel bearing
housing downwards and push shock absorber tube slightly to
one side.
Installing
Installation is carried out in reverse order; note the following:
– Attach shock absorber fork.

• Equipment version with air suspension: T-bolt -1- of suspen‐

sion strut must engage in groove -arrow- on shock absorber
fork.
– Screw in bolts for components with bonded rubber bushes in‐
itially until they make contact, but do not tighten to final torque
yet.
• Bonded rubber bushes can only be turned to a limited extent.
The suspension mountings must therefore only be tightened
when the suspension is in the unladen position or normal level.
– Lift suspension to unladen position ⇒ page 9 or normal level
⇒ page 12 .
• Overview table: when does wheel alignment have to be
checked? ⇒ page 238
Tightening torques
♦ ⇒ “4.1 Exploded view - suspension strut, upper links”,
page 60
♦ ⇒ “5.1 Exploded view - lower suspension links, swivel joint”,
page 78
♦ ⇒ “1 Wheels, tyres”, page 234

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4.9 Removing and installing body brace

Special tools and workshop equipment required
♦ Torque wrench - V.A.G 1331-

Removing
– Remove plenum chamber cover ⇒ General body repairs, ex‐
terior; Rep. gr. 50 ; Bulkhead; Removing and installing plenum
chamber cover .
– Unclip bracket -2-.
– Remove bolts -arrows- and detach body brace -1-.
Installing
Installation is carried out in reverse sequence.
Tightening torques
♦ ⇒ “4.2 Exploded view - body brace”, page 64

4. Suspension strut, upper links 77

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5 Lower suspension links, swivel joint

⇒ “5.1 Exploded view - lower suspension links, swivel joint”, page
78
⇒ “5.2 Removing and installing track control link”, page 79
⇒ “5.3 Removing and installing guide link”, page 83
⇒ “5.4 Renewing bush for track control link”, page 85
⇒ “5.5 Removing and installing swivel joint”, page 90
⇒ “5.6 Removing and installing bonded rubber bush for guide
link”, page 91

5.1 Exploded view - lower suspension links, swivel joint

1 - Bonded rubber bush (wheel

bearing housing end)
❑ Renewing ⇒ page 85
2 - Bolt
❑ Renew after removing
3 - Bonded rubber bush (sub‐
frame end)
❑ Renewing ⇒ page 87
4 - Track control link
❑ Removing and installing
⇒ page 79
5 - Shock absorber fork
❑ Removing and installing
⇒ page 74
6 - Nut
❑ Renew after removing
❑ Tighten in unladen posi‐
tion ⇒ page 9 or at nor‐
mal level ⇒ page 12
❑ 70 Nm +180°
7 - Bolt
❑ Renew after removing
8 - Subframe
9 - Bolt
❑ Renew after removing
10 - Nut
❑ Renew after removing
❑ Tighten in unladen posi‐
tion ⇒ page 9 or at nor‐
mal level ⇒ page 12
❑ 70 Nm +180°
11 - Bonded rubber bush
❑ Bonded rubber bush in guide link may only be renewed once.
❑ Renewing ⇒ page 91
12 - Guide link
❑ Bonded rubber bush in guide link may only be renewed once.

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❑ Removing and installing ⇒ page 83

13 - Wheel bearing housing
14 - Nut
❑ Renew after removing
❑ If re-installing guide link, clean any remaining locking fluid off thread of joint pin
❑ 140 Nm
15 - Bolt
❑ Renew after removing
❑ 40 Nm
16 - Nut
❑ Tightening torque ⇒ Item 20 (page 62)
17 - Swivel joint
❑ Removing and installing ⇒ page 90
❑ Insert onto contact surface in wheel bearing housing ⇒ page 82
18 - Nut
❑ Renew after removing
❑ If re-installing swivel joint, clean any remaining locking fluid off thread of joint pin
❑ 140 Nm

5.2 Removing and installing track control

link
Special tools and workshop equipment required
♦ Spreader - 3424-

♦ Torque wrench - V.A.G 1332-

5. Lower suspension links, swivel joint 79

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♦ Hose clip pliers - VAS 6362-

♦ Engine and gearbox jack - VAS 6931-

♦ Ball joint ejector - VAS 251 805-

♦ Support - T10149-

Removing
Before commencing work:
– Equipment version with coil springs: ascertain unladen posi‐
tion ⇒ page 242 .

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– Equipment version with air suspension: ascertain normal level

⇒ page 244 .
– Remove front wheel ⇒ page 234 .
– Remove noise insulation ⇒ General body repairs, exterior;
Rep. gr. 66 ; Noise insulation; Exploded view - noise insula‐
tion .
– Unbolt subframe shield and place it to one side ⇒ page 52 .
– Clean steering rack and subframe in area of rubber boot.
– Release spring-type clip -3- using hose clip pliers - VAS 6362- .
– Detach hose clip -1- and pull boot -2- outwards off steering
rack.

– To protect thread, unscrew nut -arrow- on joint pin of track rod

ball joint until nut is flush with thread of joint pin.
• To prevent damage to ball joint puller, make sure the two lever
arms of the puller are parallel when maximum force is exerted.

CAUTION
Track rod ball joint is released abruptly when it is pressed out -
risk of injury.
Risk of contusions.
– Secure tools by placing engine and gearbox jack under‐
neath.

– Press track rod ball joint off wheel bearing housing using ball
joint ejector - VAS 251 805- .
– Then unscrew nut; if necessary, counterhold at joint pin with
a 6 mm hexagon socket.
– Lift track rod clear and tie up.

• To avoid damage to joints of upper links, support wheel bear‐

ing housing to prevent the suspension from extending too far.
– Turn wheel hub until one of the wheel bolt holes is at the top.
– Attach support - T10149- to wheel hub using wheel bolt -2-.
– Support wheel bearing housing using support - T10149- with
engine and gearbox jack - VAS 6931- .

CAUTION
Risk of accident if vehicle is lowered or raised when engine and
gearbox jack is positioned underneath.
– Never raise or lower the vehicle when the engine and gear‐
box jack is underneath it.
– Never leave the engine and gearbox jack under the vehicle
for longer than necessary.

5. Lower suspension links, swivel joint 81

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– Depending on equipment version: Remove nut -2- and move

coupling rod for vehicle level sender clear.
– Detach bolt connections -1, 3- for track control link.
– Swivel track control link to the front.
Note:
To remove bolt -1-, turn steering to full left/right lock.

– Remove bolt -2-.

– Insert spreader - 3424- in slot in wheel bearing housing -3- and
turn it 90°.
– Take out track control link -1- with swivel joint.

Installing
Installation is carried out in reverse order; note the following:
– If re-installing swivel joint, clean any remaining locking fluid off
thread of joint pin.
– Move track control link with swivel joint into installation posi‐
tion.

NOTICE
Risk of damage to wheel bearing housing in area of bolted con‐
nection if handled incorrectly.
– Observe correct installation position.

• Insert swivel joint -1- all the way onto contact surface
-arrows- on wheel bearing housing -2-.
– Screw in bolts for components with bonded rubber bushes in‐
itially until they make contact, but do not tighten to final torque
yet.
• Bonded rubber bushes can only be turned to a limited extent.
The suspension mountings must therefore only be tightened
when the suspension is in the unladen position or normal level.
– Lift suspension to unladen position ⇒ page 9 or normal level
⇒ page 12 .

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– When tightening bolt connection -1-, track control link must be

pressed towards inside of vehicle.
– Install boot for steering rack ⇒ page 284 .
• Overview table: when does wheel alignment have to be
checked? ⇒ page 238
Equipment version with coil springs:
• Adjust headlights ⇒ Electrical system; Rep. gr. 94 ; Head‐
lights; Adjusting headlights .
• Calibrate front camera for driver assist systems ⇒ Driver as‐
sist systems; Rep. gr. 98 ; Front camera for driver assist
systems; Calibrating front camera for driver assist systems .
Equipment version with air suspension:
• Re-adapt normal level ⇒ page 219 .
Tightening torques
♦ ⇒ “5.1 Exploded view - lower suspension links, swivel joint”,
page 78
♦ ⇒ “2.1 Exploded view - front vehicle level senders”,
page 208
♦ ⇒ General body repairs, exterior; Rep. gr. 66 ; Noise insula‐
tion; Exploded view - noise insulation
♦ ⇒ “1 Wheels, tyres”, page 234

5.3 Removing and installing guide link

Special tools and workshop equipment required
♦ Torque wrench - V.A.G 1332-

♦ Ring spanner insert - V.A.G 1332/7-

5. Lower suspension links, swivel joint 83

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♦ Engine and gearbox jack - VAS 6931-

♦ Ball joint ejector - VAS 251 809- with -VAS 251 809/1-

Removing
Before commencing work:
– Equipment version with coil springs: ascertain unladen posi‐
tion ⇒ page 242 .
– Equipment version with air suspension: ascertain normal level
⇒ page 244 .
– Remove front wheel ⇒ page 234 .
– Remove noise insulation ⇒ General body repairs, exterior;
Rep. gr. 66 ; Noise insulation; Exploded view - noise insula‐
tion .
– Unfasten rear section of wheel housing liner (front) and press
towards front ⇒ General body repairs, exterior; Rep. gr. 66 ;
Wheel housing liners; Exploded view - wheel housing liner
(front) .
– Unbolt subframe shield and place it to one side ⇒ page 52 .

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– To protect thread, unscrew nut -arrow- on joint pin of guide link

until nut is flush with thread of joint pin.

CAUTION
Swivel joint is released abruptly when it is pressed out - risk of
injury.
Risk of contusions.
– Secure tools by placing engine and gearbox jack under‐
neath.

– Press joint pin of guide link out of tapered seat using ball joint
ejector - VAS 251 809- with -VAS 251 809/1- , taking care not
to damage boot.
– Unscrew nut; if necessary, counterhold at joint pin with a TX40
hexagon socket.
– Move guide link clear at wheel bearing housing.

– Remove bolt -2- and detach guide link -1-.

Installing
Installation is carried out in reverse order; note the following:
– If re-installing guide link, clean any remaining locking fluid off
thread of joint pin.
– Screw in bolts for components with bonded rubber bushes in‐
itially until they make contact, but do not tighten to final torque
yet.
• Bonded rubber bushes can only be turned to a limited extent.
The suspension mountings must therefore only be tightened
when the suspension is at the normal level.
– Lift suspension to unladen position ⇒ page 9 or normal level
⇒ page 12 .
• Overview table: when does wheel alignment have to be
checked? ⇒ page 238
Tightening torques
♦ ⇒ “5.1 Exploded view - lower suspension links, swivel joint”,
page 78
♦ ⇒ “2.1 Exploded view - subframe”, page 20
♦ ⇒ “1 Wheels, tyres”, page 234
♦ ⇒ General body repairs, exterior; Rep. gr. 66 ; Noise insula‐
tion; Exploded view - noise insulation
♦ ⇒ General body repairs, exterior; Rep. gr. 66 ; Wheel housing
liners; Exploded view - wheel housing liner (front)

5.4 Renewing bush for track control link

⇒ “5.4.1 Renewing bush for track control link (wheel bearing
housing end)”, page 85
⇒ “5.4.2 Renewing bush for track control link (subframe end)”,
page 87

5.4.1 Renewing bush for track control link

(wheel bearing housing end)
Special tools and workshop equipment required

5. Lower suspension links, swivel joint 85

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♦ Thrust plate - VW 402-

♦ Press tool - VW 412-

♦ Tube - VW 516-

♦ Tube - 3296-

♦ Assembly paste - G 052 109 A2-

Procedure
• Track control link removed ⇒ page 79

86 Rep. gr.40 - Front suspension

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Pressing out bonded rubber bush

– Mark installation depth -arrow- on bonded rubber bush -1- us‐
ing a waterproof felt-tip pen or similar.
– Set up workshop tools, as shown in illustration.
• Hold the track control link when pressing the bonded rubber
bush in or out.
– Press bonded rubber bush out of track control link -2-.

Pressing in bonded rubber bush

– Transfer marking for installation depth from old bonded rubber
bush to new bush.
– Apply a thin coat of assembly paste - G 052 109 A2- to bonded
rubber bush.
– Insert bonded rubber bush -1- into track control link -2-.
– Set up workshop tools, as shown in illustration.
– Press bonded rubber bush into track control link, taking care
to keep it straight.
– Use marking made before removal -arrow- as a guide.

– Check installation depth of bonded rubber bush -1- in track

control link -2-.
• Specification: Dimension -a- = dimension -b-
– Press bonded rubber bush in further if dimensions are not
equal.

5.4.2 Renewing bush for track control link

(subframe end)
Special tools and workshop equipment required

5. Lower suspension links, swivel joint 87

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♦ Thrust plate - VW 402-

♦ Press tool - VW 412-

♦ Tube - 3296-

♦ Assembly tool - T40032-

♦ Assembly paste - G 052 109 A2-

Procedure
• Track control link removed ⇒ page 79

88 Rep. gr.40 - Front suspension

 Audi A6 2019 ➤ , Audi A6 China 2019 ➤ , Audi A7 Sportback 2018 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 04.2019

Pressing out bonded rubber bush

– Mark installation depth -arrow- and position -3, 4- on bonded
rubber bush -1- using a waterproof felt-tip pen or similar.
– Set up workshop tools, as shown in illustration.
• Hold the track control link when pressing the bonded rubber
bush in or out.
– Press bonded rubber bush out of track control link -2-.

Pressing in bonded rubber bush

– Transfer marking for installation depth from old bonded rubber
bush to new bush.

– Apply a thin coat of assembly paste - G 052 109 A2- to bonded

rubber bush.
– Fit bonded rubber bush -1- into track control link -2- and align
marking -3- with marking -4-.
– Set up workshop tools, as shown in illustration.
– Press bonded rubber bush into track control link, taking care
to keep it straight.
– Use marking -arrow- made before removal as a guide.

5. Lower suspension links, swivel joint 89

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– Check installation depth of bonded rubber bush -1- in track

control link -2-.
• Specification: Dimension -a- = dimension -b-
– Press bonded rubber bush in further if dimensions are not
equal.

5.5 Removing and installing swivel joint

Special tools and workshop equipment required
♦ Torque wrench - V.A.G 1332-

♦ Ring spanner insert - V.A.G 1332/7-

♦ Ball joint puller - T40277-

Removing
• Track control link removed ⇒ page 79

90 Rep. gr.40 - Front suspension

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– Clamp ball joint puller - T40277- in a vice using protective jaw

covers.
– To protect thread, unscrew nut -arrow- on joint pin of swivel
joint until nut is flush with thread of joint pin.
– Use your hand to keep track control link from falling.
– Press swivel joint off track control link using ball joint puller,
taking care not to damage boot.
– Then unscrew nut and detach swivel joint; if necessary, coun‐
terhold at joint pin with a TX40 socket.
Installing
Installation is carried out in reverse sequence.

5.6 Removing and installing bonded rubber

bush for guide link
Special tools and workshop equipment required
♦ Thrust plate - VW 402-

♦ Press tool - VW 412-

♦ Tube - VW463/2-

5. Lower suspension links, swivel joint 91

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♦ Sleeve - 3144-

♦ Workshop press - VAS 6654- , not illustrated

♦ Assembly lubricant - G 294 421 A1- ⇒ Electronic parts cata‐
logue
Pressing out bonded rubber bush
• Guide link removed ⇒ page 83
– Mark installation depth -arrow- on bonded rubber bush -4- us‐
ing a waterproof felt-tip pen or similar.
– Set up workshop tools, as shown in illustration.
1- Press tool of workshop press - VAS 6654-
2- Press tool - VW 412-
3- Tube - VW463/2-
4- Bonded rubber bush
5- Guide link
6- Sleeve - 3144-
7- Thrust plate - VW 402-
Note:
Hold the guide link when pressing the bonded rubber bush in or
out.
– Press bonded rubber bush out of guide link.

Pressing in bonded rubber bush

– Transfer marking for installation depth from old bonded rubber
bush to new bush.
– Lightly lubricate new bush with assembly lubricant - G 294 421
A1- .
Installation position of bonded rubber bush:
• Notch -1- should be parallel with guide link and should point
inwards towards guide link.
• Arrow -2- points inwards towards guide link.

92 Rep. gr.40 - Front suspension

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– Fit bonded rubber bush into guide link (note correct installation
position).
– Set up workshop tools, as shown in illustration.
1- Press tool of workshop press - VAS 6654-
2- Press tool - VW 412-
3- Tube - VW463/2-
4- Bonded rubber bush
5- Guide link
6- Sleeve - 3144-
7- Thrust plate - VW 402-
– Press bonded rubber bush into guide link, taking care to keep
it straight.
– Use marking made before removal -arrow- as a guide.

– Check installation depth -a- of bonded rubber bush in guide

link.
• Dimension -a- = 23 mm
– Press bonded rubber bush in further if specification is not met.

5. Lower suspension links, swivel joint 93

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Running gear, front-wheel drive and four-wheel drive - Edition 04.2019

6 Wheel bearing
⇒ “6.1 Exploded view - wheel bearing”, page 94
⇒ “6.2 Removing and installing wheel bearing housing”,
page 95
⇒ “6.3 Removing and installing wheel bearing unit”, page 98
⇒ “6.4 Servicing wheel bearing unit”, page 99

6.1 Exploded view - wheel bearing

1 - Wheel bearing housing

❑ Removing and installing
⇒ page 95
2 - Bolt
❑ Renew after removing
❑ 80 Nm +90°
3 - Drive shaft
4 - Wheel bearing
❑ Removing and installing
wheel bearing unit
⇒ page 98
❑ Removing and installing
⇒ page 99
❑ Instructions for handling
⇒ page 95
5 - Wheel hub
❑ Lateral run-out of wheel
hub (measured at outer
diameter) when instal‐
led: 0.02 mm
❑ Measure lateral run-out
with dial gauge - VAS
6079- and dial gauge
bracket for brake discs -
VAS 6079/1-
❑ Removing and installing
⇒ page 99
6 - Bolt
❑ Renew after removing
❑ Before securing, clean
threads in CV joint using
a thread tap
❑ Loosening and tighten‐
ing bolt securing drive shaft ⇒ page 106

94 Rep. gr.40 - Front suspension

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Instructions for handling wheel bearing

NOTICE
Risk of irreparable damage to wheel bearing due to improper
handling and insufficient attention to cleanliness.
– Observe the following instructions for handling the wheel
bearing:

• Always place wheel bearing -1- so that it faces upwards.

• 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.

6.2 Removing and installing wheel bearing

housing
Special tools and workshop equipment required
♦ Spreader - 3424-

6. Wheel bearing 95
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♦ Torque wrench - V.A.G 1332-

♦ Engine and gearbox jack - VAS 6931-

♦ Ball joint ejector - VAS 251 805-

♦ Ball joint ejector - VAS 251 809- with -VAS 251 809/1-

Removing
– Slacken bolt securing drive shaft to wheel hub ⇒ page 106 .
– Remove front speed sensor ⇒ Brake system; Rep. gr. 45 ;
Sensors; Removing and installing front speed sensor -G45- /
-G47- .

96 Rep. gr.40 - Front suspension

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– Remove brake caliper ⇒ Brake system; Rep. gr. 46 ; Front

brakes; Removing and installing brake caliper .
– To protect thread, unscrew nut -arrow- on joint pin of track rod
ball joint until nut is flush with thread of joint pin.
• To prevent damage to ball joint puller, make sure the two lever
arms of the puller are parallel when maximum force is exerted.

CAUTION
Track rod ball joint is released abruptly when it is pressed out -
risk of injury.
Risk of contusions.
– Secure tools by placing engine and gearbox jack under‐
neath.

– Press track rod ball joint off wheel bearing housing using ball
joint ejector - VAS 251 805- .
– Unscrew nut; if necessary, counterhold at joint pin with a 6 mm
hexagon socket.

– To protect thread, unscrew nut -arrow- on joint pin of guide link

(on both sides) until nut is flush with thread of joint pin.

CAUTION
Swivel joint is released abruptly when it is pressed out - risk of
injury.
Risk of contusions.
– Secure tools by placing engine and gearbox jack under‐
neath.

– Press joint pin of guide link out of tapered seat using ball joint
ejector - VAS 251 809- with -VAS 251 809/1- , taking care not
to damage boot.
– Unscrew nut; if necessary, counterhold at joint pin with a TX40
hexagon socket.
– Move guide link clear at wheel bearing housing.

– Detach bolt connection -2-.

– Take joint pins of upper links -3- out of wheel bearing housing.

6. Wheel bearing 97
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– Remove bolt -2-.

NOTICE
Risk of damage to wheel bearing housing due to deformation.
– Do not enlarge the slots in the wheel bearing housing.

– Insert spreader - 3424- in slot in wheel bearing housing -3- and

turn it 90°.

CAUTION
Risk of accident caused by high weight of wheel bearing hous‐
ing.
– Perform the following work with the assistance of a second
mechanic.

– Pull wheel bearing housing downwards off swivel joint and re‐
move.
– Tie up drive shaft.
• Do not let the drive shaft hang down under its own weight, as
otherwise excessive bending could damage the inner CV joint.
Installing
Installation is carried out in reverse order; note the following:
– Push wheel bearing housing onto drive shaft splines.
– Install track control link ⇒ page 79 .
– Install upper link ⇒ page 68 .
– Install brake caliper ⇒ Brake system; Rep. gr. 46 ; Front
brakes; Removing and installing brake caliper .
– Tighten bolt securing drive shaft to wheel hub ⇒ page 106 .
• Overview table: when does wheel alignment have to be
checked? ⇒ page 238
Tightening torques
♦ ⇒ “6.1 Exploded view - wheel bearing”, page 94
♦ ⇒ “5.1 Exploded view - lower suspension links, swivel joint”,
page 78
♦ ⇒ Brake system; Rep. gr. 45 ; Sensors; Exploded view - front
wheel speed sensor

6.3 Removing and installing wheel bearing

unit
Special tools and workshop equipment required

98 Rep. gr.40 - Front suspension

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Running gear, front-wheel drive and four-wheel drive - Edition 04.2019

♦ Torque wrench - V.A.G 1332-

Removing
– Slacken bolt securing drive shaft to wheel hub ⇒ page 106 .
– Remove brake disc ⇒ Brake system; Rep. gr. 46 ; Front
brakes; Removing and installing brake disc .
– Remove bolts -arrows-.
– Detach wheel hub -2- with wheel bearing unit from drive shaft
-3- and from wheel bearing housing -1-.
• Observe instructions for handling wheel bearing ⇒ page 95 .
Installing
Installation is carried out in reverse order; note the following:
– Install brake disc ⇒ Brake system; Rep. gr. 46 ; Front brakes;
Removing and installing brake disc .
– Tighten bolt securing drive shaft to wheel hub ⇒ page 106 .
Tightening torques
♦ ⇒ “6.1 Exploded view - wheel bearing”, page 94

6.4 Servicing wheel bearing unit

Special tools and workshop equipment required
♦ Thrust plate - VW 401-

6. Wheel bearing 99
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♦ Thrust plate - VW 402-

♦ Press tool - VW 412-

♦ Assembly tool - T10230-

♦ Workshop press - VAS 6654- , not illustrated

♦ Puller set for inner bearing races - VAS 701 003- (not illustra‐
ted)
Procedure
• Wheel bearing unit removed ⇒ page 98

100 Rep. gr.40 - Front suspension

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Pressing wheel hub out of wheel bearing

– Set up workshop tools, as shown in illustration.
1- Press tool - VW 412-
2- Sleeve -T10230/3-
3- Thrust piece -T10230/8-
4- Wheel bearing unit
5- Thrust plate - VW 402-
6- Thrust plate - VW 401-
– Press wheel hub out of wheel bearing.

Pressing inner bearing race off wheel hub

– Prepare puller from puller set for inner bearing races - VAS
701 003- as follows:
– Screw clamping sleeve - VAS 701 003/1- onto clamp tensioner
- VAS 701 003/7- .
– Screw threaded spindle - VAS 701 003/2- into clamping sleeve
and fit thrust piece - VAS 701 003/3- .

Inner bearing race version 1:

– Remove ball cage from inner bearing race -2-.
– Apply puller -1- to ball raceways -arrow- of inner race, as
shown.

6. Wheel bearing 101

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Inner bearing race version 2:

– Apply puller -1- to groove -arrow- of inner race -2-.

All versions (continued):

– Clamp puller in place on inner race -2-; to do so, use spanner
- VAS 701 003/7- to turn clamp tensioner - VAS 701 003/5- in
direction of -arrow- and counterhold clamping sleeve - VAS
701 003/1- with tensioner handle - VAS 701 003/4- .
– Use threaded spindle - VAS 701 003/2- to detach inner bearing
race from wheel hub -1-.

Pressing wheel hub into wheel bearing

– Set up workshop tools, as shown in illustration.
1- Press tool - VW 412-
2- Thrust plate - VW 402-
3- Wheel hub
4- Wheel bearing
5- Thrust plate - VW 401-
• The machined surface of the wheel bearing outer race faces
downwards.

NOTICE
Risk of irreparable damage to wheel bearing if it is not clean.
– Protect contact surface of wheel bearing and press tool from
becoming dirty.

– Press wheel hub into wheel bearing.

102 Rep. gr.40 - Front suspension

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7 Drive shaft
⇒ “7.1 Exploded view - drive shaft”, page 103
⇒ “7.2 Removing and installing drive shaft”, page 105
⇒ “7.3 Removing and installing heat shield for drive shaft”,
page 105
⇒ “7.4 Loosening and tightening bolt securing drive shaft”,
page 106
⇒ “7.5 Dismantling and assembling drive shaft”, page 107
⇒ “7.6 Servicing constant velocity joint”, page 119
⇒ “7.7 Checking outer constant velocity joint”, page 120
⇒ “7.8 Tightening hose clip on triple roller joint and outer joint”,
page 121

7.1 Exploded view - drive shaft

1 - Hose clip
❑ Renew after removing
❑ Tightening ⇒ page 121
2 - Boot
❑ A triple roller joint adapt‐
er is installed on drive
shafts with peened triple
roller joint AAR 3300 i
❑ Boot must rest in groove
and on contour of joint
body
3 - Hose clip
❑ Renew after removing
❑ Tightening ⇒ page 121
4 - Circlip
❑ Renew after removing
❑ Fit into annular groove
on shaft before installing
(no longer visible once
joint is installed)
❑ Before fitting constant
velocity joint, align cir‐
clip centrally with open‐
ing facing upwards
5 - Outer constant velocity joint
❑ Renew as a complete
unit
❑ Removing ⇒ page 119
❑ Checking ⇒ page 120
❑ Installing ⇒ page 119
❑ Greasing ⇒ page 104
❑ Grease splines on drive
shaft lightly with grease
used in joint before fitting constant velocity joint onto drive shaft
6 - Bolt
❑ Renew after removing

7. Drive shaft 103

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❑ Clean threads in constant velocity joint using a thread tap or similar

❑ Loosening and tightening bolt securing drive shaft ⇒ page 106
7 - Hose clip
❑ Renew after removing
❑ Tightening ⇒ page 121
8 - Boot
❑ Check for splits and chafing
9 - Hose clip
❑ Renew after removing
❑ Tightening ⇒ page 121
10 - Drive shaft
❑ Different versions. For correct version refer to ⇒ Electronic parts catalogue
❑ Removing and installing ⇒ page 105
❑ Dismantling and assembling drive shaft ⇒ page 107
11 - Circlip
❑ Renew after removing
❑ Insert in groove on shaft
12 - Triple roller spider
❑ Mark installation position for re-installation
❑ Dismantling and assembling ⇒ page 107
❑ Grease splines on drive shaft lightly with grease used in joint before fitting triple roller spider onto drive
shaft
13 - Circlip
❑ Renew after removing
❑ Insert in groove on shaft
14 - Bolt
❑ Renew after removing
❑ M10: 50 Nm +90°
❑ M12: 90 Nm +90°
15 - Joint body
❑ Dismantling and assembling ⇒ page 107

Grease quantity and type

♦ Regrease joint when renewing boot.
♦ Please note the correct type of grease for the inner and outer
joints ⇒ Electronic parts catalogue .
Joint ∅ mm Grease quantity
Total quantity In joint In rubber boot
g g g
Outer joint 94.2 200 100 1) 100
Inner joint 123 160 80 2) 80
1) Pack this amount of grease through splines into ball joint. Distribute remainder on face of joint underneath boot.
2) Pack this amount of grease through ball joint. Distribute remainder on face of joint underneath boot.

104 Rep. gr.40 - Front suspension

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7.2 Removing and installing drive shaft

Special tools and workshop equipment required
♦ Torque wrench - V.A.G 1332-

Removing
– Slacken bolt securing drive shaft to wheel hub ⇒ page 106 .
– Remove front wheel ⇒ page 234 .
– Remove subframe shield ⇒ page 52 .
– Unscrew bolts -arrows- securing drive shaft to flange shaft.
– Detach drive shaft, taking care not to damage boot and coating
on drive shaft.
Installing
Installation is carried out in reverse order; note the following:
– Tighten bolt securing drive shaft to wheel hub ⇒ page 106 .
Tightening torques
♦ ⇒ “2.1 Exploded view - subframe”, page 20
♦ ⇒ “7.1 Exploded view - drive shaft”, page 103
♦ ⇒ “1 Wheels, tyres”, page 234

7.3 Removing and installing heat shield for

drive shaft
• Drive shaft cover removed ⇒ General body repairs, exterior;
Rep. gr. 66 ; Wheel housing liners; Exploded view - wheel
housing liner (front) .
Heat shield for drive shaft (left-side)
Component Tightening torque
Bolts -arrows- 23 Nm

7. Drive shaft 105

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Heat shield for drive shaft (right-side)

Component Tightening torque
Bolts -arrows- 23 Nm

7.4 Loosening and tightening bolt securing

drive shaft
Special tools and workshop equipment required
♦ Torque wrench - V.A.G 1576-

♦ Hexagon socket, 19 mm (commercially available)

Loosening bolt securing drive shaft to wheel hub
– To avoid damage to wheel bearing, do not loosen bolt
-arrow- using hexagon socket, 19 mm further than 90° with
vehicle still standing on its wheels.
– Raise vehicle so that wheels are off the ground.
– Have a second mechanic press the brake pedal.
– Remove bolt.
Tightening bolt securing drive shaft to wheel hub
• Always renew bolt after removal.
• Before securing, clean threads in constant velocity joint/stub
axle using a thread tap.
• The wheels must not be in contact with the ground when ini‐
tially tightening the bolt for the drive shaft/stub axle; otherwise
the wheel bearing can be damaged.
– Have a second mechanic press the brake pedal.
– Tighten bolt to 200 Nm.
– Lower vehicle onto its wheels.
– Turn bolt 180° further.

106 Rep. gr.40 - Front suspension

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7.5 Dismantling and assembling drive shaft

⇒ “7.5.1 Dismantling and assembling drive shaft (triple roller joint
AAR 2600 i, AAR 3300 i)”, page 107
⇒ “7.5.2 Dismantling and assembling drive shaft - triple roller joint
AAR 3700 i”, page 112

7.5.1 Dismantling and assembling drive shaft

(triple roller joint AAR 2600 i, AAR
3300 i)
♦ The procedure is the same for drive shafts with triple roller
joints AAR 2600 i and AAR 3300 i except for the following dif‐
ference:
♦ Assembly tool - T40084- is used for triple roller joint AAR
2600 i.
♦ Removal and assembly tool - T40018- is used for triple roller
joint AAR 3300 i.
Special tools and workshop equipment required
♦ Thrust plate - VW 401-

♦ Thrust plate - VW 402-

♦ Press tool - VW 408A-

7. Drive shaft 107

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♦ Press tool - VW 411-

♦ Tube - VW 416B-

♦ Pressure washer - VW 447H-

♦ Multi-purpose tool - VW 771-

108 Rep. gr.40 - Front suspension

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♦ Clamp tensioner - V.A.G 1682 A- with adapter -V.A.G 1682 A/

1-

♦ Assembly tool - T10065-

♦ Removal and assembly tool - T40018- for drive shaft with triple
roller joint AAR 3300 i

♦ Assembly tool - T40084- for drive shaft with triple roller joint
AAR 2600 i

♦ Workshop press - VAS 6654- , not illustrated

♦ Circlip pliers, commercially available

7. Drive shaft 109

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Dismantling
– Clamp drive shaft horizontally in vice using protective jaw cov‐
ers.
• Take care not to damage drive shaft.
– Open hose clips -arrows-.
– Push back boot.
– Remove grease with a lint-free cloth.

NOTICE
Changing fitting location of components can cause noise during
vehicle operation.
– Mark installation position of components for re-installation.

– Mark installation position of joint body in relation to drive shaft

with paint.

– Apply removal and assembly tool - T40018- or assembly tool

- T40084- behind joint body.
• Locating pin -1- must lie against outside of joint body.
– Bring removal and assembly tool - T40018- or assembly tool
- T40084- into contact with joint body by turning knurled
screws -2-.
• Joint body must be fixed in removal and assembly tool -
T40018- without play.
• Tighten knurled screws just hand-tight.

– Screw multi-purpose tool - VW 771- into removal and assem‐

bly tool - T40018- or assembly tool - T40084- .
– Use -VW 771- to detach joint body horizontally.
• Leave joint body clamped in removal and assembly tool -
T40018- or assembly tool - T40084- .

– Remove grease with a lint-free cloth.

NOTICE
Changing fitting location of components can cause noise during
vehicle operation.
– Mark installation position of components for re-installation.

– Mark installation position of drive shaft -1- in relation to triple

roller spider -2- using paint or similar -arrow-.

110 Rep. gr.40 - Front suspension

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– Remove circlip using circlip pliers -1-.

– Set up workshop tools, as shown in illustration.

1- Assembly tool - T10065/1-
2- Assembly tool - T10065/5-
3- Thrust plate - VW 401-
4- Press tool - VW 408A-
5- Thrust plate - VW 402-
• Assembly tool - T10065/5- must make contact with base of
triple roller spider.
• Assembly tool - T10065/5- must not rest on rollers (swivel the
rollers aside if necessary).
– Press triple roller spider off drive shaft.
– Pull off boot.
– Remove grease from shaft splines.
– Check rollers and roller races for wear.
– Clean drive shaft and housing.

Assembling
– Slide smaller hose clip on with boot.
– Position boot between -arrows- on drive shaft.

– Grease splines -arrow A- on drive shaft lightly with grease

used in joint before fitting joint or triple roller spider onto drive
shaft.
– Fit triple roller spider onto shaft so that markings are aligned
and drive home onto stop.

7. Drive shaft 111

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– Set up workshop tools, as shown in illustration.

1- Assembly tool - T10065/1-
2- Assembly tool - T10065/6-
3- Thrust plate - VW 401-
4- Tube - VW 416B-
5- Pressure washer - VW 447H-
6- Press tool - VW 411-
7- Thrust plate - VW 402-
• Assembly tool - T10065/6- must grip drive shaft at bottom
seam -arrow-.
• Assembly tool - T10065/6- must not rest on rollers (swivel the
rollers aside if necessary).

– Install circlip using circlip pliers -1-.

• Circlip must engage audibly. Triple roller spider must lie di‐
rectly against circlip (zero gap).
– Pack grease from repair kit into rear of triple roller joint
⇒ page 104 .
– Lightly grease the rollers.

– Use plastic-headed hammer to drive joint body over triple roller

spider -arrow-; ensure that rollers are not tilted (shown with
assembly tool - T40018- ).
– Pack remaining quantity of grease into boot.
– Make sure boot is properly positioned on joint body.
• Boot must rest in groove and on contour of joint body.
– Fit and tighten hose clips on triple roller joint ⇒ page 121 .

7.5.2 Dismantling and assembling drive shaft

- triple roller joint AAR 3700 i
Special tools and workshop equipment required

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♦ Thrust plate - VW 401-

♦ Thrust plate - VW 402-

♦ Press tool - VW 409-

♦ Press tool - VW 412-

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♦ Tube - VW 416B-

♦ Support sleeve - VW 522-

♦ Multi-purpose tool - VW 771-

♦ Clamp - 40-204A-

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♦ Assembly tool - T40236-

♦ Workshop press - VAS 6654- , not illustrated

♦ Circlip pliers, commercially available
Dismantling
– Clamp drive shaft horizontally in vice using protective jaw cov‐
ers.
• Take care not to damage drive shaft.
– Open hose clips -arrows-.
– Push back boot.
– Remove grease with a lint-free cloth.

NOTICE
Changing fitting location of components can cause noise during
vehicle operation.
– Mark installation position of components for re-installation.

– Mark installation position of joint body in relation to drive shaft

with paint.

– Apply assembly tool - T40236- behind joint body.

• Locating pin -1- must lie against outside of joint body.
– Bring assembly tool into contact with joint body by turning
knurled screws -2-.
• Joint body must be fixed in assembly tool - T40236- without
play.
• Tighten knurled screws just hand-tight.

7. Drive shaft 115

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– Screw multi-purpose tool - VW 771- -item 3- into assembly tool

- T40236- -item 2-.
– Use -VW 771- to detach joint body -1- horizontally.
• Joint body stays in assembly tool - T40236- .

– Remove grease with a lint-free cloth.

NOTICE
Changing fitting location of components can cause noise during
vehicle operation.
– Mark installation position of components for re-installation.

– Mark installation position of drive shaft -1- in relation to triple

roller spider -2- using paint or similar -arrow-.

– Remove circlip using circlip pliers -1-.

– Set up workshop tools, as shown in illustration.

1- Press tool - VW 409-
2- Triple roller spider
3- Support sleeve - VW 522-
4- Thrust plate - VW 401-
5- Thrust plate - VW 402-
• Support sleeve - VW 522- must lie against circlip -arrow-. Cir‐
clip is removed from drive shaft together with triple roller
spider.
• Support sleeve - VW 522- must not rest on rollers (swivel the
rollers aside if necessary).
– Press triple roller spider off drive shaft.
– Pull off boot.
– Remove grease from shaft splines.
– Check rollers and roller races for wear.
– Clean drive shaft and housing.

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Assembling
– Slide smaller hose clip on with boot.
– Position boot between -arrows- on drive shaft.

– Grease splines -arrow A- on drive shaft lightly with grease

used in joint before fitting joint or triple roller spider onto drive
shaft.

– Attach clamp - 40-204A- -item 2-, as shown.

• Clamp - 40-204A- must grip drive shaft at bottom seam
-arrow-.
– Hand-tighten nuts -3-.
– Fit new circlip -1- as far as centre of splines.
– Fit triple roller spider onto shaft so that markings are aligned
and drive home onto stop.

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– Set up workshop tools, as shown in illustration.

1- Press tool - VW 412-
2- Tube - VW 416B-
3- Triple roller spider
4- Clamp - 40-204A-
5- Thrust plate - VW 402-
6- Thrust plate - VW 401-
• Side of tube - VW 416B- with larger internal diameter faces
triple roller spider.
• Clamp - 40-204A- must grip drive shaft at bottom seam
-arrow-.
• Clamp - 40-204A- must not rest on rollers (swivel the rollers
aside if necessary).
– Press on triple roller spider.
• Circlip must engage audibly. Triple roller spider must lie di‐
rectly against circlip (zero gap).

– Install circlip using circlip pliers -1-.

– Pack grease from repair kit into rear of triple roller joint
⇒ page 104 .
– Lightly grease the rollers.

– Use plastic-headed hammer to drive joint body -2- over triple

roller spider -arrow-; ensure that rollers are not tilted.
1- Assembly tool - T40236-
– Pack remaining quantity of grease into boot.
– Make sure boot is properly positioned on joint body.
• Boot must rest in groove and on contour of joint body.
– Fit and tighten hose clip on triple roller joint ⇒ page 121 .

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7.6 Servicing constant velocity joint

Removing outer constant velocity joint
– Clamp drive shaft horizontally in vice using protective jaw cov‐
ers.
• Take care not to damage drive shaft.
– Unfasten both clips and detach boot from outer joint.
– Drive constant velocity joint off drive shaft by applying a copper
or brass drift -A- to inner race.
– Detach joint and boot.

Installing outer constant velocity joint

• Boot and drive shaft must be free from grease.
– Renew circlip -1- after removing.
– Slide smaller hose clip on with boot.
– Position boot in outer groove -arrow B-.
• Inner groove -arrow A- remains visible (“identification groove”
for correct boot assembly).
– Refer to ⇒ page 104 and pack specified quantity of grease
inside joint body.

– Grease splines -arrow A- on drive shaft lightly with grease

used in joint before fitting joint body onto drive shaft.
– Fit circlip in groove on shaft.

– Slide on constant velocity joint as far as circlip.

– Align circlip so that opening faces upwards -arrows-.

7. Drive shaft 119

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– Screw old drive shaft bolt into joint body.

– Use plastic-headed hammer to drive joint onto drive shaft until
circlip engages.
– Refer to ⇒ page 104 and pack specified quantity of grease into
boot side of joint body.
– Push boot onto joint body.
– Vent air from boot.
– Make sure boot is properly positioned on joint body.
• Boot must rest in groove and on contour of joint body.
– Tighten hose clips on outer joint ⇒ page 121 .

7.7 Checking outer constant velocity joint

The joint should be dismantled to renew dirty grease or for check‐
ing the balls and ball races for wear and damage.
Dismantling
– Before dismantling, mark position of ball hub -2- in relation to
ball cage -3- and joint body -1- with an electric scriber or oil
stone.
– Swivel ball hub and ball cage.
– Take out balls one after the other.

– Turn the cage until the two rectangular openings -arrow- are
level with the joint body.
– Lift out cage together with hub.

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– Swivel segment of hub with short lobe into square cage open‐
ing.
– Pivot hub out of cage.
Checking
The balls in each joint belong to one tolerance group. Check stub
axle, hub, cage and balls for pitting and signs of seizure. Exces‐
sive backlash in the joint will cause knocking or jolts under load
change; in such cases the joint must be renewed. Polished areas
and visible tracks in the ball races do not justify renewal of the
joint.
Assembling
– Fit cage with hub into joint body.
• Make sure cage is inserted in correct position (i.e. sides facing
in same direction as original position).
– 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.
– Pack required amount of grease into joint body ⇒ page 104 .

7.8 Tightening hose clip on triple roller joint

and outer joint
Use the following tools depending on type of hose clip:
Special tools and workshop equipment required
♦ Torque wrench - V.A.G 1331-

♦ Clamp tensioner - V.A.G 1682 A-

7. Drive shaft 121

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♦ Locking pliers for Phaeton steering rack - VAS 6199-

Tightening stainless steel hose clip using clamp tensioner - V.A.G

1682 A-
– Apply clamp tensioner - V.A.G 1682 A- as shown.
• Tips of tool must be applied centrally -arrow- to clip -2-.
• The thread of the spindle should move freely; if necessary,
lubricate with MoS2 grease.
Note:
If the thread is stiff (e.g. due to dirt), the required clamping force
will not be attained at the hose clip when the specified tightening
torque is applied.
– Tighten hose clip by turning spindle -1- with torque wrench
(take care to keep clamp tensioner straight).
• Tightening torque: 20 Nm.

Tightening hose clip with retaining lugs using locking pliers for
Phaeton steering rack - VAS 6199-
Note:
To facilitate fitting of multi-point socket head bolts when installing
drive shaft, fastener lug -2- on hose clip must be positioned be‐
tween mounting flanges -1- on joint body.
– Engage hose clip by hand at first lug.

– Close hose clip using locking pliers for Phaeton steering rack
- VAS 6199- -item 2-.

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42 – Rear suspension
1 Rear axle
⇒ “1.1 Overview - rear axle”, page 123

1.1 Overview - rear axle

I - ⇒ “2 Subframe”, page 124

II -
⇒ “3 Anti-roll bar”, page 143
III -
⇒ “4 Suspension links, track
rod”, page 146
IV -
⇒ “5 Suspension strut/shock
absorber, spring”, page 161
V-
⇒ “6 Wheel bearing, trailing
arm”, page 177
VI -
⇒ “7 Drive shaft”, page 190

1. Rear axle 123

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2 Subframe
⇒ “2.1 Exploded view - subframe”, page 124
⇒ “2.2 Fixing position of subframe”, page 125
⇒ “2.3 Removing and installing subframe”, page 129
⇒ “2.4 Servicing subframe”, page 132

2.1 Exploded view - subframe

1 - Bolt
❑ Renew after removing
❑ 50 Nm +180°
2 - Vibration damper
3 - Bolt
❑ Renew after removing
❑ 130 Nm +180°
4 - Diagonal strut
❑ Exploded view ⇒ Gen‐
eral body repairs, exte‐
rior; Rep. gr. 66 ; Un‐
derbody trim; Exploded
view - underbody struts
5 - Hydraulic bonded rubber
bush (front)
❑ For subframe
❑ Removing and installing
⇒ page 132
❑ Installation position
⇒ page 125
6 - Subframe
❑ Fixing position
⇒ page 125
❑ Removing and installing
⇒ page 129
7 - Speed nut
8 - Bonded rubber bush (rear)
❑ For rear final drive
❑ Installation position
⇒ page 125
9 - Steering adapter
❑ Depending on vehicle equipment
❑ Installing ⇒ page 125
10 - Bolt
❑ Renew after removing
❑ 90 Nm +180°
11 - Bonded rubber bush (rear)
❑ For subframe
❑ Removing and installing ⇒ page 136
12 - Bolt
❑ Renew after removing

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❑ 130 Nm +180°
13 - Bolt
❑ Renew after removing
❑ 70 Nm +90°
14 - Buffer

Installation position of front hydraulic bonded rubber bush for

subframe
• Grooves -arrows- are perpendicular to direction of travel.

Installation position of rear bonded rubber bushes for rear final

drive
• Grooves -arrows- on bonded rubber bush -1- should be verti‐
cal.

Installing steering adapter

Depending on vehicle equipment

CAUTION
Risk of accident if bolts/nuts are not tightened as specified.
– Always tighten bolts/nuts as specified before driving the ve‐
hicle on public roads.

– Bring steering adapter -1- into installation position and screw

in bolts by hand until they make contact.
– Align steering adapter with subframe using locking pins -
T40393- and tighten bolts ⇒ Item 10 (page 124) .

2.2 Fixing position of subframe

Special tools and workshop equipment required

2. Subframe 125
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♦ Torque wrench - V.A.G 1331-

♦ Torque wrench - V.A.G 1332-

♦ Support plate (2x) -6131/13-4- from support set, Audi Q7

>2005 - VAS 6131/13-

♦ Engine and gearbox jack - VAS 6931-

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♦ Gearbox support - T40173-

♦ Fastening device - T40329- (not illustrated)

♦ Bolt, M8x30 (4x)
♦ Nuts M8 (4x)
♦ Washer (8x)
Setting up gearbox support - T40173-
– Secure support plate -6131/13-4- with support elements
-1, 2- to gearbox support - T40173- -arrows-, as shown.
Procedure
– Remove rear wheels ⇒ page 234 .
– Depending on equipment version: Remove diagonal struts ⇒
General body repairs, exterior; Rep. gr. 66 ; Underbody trim;
Exploded view - underbody struts .
– Remove silencers ⇒ Engine; Rep. gr. 26 ; Exhaust pipes/
silencers; Removing and installing silencers .
– Remove underbody trim on relevant side ⇒ General body re‐
pairs, exterior; Rep. gr. 66 ; Underbody trim; Exploded view -
underbody trim .
– Detach wind deflector from transverse link ⇒ page 153 .
– Equipment version with coil springs: Remove springs (rear)
⇒ page 167 .
– Equipment version with air suspension: Bleed air spring sys‐
tem ⇒ page 220 .

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– Support weight of subframe as shown using engine and gear‐

box jack - VAS 6931- and gearbox support - T40173- .
– Secure subframe to engine and gearbox jack using tensioning
strap -arrow-.

NOTICE
Risk of damage to threads in body due to improper handling.
– Never use an impact wrench to loosen or tighten.
– Fit bolts by hand only; make the first few turns by hand.

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– One after the other, remove bolt -2- on each side at rear of
subframe and screw in a locating pin for locating device -
T40329- .
• If it is not possible to fit the locating pin, use a file to re-work
the stop plate in the subframe in the area of the retaining lugs.
– Tighten locating pins to 20 Nm.
• The position of the subframe is now fixed.
– Remove subframe bolt -1- on both sides.
Removing locating pins -T40329-

NOTICE
Risk of damage to threads in body due to improper handling.
– Never use an impact wrench to loosen or tighten.
– Fit bolts by hand only; make the first few turns by hand.

• Subframe bolts tightened.

– Unscrew locating pins, fit new bolts in their place and tighten.
– Equipment version with coil springs: Install springs (rear)
⇒ page 167 .
– Equipment version with air suspension: Charge air spring sys‐
tem ⇒ page 220 .

CAUTION
Risk of accident if bolts/nuts are not tightened as specified.
– Always tighten bolts/nuts as specified before driving the ve‐
hicle on public roads.

– Perform test drive after completing repair work. Wheel align‐

ment must be checked and adjusted if the steering wheel is
not straight ⇒ page 235 .
Tightening torques
♦ ⇒ “2.1 Exploded view - subframe”, page 124
♦ ⇒ Engine; Rep. gr. 26 ; Exhaust pipes/silencers; Exploded
view - silencers
♦ ⇒ General body repairs, exterior; Rep. gr. 66 ; Underbody
trim; Exploded view - underbody trim
♦ ⇒ General body repairs, exterior; Rep. gr. 66 ; Underbody
trim; Exploded view - underbody struts
♦ ⇒ “1 Wheels, tyres”, page 234

2.3 Removing and installing subframe

If the bolt securing the drive shaft/stub axle to the wheel hub has
to be slackened for subsequent operations, this must be done
with the vehicle standing on its wheels. Loosen bolt securing drive
shaft ⇒ page 194 .
Removing
– Fix position of subframe ⇒ page 125 .
– Remove brake calipers (rear) on both sides ⇒ Brake system;
Rep. gr. 46 ; Rear brakes; Removing and installing brake cal‐
iper .

2. Subframe 129
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– Depending on equipment version: Disconnect propshaft from

rear final drive and tie it up ⇒ Rear final drive; Rep. gr. 39 ;
Propshaft; Removing and installing propshaft .
– Depending on equipment version: Unplug electrical connec‐
tors -arrows- for rear wheel steering control unit - J1019- and
move electrical wiring clear.

Final drive 0D3 “quattro sport”:

– Remove bolts -arrows- and detach bracket -1- from rear final
drive.
– Unplug electrical connectors -2- for oil pressure and oil tem‐
perature sender and at clutch valves (mark allocation before
unplugging).
– Unplug electrical connector -4- at all-wheel drive pump -
V415- .
– Unclip electrical wiring harness -3- from final drive
-items 5, 6, 7- and tie up.

Final drive 0B0 “quattro ultra”:

– Unplug electrical connectors -1, 2-.
– Detach wiring guide from final drive and move electrical wiring
clear.

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All versions (continued):

– Depending on equipment version: Unplug electrical connector
-arrow- for rear vehicle level sender on both sides and move
wiring clear.

– Unplug electrical connector -1- (left and right) for speed sen‐
sor.

– Unscrew bolted connection -arrow- on left and right.

Equipment version with air suspension:

– Unscrew connection piece -arrow- on rear air spring (left and
right).
– Close both connections.
Note:
When unscrewing the air pipe from a component, check whether
the cutting ring is seated on the air pipe.

2. Subframe 131
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All versions (continued):

– Remove bolt -arrow- on both sides and move bracket -1- with
electrical wiring clear.
– Lower subframe using engine and gearbox jack - VAS 6931- ;
move SCR line clear at same time if necessary.
• When lowering the subframe, make sure there is enough
clearance to the surrounding components.
Installing
Installation is carried out in reverse order; note the following:
Note:
Cutting ring must be fitted to ensure that air pipe is fitted securely.
– Tighten subframe bolts in diagonal sequence (do not tighten
through specified angle yet).

CAUTION
Risk of accident if bolts/nuts are not tightened as specified.
– Always tighten bolts/nuts as specified before driving the ve‐
hicle on public roads.

– Install propshaft ⇒ Rear final drive; Rep. gr. 39 ; Propshaft;

Removing and installing propshaft .
– Install rear brake calipers ⇒ Brake system; Rep. gr. 46 ; Rear
brakes; Removing and installing brake caliper .
– Perform test drive after completing repair work. Wheel align‐
ment must be checked and adjusted if the steering wheel is
not straight ⇒ page 235 .
Tightening torques
♦ ⇒ “2.1 Exploded view - subframe”, page 124

2.4 Servicing subframe

⇒ “2.4.1 Renewing front hydraulic bonded rubber bush for sub‐
frame”, page 132
⇒ “2.4.2 Renewing rear bonded rubber bush for subframe”, page
136

2.4.1 Renewing front hydraulic bonded rubber

bush for subframe
• If a bonded rubber bush on one side is defective, the bush on
the other side must be renewed at the same time. For correct
version refer to ⇒ Electronic parts catalogue .
• Also check the other bushes before renewing a defective bon‐
ded rubber bush.
• If cracks, oil stains or other damage is visible, these bonded
rubber bushes must also be renewed.
Special tools and workshop equipment required

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♦ Torque wrench - V.A.G 1332-

♦ Hydraulic cylinder - VAS 6178-

♦ Foot pump - VAS 6179-

♦ Engine and gearbox jack - VAS 6931-

2. Subframe 133
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♦ Assembly tool - T10205A-

♦ Gearbox support - T10337-

♦ Assembly tool - T40328- (not illustrated)

Removing
– Remove rear wheels ⇒ page 234 .
– Equipment version with air suspension: Bleed air spring sys‐
tem ⇒ page 220 .
• The front part of the subframe is lowered in order to renew the
bonded rubber bushes. The subframe does not have to be re‐
moved.
• Do not lower the subframe more than 40 mm.
– Fit gearbox support - T10337- onto engine and gearbox jack
- VAS 6931- and position underneath subframe.

CAUTION
Risk of accident if vehicle is lowered or raised when engine and
gearbox jack is positioned underneath.
– Never raise or lower the vehicle when the engine and gear‐
box jack is underneath it.
– Never leave the engine and gearbox jack under the vehicle
for longer than necessary.

– Depending on equipment version: Remove diagonal struts ⇒

General body repairs, exterior; Rep. gr. 66 ; Underbody trim;
Exploded view - underbody struts .
– Remove silencers ⇒ Engine; Rep. gr. 26 ; Exhaust pipes/
silencers; Removing and installing silencers .

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– Using a screwdriver, prise locating element -2- off bonded

rubber bush on alternate sides in area of retaining lugs.
– Prise plastic insert -1- off bonded rubber bush.
– Mark installation position of hydraulic bonded rubber bush in
relation to subframe -arrows- using a felt-tip pen or similar.

– If necessary, unscrew small-diameter support -arrow- from

hydraulic press - VAS 6178- and screw in support T10205/13
in its place.
– If necessary, move electrical wiring clear.
– Only lower subframe as far as is necessary to apply special
tools.

– Set up special tools as shown.

1- Spindle -T10205/8-1-
2- Hydraulic cylinder - VAS 6178-
3- Support ring -T40328/3-
4- Tube -T40328/1-
5- Support ring -T40328/7- . Tapered end faces upwards and
projections engage in recesses in bonded rubber bush.
6- Thrust piece -T40328/10- . Recess faces towards bonded
rubber bush.
7- Nuts -T10205/8-2-

CAUTION
Risk of injury from falling parts when pressing out.
Risk of contusions.
– Hold hydraulic cylinder securely during pressing operation.

Installing
– Prise locating element -1- off new bonded rubber bush using
a screwdriver on alternate sides.
– Version with plastic insert: Prise plastic insert -2- off bonded
rubber bush.

2. Subframe 135
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– Set up special tools as shown.

1- Spindle -T10205/8-1-
2- Hydraulic cylinder - VAS 6178-
3- Support ring -T40328/6-
4- Thrust piece -T40328/8- . Projections must engage in re‐
cesses in bonded rubber bush
5- Bonded rubber bush. Installation position ⇒ page 125 .
6- Thrust piece -T40328/6-
7- Nuts -T10205/8-2-
– Align bonded rubber bush according to markings made earlier
and press in at the correct position until collar is flush with
subframe bushing.
• If necessary, slacken using foot pump - VAS 6179- and then
press home again.
• Ensure that the bonded rubber bush remains straight when
you begin pressing it in, otherwise the outer ring may be dam‐
aged.

• Ends of rubber beads on bonded rubber bush must align with

markings -arrows- made earlier on subframe.
• Repair any paint damage created on subframe with anti-cor‐
rosion coating, primer and black topcoat.
– Fit plastic insert and locating element on hydraulic bonded
rubber bush.
Remaining installation steps are the reverse of removal; note the
following:
– Equipment version with air suspension: Charge air spring sys‐
tem ⇒ page 220 .
Tightening torques
♦ ⇒ Engine; Rep. gr. 26 ; Exhaust pipes/silencers; Exploded
view - silencers
♦ ⇒ General body repairs, exterior; Rep. gr. 66 ; Underbody
trim; Exploded view - underbody struts
♦ ⇒ “1 Wheels, tyres”, page 234

2.4.2 Renewing rear bonded rubber bush for

subframe
Special tools and workshop equipment required
♦ Torque wrench - V.A.G 1332-

136 Rep. gr.42 - Rear suspension

 Audi A6 2019 ➤ , Audi A6 China 2019 ➤ , Audi A7 Sportback 2018 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 04.2019

♦ Hydraulic cylinder - VAS 6178-

♦ Foot pump - VAS 6179-

♦ Assembly tool - T10205A-

♦ Assembly tool - T40328- (not illustrated)

Removing
– Disconnect propshaft from rear final drive and tie it up ⇒ Rear
final drive; Rep. gr. 39 ; Propshaft; Removing and installing
propshaft .
– Depending on equipment version: Unplug electrical connector
-arrow- for rear vehicle level sender on both sides and move
wiring clear.

2. Subframe 137
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– Depending on equipment version: Unplug electrical connec‐

tors -arrows- for rear wheel steering control unit - J1019- and
move electrical wiring clear.

Final drive 0D3 “quattro sport”:

– Remove bolts -arrows- and detach bracket -1- from rear final
drive.
– Unplug electrical connectors -2- for oil pressure and oil tem‐
perature sender and at clutch valves (mark allocation before
unplugging).
– Unplug electrical connector -4- at all-wheel drive pump -
V415- .
– Unclip electrical wiring harness -3- from final drive
-items 5, 6, 7- and tie up.

Final drive 0B0 “quattro ultra”:

– Unplug electrical connectors -1, 2-.
– Detach wiring guide from final drive and move electrical wiring
clear.
All versions (continued):
– Depending on equipment version: Move SCR supply line
clear.

– Remove bolt -arrow- on both sides and move bracket -1- with
electrical wiring clear.
– Fix position of subframe ⇒ page 125 .
– Lower subframe by a maximum of 100 mm (in total).

138 Rep. gr.42 - Rear suspension

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– Using a screwdriver, prise locating element -2- off bonded

rubber bush on alternate sides in area of retaining lugs.
– Prise plastic insert -1- off bonded rubber bush.
– Mark installation position of hydraulic bonded rubber bush in
relation to subframe -arrows- using a felt-tip pen or similar.

– If necessary, unscrew small-diameter support -arrow- from

hydraulic press - VAS 6178- and screw in support T10205/13
in its place.

– Set up special tools as shown.

1- Spindle -T10205/8-1-
2- Hydraulic cylinder - VAS 6178-
3- Support ring -T40328/3-
4- Tube -T40328/1-
5- Support ring -T40328/2- . Tapered end faces upwards and
projections engage in recesses in bonded rubber bush.
6- Thrust piece -T40328/4-
7- Nuts -T10205/8-2-

CAUTION
Bonded rubber bush is released abruptly when it is pressed out
- risk of injury.
Risk of contusions.
– Hold hydraulic cylinder securely during pressing operation.
– Secure tools by placing engine and gearbox jack under‐
neath.

2. Subframe 139
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Installing
– Using a screwdriver, prise locating element -1- off new bonded
rubber bush on alternate sides in area of retaining lugs
-arrows-.
– Prise plastic insert off bonded rubber bush.

– Set up special tools as shown.

1- Spindle -T10205/8-1-
2- Hydraulic cylinder - VAS 6178-
3- Thrust piece -T40328/5-
4- Bonded rubber bush
5- Thrust piece -T40328/6-
6- Nuts -T10205/8-2-
– Align bonded rubber bush according to markings made earlier
and press in at the correct position until collar is flush with
subframe bushing.
• If necessary, slacken cylinder and then press home again.
• Ensure that the bonded rubber bush remains straight when
you begin pressing it in, otherwise the outer ring may be dam‐
aged.

• Ends of rubber beads on bonded rubber bush must align with

markings -arrows- made earlier on subframe.
• Repair any paint damage created on subframe with anti-cor‐
rosion coating, primer and black topcoat.
– Fit plastic insert -1- and locating element -2- on hydraulic bon‐
ded rubber bush.
Remaining installation steps are the reverse of removal; note the
following:
– Remove locating pins -T40329- ⇒ page 125 .
– Install propshaft ⇒ Rear final drive; Rep. gr. 39 ; Propshaft;
Removing and installing propshaft .

2.4.3 Removing and installing rear bonded

rubber bushes for rear final drive
Special tools and workshop equipment required

140 Rep. gr.42 - Rear suspension

 Audi A6 2019 ➤ , Audi A6 China 2019 ➤ , Audi A7 Sportback 2018 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 04.2019

♦ Assembly tool - T40032-

♦ Assembly tool - T40033-

Removing
• Rear final drive removed ⇒ Rear final drive; Rep. gr. 39 ; Final
drive; Removing and installing final drive .
– Depending on equipment version: Unscrew bolts -arrows-,
lower rear wheel steering rack slightly and secure it in place.

– Set up assembly tool - T40032- and assembly tool - T40033-

at bonded rubber bush and subframe, as shown.
– Pull bonded rubber bush out of subframe.

2. Subframe 141
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Installing
– Set up assembly tool - T40032- and assembly tool - T40033-
at bonded rubber bush -arrow- and subframe, as shown.
– Pull bonded rubber bush into subframe as far as stop.

142 Rep. gr.42 - Rear suspension

 Audi A6 2019 ➤ , Audi A6 China 2019 ➤ , Audi A7 Sportback 2018 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 04.2019

3 Anti-roll bar
⇒ “3.1 Exploded view - anti-roll bar”, page 143
⇒ “3.2 Removing and installing anti-roll bar”, page 143
⇒ “3.3 Removing and installing coupling rod”, page 145

3.1 Exploded view - anti-roll bar

1 - Bolt
❑ Renew after removing
❑ Tighten in unladen posi‐
tion ⇒ page 9 or at nor‐
mal level ⇒ page 12
❑ 25 Nm +90°
2 - Anti-roll bar
❑ With rubber bush (can‐
not be renewed sepa‐
rately)
❑ Removing and installing
⇒ “3.2 Removing and in‐
stalling anti-roll bar”,
page 143
3 - Subframe
4 - Nut
❑ Renew after removing
5 - Upper transverse link (front)
6 - Bolt
❑ Renew after removing
❑ Tighten in unladen posi‐
tion ⇒ page 9 or at nor‐
mal level ⇒ page 12
❑ 40 Nm +180°
7 - Coupling rod
❑ Removing and installing
⇒ page 145
8 - Bolt
❑ Renew after removing
❑ Tighten in unladen posi‐
tion ⇒ page 9 or at nor‐
mal level ⇒ page 12
❑ 40 Nm +180°
9 - Nut
❑ Renew after removing

3.2 Removing and installing anti-roll bar

Special tools and workshop equipment required

3. Anti-roll bar 143

 Audi A6 2019 ➤ , Audi A6 China 2019 ➤ , Audi A7 Sportback 2018 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 04.2019

♦ Torque wrench - V.A.G 1331-

♦ Bit XZN 10 - T10501-

Removing
Before commencing work:
– Equipment version with coil springs: ascertain unladen posi‐
tion ⇒ page 242 .
– Equipment version with air suspension: ascertain normal level
⇒ page 244 .
– Depending on equipment version: Remove diagonal struts ⇒
General body repairs, exterior; Rep. gr. 66 ; Underbody trim;
Exploded view - underbody struts .
– Remove bolts -arrows- on both sides.
– Separate bolted connection -1- on both sides and detach anti-
roll bar -2-.
Installing
Installation is carried out in reverse order; note the following:
– Screw in bolts for anti-roll bar initially until they make contact,
but do not tighten to final torque yet.
• Bonded rubber bushes can only be turned to a limited extent.
The suspension mountings must therefore only be tightened
when the suspension is at the normal level.
– Lift suspension to unladen position ⇒ page 9 or normal level
⇒ page 12 .
Tightening torques
♦ ⇒ “3.1 Exploded view - anti-roll bar”, page 143
♦ ⇒ Engine; Rep. gr. 26 ; Exhaust pipes/silencers; Exploded
view - silencers
♦ ⇒ General body repairs, exterior; Rep. gr. 66 ; Underbody
trim; Exploded view - underbody struts

144 Rep. gr.42 - Rear suspension

 Audi A6 2019 ➤ , Audi A6 China 2019 ➤ , Audi A7 Sportback 2018 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 04.2019

3.3 Removing and installing coupling rod

Special tools and workshop equipment required
♦ Torque wrench - V.A.G 1331-

Removing
Before commencing work:
– Equipment version with coil springs: ascertain unladen posi‐
tion ⇒ page 242 .
– Equipment version with air suspension: ascertain normal level
⇒ page 244 .
– Remove bolts -1, 2- and detach coupling rod -3-.
Installing
Installation is carried out in reverse order; note the following:
– Screw in bolts for coupling rod initially until they make contact,
but do not tighten to final torque yet.
• Bonded rubber bushes can only be turned to a limited extent.
The suspension mountings must therefore only be tightened
when the suspension is at the normal level.
– Lift suspension to unladen position ⇒ page 9 or normal level
⇒ page 12 .
Tightening torques
♦ ⇒ “3.1 Exploded view - anti-roll bar”, page 143

3. Anti-roll bar 145

 Audi A6 2019 ➤ , Audi A6 China 2019 ➤ , Audi A7 Sportback 2018 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 04.2019

4 Suspension links, track rod

⇒ “4.1 Exploded view - transverse links”, page 146
⇒ “4.2 Removing and installing upper transverse links”,
page 149
⇒ “4.3 Removing and installing wind deflector”, page 153
⇒ “4.4 Removing and installing lower transverse links”,
page 154
⇒ “4.5 Removing and installing track rod”, page 158

4.1 Exploded view - transverse links

♦ Upper transverse links ⇒ page 146
♦ Installation position of transverse link and track rod
⇒ page 147
♦ Lower transverse links ⇒ page 147
♦ Installation position of buffer ⇒ page 149
Upper transverse links

1 - Bolt
❑ Renew after removing
❑ Tighten in unladen posi‐
tion ⇒ page 9 or at nor‐
mal level ⇒ page 12
❑ 70 Nm +180°
2 - Upper transverse link (front)
❑ Removing and installing
⇒ page 149
❑ Installation position
⇒ page 147
3 - Eccentric bolt
4 - Subframe
5 - Bolt
❑ Renew after removing
❑ Tighten in unladen posi‐
tion ⇒ page 9 or at nor‐
mal level ⇒ page 12
❑ 40 Nm +180°
6 - Flange nut
❑ Renew after removing
7 - Flange nut
❑ Renew after removing
8 - Bolt
❑ Renew after removing
❑ Tighten in unladen posi‐
tion ⇒ page 9 or at nor‐
mal level ⇒ page 12
❑ 70 Nm +180°
9 - Upper transverse link (rear)
❑ Removing and installing ⇒ page 150

146 Rep. gr.42 - Rear suspension

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Running gear, front-wheel drive and four-wheel drive - Edition 04.2019

❑ Installation position ⇒ page 147

10 - Eccentric washer
11 - Nut
❑ Renew after removing
❑ Tighten in unladen position ⇒ page 9 or at normal level ⇒ page 12
❑ 110 Nm
12 - Bolt
❑ Renew after removing
❑ Tighten in unladen position ⇒ page 9 or at normal level ⇒ page 12
❑ 100 Nm +180°
13 - Bolt
❑ Renew after removing
❑ Tighten in unladen position ⇒ page 9 or at normal level ⇒ page 12
❑ 100 Nm +180°
14 - Track rod
❑ If track rod is deformed, rear wheel steering rack must be renewed additionally
❑ Removing and installing ⇒ page 158
❑ Installation position ⇒ page 147
15 - Nut
❑ Renew after removing
16 - Wheel bearing housing

Installation position of transverse link and track rod

• The tapered side -2- of the transverse link and the track rod
must engage in the wheel bearing housing -1-.

Lower transverse links

4. Suspension links, track rod 147

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Running gear, front-wheel drive and four-wheel drive - Edition 04.2019

1 - Flange nut
❑ Renew after removing
2 - Lower transverse link (front)
❑ Removing and installing
⇒ page 157
❑ Installation position
⇒ page 147
3 - Bolt
❑ Renew after removing
❑ Tighten in unladen posi‐
tion ⇒ page 9 or at nor‐
mal level ⇒ page 12
❑ 40 Nm +180°
4 - Wind deflector
❑ Different versions. For
correct version refer to
⇒ Electronic parts cata‐
logue
❑ Removing and installing
⇒ page 153
5 - Spreader rivet
6 - Buffer
❑ Renew if damaged
❑ Installation position
⇒ page 149
7 - Eccentric bolt
8 - Subframe
9 - Nut
❑ Renew after removing
❑ Tighten in unladen posi‐
tion ⇒ page 9 or at nor‐
mal level ⇒ page 12
❑ 160 Nm
10 - Eccentric washer
11 - Lower transverse link (rear)
❑ Removing and installing ⇒ page 154
12 - Bolt
❑ Renew after removing
13 - Nut
❑ Renew after removing
❑ Tighten in unladen position ⇒ page 9 or at normal level ⇒ page 12
❑ 130 Nm +180°
14 - Wheel bearing housing
15 - Bolt
❑ Renew after removing
❑ Tighten in unladen position ⇒ page 9 or at normal level ⇒ page 12
❑ 70 Nm +180°

148 Rep. gr.42 - Rear suspension

 Audi A6 2019 ➤ , Audi A6 China 2019 ➤ , Audi A7 Sportback 2018 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 04.2019

Installation position of buffer

• Installation is only permissible on vehicles without diagonal
strut.
– Fit buffer on lower transverse link (rear) and align it.

4.2 Removing and installing upper trans‐

verse links
⇒ “4.2.1 Removing and installing upper transverse link (front)”,
page 149
⇒ “4.2.2 Removing and installing upper transverse link (rear)”,
page 150

4.2.1 Removing and installing upper trans‐

verse link (front)
Special tools and workshop equipment required
♦ Torque wrench - V.A.G 1332-

Removing
Before commencing work:
– Equipment version with coil springs: ascertain unladen posi‐
tion ⇒ page 242 .
– Equipment version with air suspension: ascertain normal level
⇒ page 244 .
– Remove rear wheel ⇒ page 234 .

4. Suspension links, track rod 149

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Running gear, front-wheel drive and four-wheel drive - Edition 04.2019

– Remove bolts -1, 2, 3, 5- and detach upper transverse link

-4-.
Installing
Installation is carried out in reverse order; note the following:
– Screw in bolts initially until they make contact, but do not tight‐
en to final torque yet.
• Bonded rubber bushes can only be turned to a limited extent.
The suspension mountings must therefore only be tightened
when the suspension is at the normal level.
– Lift suspension to unladen position ⇒ page 9 or normal level
⇒ page 12 .
• Overview table: when does wheel alignment have to be
checked? ⇒ page 238
Tightening torques
♦ ⇒ “4.1 Exploded view - transverse links”, page 146
♦ ⇒ “3.1 Exploded view - anti-roll bar”, page 143
♦ ⇒ “1 Wheels, tyres”, page 234

4.2.2 Removing and installing upper trans‐

verse link (rear)
Special tools and workshop equipment required
♦ Torque wrench - V.A.G 1332-

♦ Engine and gearbox jack - VAS 6931-

150 Rep. gr.42 - Rear suspension

 Audi A6 2019 ➤ , Audi A6 China 2019 ➤ , Audi A7 Sportback 2018 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 04.2019

♦ Gearbox support - T10337-

♦ Socket, XZN 14 mm - T40312- (not illustrated)

Removing
Before commencing work:
– Equipment version with coil springs: ascertain unladen posi‐
tion ⇒ page 242 .
– Equipment version with air suspension: ascertain normal level
⇒ page 244 .
– Remove rear wheel ⇒ page 234 .
– Equipment version with 3.0 ltr. TFSI engine: Remove silencer
⇒ Engine; Rep. gr. 26 ; Exhaust pipes/silencers; Removing
and installing silencers .
– Equipment version with 3.0 ltr. TDI engine: Remove silencer
⇒ Engine; Rep. gr. 26 ; Exhaust pipes/silencers; Removing
and installing silencers .
– Fit gearbox support - T10337- onto engine and gearbox jack
- VAS 6931- and position underneath subframe.

CAUTION
Risk of accident if vehicle is lowered or raised when engine and
gearbox jack is positioned underneath.
– Never raise or lower the vehicle when the engine and gear‐
box jack is underneath it.
– Never leave the engine and gearbox jack under the vehicle
for longer than necessary.

– Unscrew bolt -arrow- and lower subframe by no more than 12

mm.

4. Suspension links, track rod 151

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Running gear, front-wheel drive and four-wheel drive - Edition 04.2019

– Detach bolt connection -3-.

– Remove bolt -1- and detach upper transverse link -2-.
Installing
Installation is carried out in reverse order; note the following:
• Installation position ⇒ page 147 .
– Screw in bolts initially until they make contact, but do not tight‐
en to final torque yet.
• Bonded rubber bushes can only be turned to a limited extent.
The suspension mountings must therefore only be tightened
when the suspension is at the normal level.
– Lift suspension to unladen position ⇒ page 9 or normal level
⇒ page 12 .

– Tighten bolt -arrow- to 40 Nm.

– Firmly tighten bolt -3- using socket, XZN 14 mm - T40312- and

an open-end spanner.
– Tighten bolt -1-.

152 Rep. gr.42 - Rear suspension

 Audi A6 2019 ➤ , Audi A6 China 2019 ➤ , Audi A7 Sportback 2018 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 04.2019

– Fit gearbox support - T10337- onto engine and gearbox jack

- VAS 6931- and position underneath subframe.

CAUTION
Risk of accident if vehicle is lowered or raised when engine and
gearbox jack is positioned underneath.
– Never raise or lower the vehicle when the engine and gear‐
box jack is underneath it.
– Never leave the engine and gearbox jack under the vehicle
for longer than necessary.

– Unscrew bolt -arrow- and lower subframe by no more than 12

mm.
– Tighten bolt for upper transverse link.
– Install subframe ⇒ page 129 (renew bolt when doing so).
• Overview table: when does wheel alignment have to be
checked? ⇒ page 238
Tightening torques
♦ ⇒ “2.1 Exploded view - subframe”, page 124
♦ ⇒ “4.1 Exploded view - transverse links”, page 146
♦ ⇒ Engine; Rep. gr. 26 ; Exhaust pipes/silencers; Exploded
view - silencers
♦ ⇒ “1 Wheels, tyres”, page 234

4.3 Removing and installing wind deflector

⇒ “4.3.1 Removing and installing wind deflector - equipment ver‐
sion with securing pin with catches”, page 153
⇒ “4.3.2 Removing and installing wind deflector - equipment ver‐
sion with securing pin with retaining element”, page 154

4.3.1 Removing and installing wind deflector -

equipment version with securing pin
with catches
Removing
– Press catches together -arrows- and pull securing pins -1- out
slightly.
– Detach securing pins and wind deflector.
Installing
Installation is carried out in reverse sequence.

4. Suspension links, track rod 153

 Audi A6 2019 ➤ , Audi A6 China 2019 ➤ , Audi A7 Sportback 2018 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 04.2019

4.3.2 Removing and installing wind deflector -

equipment version with securing pin
with retaining element
Removing
– Release retaining elements in direction of -arrow-.
– Pull securing pins -1- out slightly.
– Detach rear section of wind deflector -2- downwards from
transverse link.
– Detach wind deflector -2- together with securing pins -1-.
Installing
Installation is carried out in reverse order; note the following:

Make sure the retaining element is installed in the correct position.

4.4 Removing and installing lower trans‐

verse links
⇒ “4.4.1 Removing and installing lower transverse link (rear)”,
page 154
⇒ “4.4.2 Removing and installing lower transverse link (front)”,
page 157

4.4.1 Removing and installing lower trans‐

verse link (rear)
Special tools and workshop equipment required

154 Rep. gr.42 - Rear suspension

 Audi A6 2019 ➤ , Audi A6 China 2019 ➤ , Audi A7 Sportback 2018 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 04.2019

♦ Torque wrench - V.A.G 1332-

♦ Engine and gearbox jack - VAS 6931-

♦ Support - T10149-

♦ 12-point socket, 21 mm (commercially available)

Removing
– Remove rear wheel ⇒ page 234 .
Equipment version with coil springs:
– Determine unladen position ⇒ page 242 .
– Remove spring ⇒ page 167 .
Equipment version with air suspension:
– Determine normal level ⇒ page 244 .
– Bleed air spring system ⇒ page 220 .
All versions (continued):
– Depending on equipment version: Remove diagonal strut ⇒
General body repairs, exterior; Rep. gr. 66 ; Underbody trim;
Exploded view - underbody struts .
– Detach wind deflector from transverse link ⇒ page 153 .

4. Suspension links, track rod 155

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Running gear, front-wheel drive and four-wheel drive - Edition 04.2019

– Turn wheel hub until one of the wheel bolt holes is at the top.
– Attach support - T10149- to wheel hub using wheel bolt -2-.
– Use engine and gearbox jack - T10149- attached to support -
VAS 6931- to raise wheel bearing housing slightly so that bolts
can be removed more easily.

CAUTION
Risk of accident if vehicle is lowered or raised when engine and
gearbox jack is positioned underneath.
– Never raise or lower the vehicle when the engine and gear‐
box jack is underneath it.
– Never leave the engine and gearbox jack under the vehicle
for longer than necessary.

– Equipment version with air suspension: Release fasteners

-arrows-, move air spring -3- clear at lower transverse link
-1- and tie it up.

– Remove bolts -1, 3, 4- and detach lower transverse link -2-.

Installing
Installation is carried out in reverse order; note the following:
– Screw in bolts initially until they make contact, but do not tight‐
en to final torque yet.
• Bonded rubber bushes can only be turned to a limited extent.
The suspension mountings must therefore only be tightened
when the suspension is in the unladen position or normal level.
– Lift suspension to unladen position ⇒ page 9 or normal level
⇒ page 12 .
– Install buffer if necessary ⇒ page 149 .
– Equipment version with coil springs: Install springs
⇒ page 167 .

– Equipment version with air suspension: Charge air spring sys‐

tem ⇒ page 220 .
• Overview table: when does wheel alignment have to be
checked? ⇒ page 238
Tightening torques
♦ ⇒ “4.1 Exploded view - transverse links”, page 146
♦ ⇒ General body repairs, exterior; Rep. gr. 66 ; Underbody
trim; Exploded view - underbody struts

156 Rep. gr.42 - Rear suspension

 Audi A6 2019 ➤ , Audi A6 China 2019 ➤ , Audi A7 Sportback 2018 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 04.2019

4.4.2 Removing and installing lower trans‐

verse link (front)
Special tools and workshop equipment required
♦ Torque wrench - V.A.G 1332-

♦ Engine and gearbox jack - VAS 6931-

♦ Support - T10149-

Removing
Before commencing work:
– Equipment version with coil springs: ascertain unladen posi‐
tion ⇒ page 242 .
– Equipment version with air suspension: ascertain normal level
⇒ page 244 .
– Remove rear wheel ⇒ page 234 .

4. Suspension links, track rod 157

 Audi A6 2019 ➤ , Audi A6 China 2019 ➤ , Audi A7 Sportback 2018 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 04.2019

– Turn wheel hub until one of the wheel bolt holes is at the top.
– Attach support - T10149- to wheel hub using wheel bolt -2-.
– Use engine and gearbox jack - T10149- attached to support -
VAS 6931- to raise wheel bearing housing slightly so that bolts
can be removed more easily.

CAUTION
Risk of accident if vehicle is lowered or raised when engine and
gearbox jack is positioned underneath.
– Never raise or lower the vehicle when the engine and gear‐
box jack is underneath it.
– Never leave the engine and gearbox jack under the vehicle
for longer than necessary.

– Unscrew bolt -3-, separate bolted connection -1- and remove

lower transverse link -2-.
Installing
Installation is carried out in reverse order; note the following:
• Installation position ⇒ page 147 .
– Screw in bolts initially until they make contact, but do not tight‐
en to final torque yet.
• Bonded rubber bushes can only be turned to a limited extent.
The suspension mountings must therefore only be tightened
when the suspension is at the normal level.
– Lift suspension to unladen position ⇒ page 9 or normal level
⇒ page 12 .
• Overview table: when does wheel alignment have to be
checked? ⇒ page 238
Tightening torques
♦ ⇒ “4.1 Exploded view - transverse links”, page 146
♦ ⇒ “1 Wheels, tyres”, page 234

4.5 Removing and installing track rod

Special tools and workshop equipment required
♦ Torque wrench - V.A.G 1332-

158 Rep. gr.42 - Rear suspension

 Audi A6 2019 ➤ , Audi A6 China 2019 ➤ , Audi A7 Sportback 2018 ➤
Running gear, front-wheel drive and four-wheel drive - Edition 04.2019

♦ Engine and gearbox jack - VAS 6931-

♦ Support - T10149-

♦ Multi-point socket, 21 mm (commercially available)

Removing
Before commencing work:
– Equipment version with coil springs: ascertain unladen posi‐
tion ⇒ page 242 .
– Equipment version with air suspension: ascertain normal level
⇒ page 244 .
– Remove rear wheel ⇒ page 234 .
– Turn wheel hub until one of the wheel bolt holes is at the top.
– Attach support - T10149- to wheel hub using wheel bolt -2-.
– Use engine and gearbox jack - T10149- attached to support -
VAS 6931- to raise wheel bearing housing slightly so that bolts
can be removed more easily.

CAUTION
Risk of accident if vehicle is lowered or raised when engine and
gearbox jack is positioned underneath.
– Never raise or lower the vehicle when the engine and gear‐
box jack is underneath it.
– Never leave the engine and gearbox jack under the vehicle
for longer than necessary.

4. Suspension links, track rod 159

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Running gear, front-wheel drive and four-wheel drive - Edition 04.2019

– Remove bolt -1-, detach bolted connection -3- and detach

track control link -2-.
Installing
Installation is carried out in reverse order; note the following:
• If track rod is deformed, rear wheel steering rack must also be
renewed ⇒ page 293 .
– Screw in bolts initially until they make contact, but do not tight‐
en to final torque yet.
• Bonded rubber bushes can only be turned to a limited extent.
The suspension mountings must therefore only be tightened
when the suspension is at the normal level.
– Lift suspension to normal level ⇒ page 12 .
• Overview table: when does wheel alignment have to be
checked? ⇒ page 238
Tightening torques
♦ ⇒ “4.1 Exploded view - transverse links”, page 146
♦ ⇒ “1 Wheels, tyres”, page 234

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5 Suspension strut/shock absorber,

spring
⇒ “5.1 Exploded view - suspension strut/shock absorber, spring”,
page 161
⇒ “5.2 Removing and installing shock absorber”, page 165
⇒ “5.3 Removing and installing spring”, page 167

5.1 Exploded view - suspension strut/shock

absorber, spring
⇒ “5.1.1 Coil spring - exploded view”, page 161
⇒ “5.1.2 Exploded view - air spring”, page 162
⇒ “5.1.3 Exploded view - shock absorber”, page 163

5.1.1 Coil spring - exploded view

1 - Lower transverse link (rear)

❑ Removing and installing
⇒ page 154
❑ If surface of transverse
link is damaged due to
coil spring breakage,
transverse link must be
renewed
2 - Coil spring
❑ Removing and installing
⇒ page 167
❑ Installation position
⇒ page 162
3 - Top spring seat
❑ Installation position
⇒ page 162
4 - Bottom spring seat
❑ Installation position
⇒ page 162

5. Suspension strut/shock absorber, spring 161

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Installation position of coil spring and spring plate

• Position spring -2- so that sticker -4- is at upper end of spring.
• The end of the spring -2- must be positioned against the stop
on the spring seat (bottom) -1- -arrow-.
• The positioning tabs on the spring seat must engage in the
holes in the body -3- at the top, and in the holes in the trans‐
verse link (rear) -5- at the bottom.
Note:
If the sticker -4- is no longer attached, the position of the spring
can be determined by a coloured marking at the top end of the
spring.

5.1.2 Exploded view - air spring

1 - Lower transverse link (rear)

2 - Air spring
❑ Removing and installing
⇒ page 174
❑ Installation position
⇒ page 163
3 - O-ring
❑ Renew if leakage oc‐
curs
4 - Air pipe
❑ If the connection piece
is removed individually
(without the connected
pipe), check if the cut‐
ting ring is still loose in
the thread and take it out
if necessary
❑ Cutting ring must be fit‐
ted to ensure that air
pipe is fitted securely
❑ Tightening torque for
connection piece
⇒ page 215

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Installation position of air spring

Note

♦ When charging empty or newly installed air springs on the rear

axle, ensure that both positioning tabs on the air springs en‐
gage in the vehicle body at the top.
♦ Throughout the entire charging process, monitor whether the
positioning tabs are engaged at the top.
♦ Ensure that the top part of the air springs makes full contact
with the vehicle body during the charging process.

– Installing and charging the air spring:

• The catches -arrows- must engage audibly in the lower trans‐
verse link (rear).
• The catches must engage with the locking element -1-.
• During charging, engage positioning tabs at top of air spring
-2- in hole in vehicle body -3-.

5.1.3 Exploded view - shock absorber

1 - Nut
❑ Renew after removing
❑ Tighten in unladen posi‐
tion ⇒ page 9
❑ 70 Nm +180°
2 - Lower transverse link (rear)
3 - Shock absorber
❑ Different versions; for
correct version refer to
⇒ Electronic parts cata‐
logue
❑ Removing and installing
⇒ page 165
❑ Degas and drain defec‐
tive shock absorbers
before disposal
⇒ page 15
❑ Checking shock absorb‐
er following removal
⇒ page 4
❑ For equipment version
with electronic damping
control: Re-adapt refer‐
ence position after re‐
newing ⇒ Vehicle diag‐
nostic tester
4 - Cover
❑ For equipment version
with electronic damping
control: With fastener
for electrical wire
5 - Nut
❑ Renew after removing
❑ 35 Nm

5. Suspension strut/shock absorber, spring 163

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6 - Shock absorber mounting

❑ Removing and installing ⇒ page 165
7 - Bolt
❑ Renew after removing
❑ 50 Nm +90°
8 - Auxiliary spring
❑ Installation position ⇒ page 164
❑ Pressing in ⇒ page 164
9 - Protective sleeve
❑ Clipped into groove on auxiliary spring
10 - Bolt
❑ Renew after removing

Installation position of auxiliary spring

A - Installation depth -arrows- incorrect
B - Installation depth -arrows- correct

Pressing in auxiliary spring

• Shock absorber installed.
• Rear wheel installed.
– Press auxiliary spring -1- into shock absorber mounting -2- as
far as stop using special tool -T40401- -arrow-.

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Removing and installing shock absorber mounting

• Shock absorber removed
Equipment version with electronic damping control:
– Move electrical wire clear at cover.
– Release contacts and detach connector housing from electri‐
cal wire ⇒ Electrical system; General information; Rep. gr.
97 ; Releasing and dismantling connector housings .
– Disconnect wiring duct from nut.
All versions (continued):
– Set up special tools as shown.
1- Tool insert - T10001/3-
2- Ring spanner insert - V.A.G 1332/7-
3- Counterhold tool - T40255-
4- Electrical wire
5- Ring spanner
6- Torque wrench - V.A.G 1331-
7- Shock absorber mounting
Tightening torques
♦ ⇒ “5.1.3 Exploded view - shock absorber”, page 163

5.2 Removing and installing shock absorber

Because of the different shock absorber valve systems, shock
absorbers on both sides of an axle should always be from the
same manufacturer whenever possible.
Special tools and workshop equipment required
♦ Torque wrench - V.A.G 1331-

♦ Torque wrench - V.A.G 1332-

5. Suspension strut/shock absorber, spring 165

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♦ Engine and gearbox jack - VAS 6931-

♦ Support - T10149-

Removing
Before commencing work:
– Determine unladen position ⇒ page 242 .
– Remove rear wheel ⇒ page 234 .
– Remove wheel housing liner (rear) ⇒ General body repairs,
exterior; Rep. gr. 66 ; Wheel housing liners; Exploded view -
wheel housing liner (rear) .
– Detach wind deflector from transverse link ⇒ page 153 .
– Turn wheel hub until one of the wheel bolt holes is at the top.
– Attach support - T10149- to wheel hub using wheel bolt -2-.
– Fit support - T10149- in engine and gearbox jack - VAS 6931-
and raise wheel bearing housing slightly.

CAUTION
Risk of accident if vehicle is lowered or raised when engine and
gearbox jack is positioned underneath.
– Never raise or lower the vehicle when the engine and gear‐
box jack is underneath it.
– Never leave the engine and gearbox jack under the vehicle
for longer than necessary.

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– On appropriate version: Unplug electrical connector -1-.

– Remove bolts -arrows- securing shock absorber at top.

– Remove bolt -1- and detach shock absorber -2-.

Installing
Installation is carried out in reverse order; note the following:
– Screw in bolts initially until they make contact, but do not tight‐
en to final torque yet.
• Bonded rubber bushes can only be turned to a limited extent.
The suspension mountings must therefore only be tightened
when the suspension is in the unladen position.
– Lifting suspension to unladen position ⇒ page 9
• Overview table: when does wheel alignment have to be
checked? ⇒ page 238
Tightening torques
♦ ⇒ “5.1.3 Exploded view - shock absorber”, page 163
♦ ⇒ General body repairs, exterior; Rep. gr. 66 ; Wheel housing
liners; Exploded view - wheel housing liner (rear)
♦ ⇒ “1 Wheels, tyres”, page 234

5.3 Removing and installing spring

⇒ “5.3.1 Removing and installing coil spring”, page 167
⇒ “5.3.2 Removing and installing air spring”, page 174

5.3.1 Removing and installing coil spring

Special tools and workshop equipment required
♦ Foot pump - VAS 6179-

5. Suspension strut/shock absorber, spring 167

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♦ Spring compressing system - VAS 6274-

♦ Centring sleeve, 130 mm long -item 5- from supplementary set

- VAS 6274/10-

♦ Supplementary set - VAS 6274/12- (not illustrated)

Removing
– Remove rear wheel ⇒ page 234 .
– Detach wind deflector from transverse link ⇒ page 153 .
– Unbolt drive shaft from rear final drive and tie it up towards
front ⇒ page 192 .
– Position spreader device (comprised of -VAS 6274/8- and -
VAS 6274/12-5- ) as shown between upper transverse link
(front) -1- and longitudinal member, and apply light pressure.

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– Press locking plate -2- outwards -arrow A- to open.

– Insert thrust plate with securing plate - VAS 6274/12-2- from
outside into coil spring -1-, as shown.
– Insert plunger, 89 mm - VAS 6274/12-7- with T-bar - VAS
6274/5- into thrust plate and turn 90° until line marking -3- on
thrust plate is aligned with line marking -4- on plunger.
– Pull plunger downwards into thrust plate and secure with lock‐
ing plate -arrow B- to close.
– Detach T-bar - VAS 6274/5- .

NOTICE
Risk of damage to spindle if it is not lubricated or if the incorrect
lubricant is used.
– Observe the following instructions for handling the spindle.

• Before removing and installing any of the springs, always lu‐

bricate the front of the spindle - VAS 6274/3- -item 2- lightly
with the grease supplied -1-.

– Insert thrust plate with swivel mounting - VAS 6274/12-1- from

outside into coil spring -arrow-, as shown.
– Lightly lubricate front of spindle - VAS 6274/3- and use socket
- VAS 6274/6- to screw it loosely into plunger - VAS
6274/12-7- .

5. Suspension strut/shock absorber, spring 169

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CAUTION
Risk of injury if locating brackets are not secured correctly.
– Never compress or release coil spring if locating brackets
have not been secured.

• Locating brackets -2- and -5- must be secured to each other

with two bolts -3-.
– Screw thrust plate with securing plate - VAS 6274/12-2- all the
way up, and screw thrust plate with swivel mounting - VAS
6274/12-1- all the way down.
– Bolt locating brackets -2- and -5- to the two thrust plates
-arrows-.
• The locating brackets face forwards.
Note:
The attachment point of the locating brackets to the thrust plates
differs depending on the type of running gear.
– Screw in bolts -3- for locating brackets of the two thrust plates
hand-tight with lock plate -4-.
– First pre-tension thrust plates slightly using spindle - VAS
6274/3- .
– Check that coil spring -1- is correctly seated in thrust plates.

NOTICE
Risk of damage to thread on spindle due to improper handling.
– Never use an impact wrench to tighten or loosen spindle.
– Only use a standard commercially available ratchet to turn
the spindle.

• The thrust plates of the tensioning device must not make con‐
tact with the shock absorbers and drive shafts when com‐
pressing the coil springs. Rotate the thrust plates if necessary.

– Compress coil spring with socket - VAS 6274/6- (use coun‐

terhold tool - VAS 6274/7- ).
– Compress coil spring until it can be removed.
– If necessary for subsequent work, detach spreader device -
VAS 6274/8- with -VAS 6274/12-5- .

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Release coil spring in hydraulic tensioning device -VAS 6274/9- :

CAUTION
Risk of injury in the event of improper handling.
– Release coil spring in hydraulic tensioning device only.
– Check that hydraulic tensioning device has been assembled
according to specifications before use.

– Check that nuts -arrows- are fitted securely and tighten if nec‐
essary.

– Fit spring plate - VAS 6274/12-3- onto hydraulic tensioning

device - VAS 6274/9- .
– Position bottom end of compressed coil spring -2- onto spring
plate.
• End of spring coil must make contact with stop -arrow- of
spring plate.
– Extend plunger -1- of hydraulic tensioning device all the way
towards coil spring, but do not apply tension.

– Mark position of plunger -1- on hydraulic tensioning device -

VAS 6274/9- -arrow A- using a waterproof felt-tip pen or sim‐
ilar.
– Mark position of locating brackets -2- on coil spring -3-
-arrow B- using a waterproof felt-tip pen or similar.
Note:
The markings will be needed when compressing the spring during
installation.

NOTICE
Risk of damage to thread on spindle due to improper handling.
– Never use an impact wrench to tighten or loosen spindle.
– Only use a standard commercially available ratchet to turn
the spindle.

– Use socket - VAS 6274/6- to slacken coil spring completely

with hydraulic tensioning device.

5. Suspension strut/shock absorber, spring 171

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– Detach spindle - VAS 6274/3- after slackening coil spring -1-.

– Remove bolts -2- from locating bracket and detach lock plate
-3-.
– Take out thrust plate with swivel mounting - VAS 6274/12-1- .

– Press locking plate -1- outwards -arrow B- to open.

– Remove plunger - VAS 6274/12-7- with T-bar - VAS 6274/5-
from thrust plate with securing plate - VAS 6274/12-2- .
– Remove thrust plate from coil spring -2-.
• If you intend to subsequently remove the coil spring on the
opposite side of the vehicle, the installation position and fas‐
tening point of the locating brackets to the thrust plates must
be marked for later installation.
• If renewing the coil spring, transfer the marking to the new coil
spring.

Installing
Installation is carried out in reverse order; note the following:
– Fit coil spring -1- into hydraulic tensioning device - VAS
6274/9- .
• Bottom end of coil spring must make contact with stop
-arrow- of spring plate -VAS 6274/12-3- .

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– Insert thrust plate with securing plate - VAS 6274/12-2- into

coil spring -2-, as shown.
– Press locking plate -1- outwards -arrow B- to open.
– Insert plunger, 89 mm - VAS 6274/12-7- with T-bar - VAS
6274/5- into thrust plate and turn 90° until line marking -4- on
thrust plate is aligned with line marking -3- on plunger.
– Pull plunger into thrust plate and secure with locking plate
-arrow A- to close.
– Remove T-bar - VAS 6274/5- .

– Insert thrust plate with swivel mounting - VAS 6274/12-1- into

coil spring -1-.
• Pay attention to markings made during removal indicating in‐
stallation position and position of locating brackets -2- and
-5- in relation to thrust plates for each side of vehicle.
– Screw in bolts -3- for locating bracket with locking plate -4-
hand-tight.

– Screw spindle - VAS 6274/3- loosely into plunger - VAS

6274/12-7- using socket - VAS 6274/6- , compressing spring
coil -1- slightly with hydraulic tensioning device - VAS 6274/9-
as you do so.

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– Insert centring sleeve, 130 mm long -item 4- as far as it will go.

– Align locating bracket -2- according to marking -arrow B- on
coil spring -3- made during removal.
– Using socket - VAS 6274/6- and hydraulic tensioning device -
VAS 6274/9- simultaneously, compress coil spring as far as
markings -arrow A- made previously.
– When compressing coil spring, make sure that centring sleeve
does not slip off spindle; press it on if necessary.
• It may be necessary to use counterhold tool - VAS 6274/7- to
hold thrust plates in position aligned with marking -arrow B-.

NOTICE
Risk of damage to thread on spindle due to improper handling.
– Never use an impact wrench to tighten or loosen spindle.
– Only use a standard commercially available ratchet to turn
the spindle.

– Use socket - VAS 6274/6- to compress coil spring further until

it makes light contact with hydraulic tensioning device.
– Slacken off hydraulic tensioning device and remove centring
sleeve and compressed coil spring.
• Apply spreader device - VAS 6274/8- from -VAS 6274/12-5- .
– Bring coil spring and spring plate into installation position
⇒ page 162 .

NOTICE
Risk of damage to thread on spindle due to improper handling.
– Never use an impact wrench to tighten or loosen spindle.
– Only use a standard commercially available ratchet to turn
the spindle.

• The thrust plates of the tensioning device must not make con‐
tact with the transverse links when relieving the tension on the
coil springs. Rotate the thrust plates if necessary.
– Relieve tension on coil spring using socket - VAS 6274/6-
(counterhold with counterhold tool - VAS 6274/7- ).
• Overview table: when does wheel alignment have to be
checked? ⇒ page 238
Tightening torques
♦ ⇒ “7.1 Exploded view - drive shaft”, page 190
♦ ⇒ “1 Wheels, tyres”, page 234

5.3.2 Removing and installing air spring

Special tools and workshop equipment required

174 Rep. gr.42 - Rear suspension

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♦ Torque wrench - V.A.G 1331-

♦ Torque wrench - V.A.G 1332-

Removing
• Observe rules for cleanliness ⇒ page 6 .
• Take care to prevent indentations forming in boot on air spring
during assembly work.
• When unscrewing the air pipe from a component, check
whether the cutting ring is seated on the air pipe.
– Bleed air spring system ⇒ page 220 .
– Remove rear wheel ⇒ page 234 .
– Unbolt drive shaft from rear final drive and move it downwards
⇒ page 192 .
– Unscrew connection piece -arrow- on rear air spring.
– Close both connections.

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– Release fasteners -arrows- and move air spring -3- clear at

lower transverse link -1-.
– Take out air spring from below.
Installing
Installation is carried out in reverse order; note the following:
Note:
Cutting ring must be fitted to ensure that air pipe is fitted securely.
– Charge air spring system ⇒ page 220 .
• Before charging air spring, check installation position
⇒ page 163 .
• The vehicle must not be lowered from the lifting platform until
the system has been recharged.
• Re-adapt normal level ⇒ page 219 .
Tightening torques
♦ ⇒ “5.1.2 Exploded view - air spring”, page 162
♦ ⇒ “7.1 Exploded view - drive shaft”, page 190
♦ ⇒ “1 Wheels, tyres”, page 234

176 Rep. gr.42 - Rear suspension

 Audi A6 2019 ➤ , Audi A6 China 2019 ➤ , Audi A7 Sportback 2018 ➤
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6 Wheel bearing, trailing arm

⇒ “6.1 Exploded view - wheel bearing”, page 177
⇒ “6.2 Removing and installing wheel bearing housing”,
page 179
⇒ “6.3 Removing and installing wheel bearing unit”, page 182
⇒ “6.4 Servicing wheel bearing unit”, page 186

6.1 Exploded view - wheel bearing

⇒ “6.1.1 Exploded view - wheel bearing, front-wheel drive vehi‐
cles”, page 177
⇒ “6.1.2 Exploded view - wheel bearing, four-wheel drive vehi‐
cles”, page 178

6.1.1 Exploded view - wheel bearing, front-wheel drive vehicles

1 - Flange nut
❑ Depending on version
❑ Renew after removing
❑ 70 Nm +135°
❑ Loosen and tighten with
a multi-point socket (32
mm)
2 - Wheel bearing unit
❑ Removing and installing
⇒ page 182
❑ Instructions for handling
wheel bearing
⇒ page 178
3 - Additional seal
4 - Wheel bearing housing
❑ Different versions; for
correct version refer to
⇒ Electronic parts cata‐
logue
❑ Removing and installing
⇒ page 179
5 - Bolt
❑ Thread-forming
❑ Fit and screw in bolt by
hand so that it is
screwed into old thread.
Then tighten bolt to tor‐
que
❑ 13 Nm
6 - Bracket
❑ For electrical wiring
7 - Flange bolt
❑ Depending on version
❑ Renew after removing
❑ 200 Nm +180°
8 - Sealing cap

6. Wheel bearing, trailing arm 177

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Instructions for handling wheel bearing

NOTICE
Risk of irreparable damage to wheel bearing due to improper
handling and insufficient attention to cleanliness.
– Observe the following instructions for handling the wheel
bearing:

• Always place wheel bearing -1- so that it faces upwards.

• 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.

6.1.2 Exploded view - wheel bearing, four-wheel drive vehicles

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1 - Wheel bearing housing

❑ Removing and installing
⇒ page 179
2 - Bolt
❑ Renew after removing
❑ 80 Nm +90°
3 - Drive shaft
4 - Bolt
❑ 8 Nm
5 - Bracket
❑ For electrical wiring
6 - Wheel bearing
❑ Removing and installing
wheel bearing unit
⇒ page 182
❑ Servicing wheel bearing
unit ⇒ page 186
❑ Instructions for handling
wheel bearing
⇒ page 178
7 - Wheel hub
8 - Bolt
❑ Loosening and tighten‐
ing bolt securing drive
shaft ⇒ page 194

6.2 Removing and installing wheel bearing

housing
Special tools and workshop equipment required
♦ Torque wrench - V.A.G 1332-

6. Wheel bearing, trailing arm 179

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♦ Engine and gearbox jack - VAS 6931-

♦ Support - T10149-

Removing
– Vehicles with four-wheel drive: Loosen nut securing drive shaft
to wheel hub ⇒ page 194 .
– Remove splash plate ⇒ Brake system; Rep. gr. 46 ; Rear
brakes; Removing and installing splash plate .
– Vehicles with front-wheel drive: Unplug electrical connector
-1- for rear speed sensor.

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– Vehicles with four-wheel drive: Unplug electrical connector

-1- for rear speed sensor.

– Remove bolt -arrow- and move bracket -1- with electrical wir‐
ing clear to one side.

– Turn wheel hub until one of the wheel bolt holes is at the top.
– Attach support - T10149- to wheel hub using wheel bolt -2-.
– Use engine and gearbox jack - T10149- attached to support -
VAS 6931- to raise wheel bearing housing slightly so that bolts
can be removed more easily.

CAUTION
Risk of accident if vehicle is lowered or raised when engine and
gearbox jack is positioned underneath.
– Never raise or lower the vehicle when the engine and gear‐
box jack is underneath it.
– Never leave the engine and gearbox jack under the vehicle
for longer than necessary.

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– Remove bolt -2- and detach bolted connection -1-.

– Remove bolts -3, 4- and detach bolted connection -1-.

– Pull wheel bearing housing -2- off drive shaft and remove.
Installing
Installation is carried out in reverse order; note the following:
– Screw in bolts initially until they make contact, but do not tight‐
en to final torque yet.
• Bonded rubber bushes can only be turned to a limited extent.
The suspension mountings must therefore only be tightened
when the suspension is at the normal level.
– Lift suspension to normal level ⇒ page 12 .
– Install splash plate ⇒ Brake system; Rep. gr. 46 ; Rear brakes;
Removing and installing splash plate .
– Tighten bolt securing drive shaft to wheel hub ⇒ page 194 .
• Overview table: when does wheel alignment have to be
checked? ⇒ page 238
Tightening torques
♦ ⇒ “4.1 Exploded view - transverse links”, page 146
♦ ⇒ “6.1 Exploded view - wheel bearing”, page 177

6.3 Removing and installing wheel bearing

unit
⇒ “6.3.1 Removing and installing wheel bearing unit - front-wheel
drive vehicles”, page 182
⇒ “6.3.2 Removing and installing wheel bearing unit - four-wheel
drive vehicles”, page 185

6.3.1 Removing and installing wheel bearing

unit - front-wheel drive vehicles
Special tools and workshop equipment required

182 Rep. gr.42 - Rear suspension

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♦ Hub grease cap puller - VW 637/2-

♦ Fitting sleeve - 3241/4- from fitting sleeves - 3241-

♦ Torque wrench - V.A.G 1332-

♦ Torque wrench - V.A.G 1410-

6. Wheel bearing, trailing arm 183

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Removing
– Remove splash plate ⇒ Brake system; Rep. gr. 46 ; Rear
brakes; Removing and installing splash plate .
– Loosen grease cap by tapping lightly on hub grease cap puller
- VW 637/2- -1-.

– Lever off grease cap with hub grease cap puller - VW 637/2-
-1-.

NOTICE
Risk of damage to nut/bolt if handled incorrectly.
– Never use an impact wrench to loosen or tighten.
– Fit nut/bolt by hand only; make the first few turns by hand.

– Remove nut/bolt underneath and detach wheel bearing from

stub axle.
• Instructions for handling wheel bearing ⇒ page 178

– Remove additional seal -arrow- from stub axle.

Installing
Installation is carried out in reverse order; note the following:
• Always renew sealing cap if removed.
– Clean additional seal.
– Fit additional seal and lubricate stub axle -arrow- lightly with
lubricating paste .
– Install brake caliper and brake disc ⇒ Brake system; Rep. gr.
46 ; Rear brakes; Removing and installing brake disc .

184 Rep. gr.42 - Rear suspension

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NOTICE
Risk of irreparable damage to wheel bearing due to moisture
ingress caused by damaged sealing cap.
– Only install sealing cap as shown.

– Drive new sealing cap in as far as stop using fitting sleeve -

3241/4- -item 1-.
– Install splash plate ⇒ Brake system; Rep. gr. 46 ; Rear brakes;
Removing and installing splash plate .
Tightening torques
♦ ⇒ “6.1.1 Exploded view - wheel bearing, front-wheel drive ve‐
hicles”, page 177

6.3.2 Removing and installing wheel bearing

unit - four-wheel drive vehicles
Special tools and workshop equipment required
♦ Torque wrench - V.A.G 1332-

♦ Torque wrench - V.A.G 1410-

Removing
– Slacken bolt securing drive shaft to wheel hub ⇒ page 194 .
– Remove brake disc ⇒ Brake system; Rep. gr. 46 ; Rear
brakes; Removing and installing brake disc .
– Detach wind deflector from transverse link ⇒ page 153 .

6. Wheel bearing, trailing arm 185

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– Remove bolts -arrows- in stages and detach wheel bearing

unit from drive shaft and wheel bearing housing.
• Instructions for handling wheel bearing ⇒ page 178
Installing
Installation is carried out in reverse order; note the following:
– Install brake disc ⇒ Brake system; Rep. gr. 46 ; Rear brakes;
Removing and installing brake disc .
– Tighten bolt securing drive shaft to wheel hub ⇒ page 194 .
Tightening torques
♦ ⇒ “6.1.2 Exploded view - wheel bearing, four-wheel drive ve‐
hicles”, page 178

6.4 Servicing wheel bearing unit

The wheel bearing and wheel hub are currently only supplied to‐
gether. The following instructions apply as soon as these com‐
ponents are available separately.
Special tools and workshop equipment required
♦ Thrust plate - VW 401-

♦ Thrust plate - VW 402-

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♦ Press tool - VW 412-

♦ Assembly tool - T10230-

♦ Workshop press - VAS 6654- , not illustrated

♦ Puller set for inner bearing races - VAS 701 003- (not illustra‐
ted)
Procedure
• Wheel bearing unit removed ⇒ page 182
Pressing wheel hub out of wheel bearing
• Instructions for handling wheel bearing ⇒ page 178
– Set up workshop tools, as shown in illustration.
1- Press tool - VW 412-
2- Sleeve -T10230/3-
3- Thrust piece -T10230/8-
4- Wheel bearing unit
5- Thrust plate - VW 402-
6- Thrust plate - VW 401-
– Press wheel hub out of wheel bearing.

6. Wheel bearing, trailing arm 187

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Pressing inner bearing race off wheel hub

– Prepare puller from puller set for inner bearing races - VAS
701 003- as follows:
– Screw clamping sleeve - VAS 701 003/1- onto clamp tensioner
- VAS 701 003/7- .
– Screw threaded spindle - VAS 701 003/2- into clamping sleeve
and fit thrust piece - VAS 701 003/3- .

Inner bearing race version 1

– Remove ball cage from inner bearing race -2-.
– Apply puller -1- to ball raceways -arrow- of inner race, as
shown.

Inner bearing race version 2

– Apply puller -1- to groove -arrow- of inner race -2-.

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All versions (continued)

– Clamp puller in place on inner race -2-; to do so, use spanner
- VAS 701 003/7- to turn clamp tensioner - VAS 701 003/5- in
direction of -arrow- and counterhold clamping sleeve - VAS
701 003/1- with tensioner handle - VAS 701 003/4- .
– Use threaded spindle - VAS 701 003/2- to detach inner bearing
race from wheel hub -1-.

Pressing wheel hub into wheel bearing

• Instructions for handling wheel bearing ⇒ page 178
– Set up workshop tools, as shown in illustration.
1- Press tool - VW 412-
2- Thrust plate - VW 402-
3- Wheel hub
4- Wheel bearing
5- Thrust plate - VW 401-
• The machined surface of the wheel bearing outer race faces
downwards.

NOTICE
Risk of irreparable damage to wheel bearing if it is not clean.
– Protect contact surface of wheel bearing and press tool from
becoming dirty.

– Press wheel hub into wheel bearing.

6. Wheel bearing, trailing arm 189

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7 Drive shaft
⇒ “7.1 Exploded view - drive shaft”, page 190
⇒ “7.2 Removing and installing drive shaft”, page 192
⇒ “7.3 Loosening and tightening bolt securing drive shaft”,
page 194
⇒ “7.4 Dismantling and assembling drive shaft”, page 195
⇒ “7.5 Checking outer constant velocity joint”, page 201
⇒ “7.6 Checking inner constant velocity joint”, page 202

7.1 Exploded view - drive shaft

1 - Cover
❑ Drive off carefully with
drift
❑ Renew if damaged
❑ Adhesive surface must
be free of oil and grease
❑ Before attaching to con‐
stant velocity joint, apply
sealant - D 454 300 A2-
to sealing surface
⇒ page 200
2 - Circlip
❑ Renew after removing
❑ Insert in groove on shaft
3 - Inner constant velocity joint
❑ Renew only as com‐
plete unit
❑ Checking ⇒ page 202
❑ Grease quantity and
type ⇒ page 192
❑ Adhesive surfaces must
be free of oil and grease
❑ Grease splines on drive
shaft lightly with grease
used in joint when fitting
constant velocity joint
onto drive shaft
4 - Boot
❑ Without vent hole
❑ Drive cap off carefully
with drift
❑ Check for splits and
chafing
❑ Check inner constant velocity joint if boot is damaged ⇒ page 202
❑ Sealing surfaces between metal cap and constant velocity joint must be free from grease on assembly
5 - Lock plate
6 - Bolts
❑ Renew after removing
❑ 70 Nm

190 Rep. gr.42 - Rear suspension

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7 - Hose clip
❑ Renew after removing
❑ Tightening ⇒ page 192
8 - Drive shaft
❑ Removing and installing ⇒ page 192
9 - Hose clip
❑ Renew after removing
❑ Tightening ⇒ page 192
10 - Boot
❑ Without vent hole
❑ Check for splits and chafing
❑ Check outer constant velocity joint if boot is damaged ⇒ page 201
❑ Sealing surfaces between boot and outer metal cap must be free from grease on assembly
❑ Sealing surfaces between boot and drive shaft must be free from grease on assembly
11 - Hose clip
❑ Renew after removing
❑ Tightening ⇒ page 192
12 - Circlip
❑ Renew after removing
❑ Fit into annular groove on shaft before installing (no longer visible once joint is installed)
❑ Before fitting the constant velocity joint, align the circlip centrally with the opening facing upwards
13 - Outer constant velocity joint
❑ Renew only as complete unit
❑ Checking ⇒ page 201
❑ Driving off ⇒ page 195
❑ Installing: drive onto shaft with plastic hammer until compressed circlip seats
❑ Circlip must fit in chamfer on joint when installing; guide with pliers if necessary
❑ Grease quantity and type ⇒ page 192
❑ Sealing surfaces between boot and outer CV joint must be free from grease on assembly
❑ Grease splines on drive shaft lightly with grease used in joint when fitting constant velocity joint onto
drive shaft
14 - Bolt
❑ Renew after removing
❑ Clean threads in constant velocity joint using a thread tap or similar
❑ Loosening and tightening bolt securing drive shaft ⇒ page 194

7. Drive shaft 191

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Tightening hose clip with clamp tensioner - V.A.G 1682 A-

– Apply clamp tensioner - V.A.G 1682 A- as shown.
– Apply clamp tensioner - V.A.G 1682 A- as shown.
• Tips of tool must be applied centrally -arrow- to clip -2-.
• The thread of the spindle should move freely; if necessary,
lubricate with MoS2 grease.
Note:
If the thread is stiff (e.g. due to dirt), the required clamping force
will not be attained at the hose clip when the specified tightening
torque is applied.
– Tighten hose clip by turning spindle -1- with torque wrench
(take care to keep clamp tensioner straight).
• Tightening torque: 20 Nm.

Grease quantity and type

♦ Regrease joint when renewing boot.
♦ Please note the correct type of grease for the inner and outer
joints ⇒ Electronic parts catalogue .
Joint ∅ mm Grease quantity
Total quantity In joint In rubber boot
g g g
Outer joint 92.4 70 35 3) 35
Inner joint 99.8 110 55 3) 55
Outer joint 97.5 80 40 3) 40
Inner joint 107.75 120 60 3) 60
3) Pack this amount of grease through ball joint. Distribute remainder on face of joint underneath boot.

7.2 Removing and installing drive shaft

Special tools and workshop equipment required
♦ Engine and gearbox jack - VAS 6931-

192 Rep. gr.42 - Rear suspension

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♦ Support - T10149-

Removing
– Slacken bolt securing drive shaft to wheel hub ⇒ page 194 .
– Remove rear wheel ⇒ page 234 .
– Detach wind deflector from transverse link ⇒ page 153 .
Left side of vehicle:
– Remove silencer(s) ⇒ Engine; Rep. gr. 26 ; Exhaust pipes/
silencers; Exploded view - silencers .
– If fitted, remove bolts -arrows- and detach heat shield -1- for
drive shaft.

– Final drive 0D3 “quattro sport”: Unscrew bolts -arrows- and

detach heat shield -A- for drive shaft from rear final drive.

Both sides (continued):

– Remove bolts -arrows-.

7. Drive shaft 193

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– Turn wheel hub until one of the wheel bolt holes is at the top.
– Attach support - T10149- to wheel hub using wheel bolt -2-.
– Raise wheel bearing housing slightly via support - T10149-
using engine and gearbox jack - VAS 6931- until drive shaft
can be guided out of flange shaft towards rear/front and then
downwards.
– Detach drive shaft carefully, taking care not to damage boot.
• Take care not to damage protective coating on drive shaft.

CAUTION
Risk of accident if vehicle is lowered or raised when engine and
gearbox jack is positioned underneath.
– Never raise or lower the vehicle when the engine and gear‐
box jack is underneath it.
– Never leave the engine and gearbox jack under the vehicle
for longer than necessary.

Installing
Installation is carried out in reverse order; note the following:
– Tighten bolt securing drive shaft to wheel hub ⇒ page 194 .
Tightening torques
♦ ⇒ “7.1 Exploded view - drive shaft”, page 190
♦ ⇒ Engine; Rep. gr. 26 ; Exhaust pipes/silencers; Exploded
view - silencers
♦ ⇒ “1 Wheels, tyres”, page 234

7.3 Loosening and tightening bolt securing

drive shaft
Special tools and workshop equipment required
♦ Torque wrench - V.A.G 1576-

♦ Hexagon socket, 19 mm (commercially available)

194 Rep. gr.42 - Rear suspension

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Slackening bolt securing drive shaft/stub axle to wheel hub

– To avoid damage to wheel bearing, do not loosen bolt
-arrow- using hexagon socket, 19 mm further than 90° with
vehicle still standing on its wheels.
– Raise vehicle so that wheels are off the ground.
– Have a second mechanic press the brake pedal.
– Remove bolt.
Tightening bolt securing drive shaft/stub axle to wheel hub
• Always renew bolt after removal.
• Before securing, clean threads in constant velocity joint/stub
axle using a thread tap.
• The wheels must not be in contact with the ground when ini‐
tially tightening the bolt for the drive shaft/stub axle; otherwise
the wheel bearing can be damaged.
– Have a second mechanic press the brake pedal.
– Tighten bolt to 200 Nm.
– Lower vehicle onto its wheels.
– Turn bolt 180° further.

7.4 Dismantling and assembling drive shaft

⇒ “7.4.1 Dismantling and assembling drive shaft - outer constant
velocity joint”, page 195
⇒ “7.4.2 Dismantling and assembling drive shaft - inner constant
velocity joint”, page 197

7.4.1 Dismantling and assembling drive shaft

- outer constant velocity joint
Special tools and workshop equipment required
♦ Circlip pliers, commercially available
♦ Sealing compound - D454 300 A2- ⇒ Electronic parts cata‐
logue
Removing outer constant velocity joint
– Clamp drive shaft horizontally in vice using protective jaw cov‐
ers.
– Open hose clip.
– Push back boot.
– Drive constant velocity joint off drive shaft using a drift -A-.
• The drift must be applied exactly on the ball hub of the constant
velocity joint.
– Detach joint and boot.

7. Drive shaft 195

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– Remove circlip -1- using circlip pliers.

Installing outer constant velocity joint

– Push boot with new hose clip onto drive shaft.
• Boot and drive shaft must be free from grease.
– Slide boot on until it engages between -arrows- in groove -2-.
– Pack drive shaft grease evenly into inside of joint body
⇒ page 192 .

– Grease splines -arrow A- on drive shaft lightly with grease

used in joint before fitting joint body onto drive shaft.
– Fit circlip in groove on shaft.

– Slide on constant velocity joint as far as circlip.

– Align circlip so that opening faces upwards -arrows-.

196 Rep. gr.42 - Rear suspension

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– Screw old bolt into joint body, as shown in illustration.

– Use a plastic-headed hammer to drive joint onto drive shaft
until circlip engages.
– Fit boot on metal cap.
– Vent air from boot.
– Make sure boot is properly positioned on joint body.
• Boot must rest in groove and on contour of joint body.
– Tighten hose clips on outer joint ⇒ page 192 .

7.4.2 Dismantling and assembling drive shaft

- inner constant velocity joint
Special tools and workshop equipment required
♦ Thrust plate - VW 401-

♦ Thrust plate - VW 402-

♦ Press tool - VW 409-

7. Drive shaft 197

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♦ Press tool - VW 412-

♦ Support sleeve - VW 522-

♦ Clamp - 40-204A-

♦ Torque wrench - V.A.G 1331-

♦ Circlip pliers, commercially available

♦ Sealing compound - D 454 300 A2-

198 Rep. gr.42 - Rear suspension

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Removing inner constant velocity joint

– Clamp drive shaft horizontally in vice using protective jaw cov‐
ers.
– Drive off cover with a copper or brass drift -arrow-.

– Drive off cap with a copper or brass drift -arrow-.

– Unfasten and detach only the small hose clip.

– Remove circlip using circlip pliers.

– Set up workshop tools, as shown in illustration.

– Press inner constant velocity joint off drive shaft.
– Pull boot off drive shaft.

7. Drive shaft 199

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Installing inner constant velocity joint

– Push boot with small hose clip onto drive shaft.
– Grease splines -arrow A- on drive shaft lightly with grease
used in joint before fitting joint body onto drive shaft.

– Set up workshop tools, as shown in illustration.

• Tensioner - 40-204A- and clamping surface on drive shaft
must be free of grease.
• Chamfer on internal diameter of ball hub (splines) must face
contact collar of drive shaft.
– Press on joint as far as stop.

– Install new circlip using circlip pliers.

– Check that circlip is seated correctly.
– Before fitting boot, pack half the drive shaft grease provided
into joint from boot side of joint.

– Degrease contact surfaces for boot and cap.

– Apply sealant - D 454 300 A2- -hatched area- on clean inner
surface of cap on boot.
♦ Width of sealant bead: 2 ... 3 mm.
– Route sealant bead around inside of holes -arrow-.

200 Rep. gr.42 - Rear suspension

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– Align cap and bolts -arrows- with bolt holes.

• The alignment must be very accurate, because no further
alignment is possible once the part has been hammered on.
– Drive on cover using a plastic hammer.
– Remove surplus sealing compound immediately as it is press‐
ed out.
– Pack remaining drive shaft grease into constant velocity joint
through ball races.

– Degrease contact surface for cover and for constant velocity

joint.
– Apply sealant - D 454 300 A2- -hatched area- to clean inner
surface of cover.
♦ Width of sealant bead: 2 ... 3 mm.
– Route sealant bead around inside of holes -arrow-.

– Using bolts -arrows-, align new cover in relation to bolt holes.

• The alignment must be very accurate, because no further
alignment is possible once the part has been hammered on.
– Drive on cover using a plastic hammer.
– Remove surplus sealant immediately as it is pressed out.

– Slide boot onto drive shaft and position it in groove -2- between
-arrows-.
– Tighten hose clips on inner joint ⇒ page 192 .

7.5 Checking outer constant velocity joint

♦ Outer constant velocity joint with cap cannot be dismantled.
♦ Only a visual inspection can be performed on outer constant
velocity joint with cap.
♦ Grease remaining in joint must be free from water and dirt.

7. Drive shaft 201

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♦ If the visual inspection reveals wear or damage on the balls or

ball races, the complete outer constant velocity joint with cap
must be renewed.
Quantities and type of grease for drive shaft with outer constant
velocity joint ⇒ page 192 .

7.6 Checking inner constant velocity joint

The joint should be dismantled to renew dirty grease or for check‐
ing the balls and ball races for wear and damage.
Dismantling
• Ball hub and joint body are paired and must be marked before
dismantling. Ensure that the balls run in the same races after
assembly.
– Swivel ball hub and ball cage.
– Press 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:
Excessive backlash in the joint will cause knocking or jolts under
load change. In such cases the joint must be renewed. Polished
areas and visible tracks in the ball races are not a reason for re‐
newing the joint.

Assembling
– 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.

202 Rep. gr.42 - Rear suspension

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♦ 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
drive shaft.

– 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.

– Swivel in the hub with balls by applying firm pressure on the

cage -arrow-.
Checking function of constant velocity joint
The constant velocity joint has been correctly assembled if the
ball hub can be moved by hand backwards and forwards over its
entire axial range of movement.
– Pack required amount of grease into joint body.
Quantities and type of grease for drive shaft with inner constant
velocity joint ⇒ page 192 .

7. Drive shaft 203

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43 – Self-levelling suspension
1 Electronic damping control
⇒ “1.1 Overview of fitting locations - electronic damping control”,
page 204
⇒ “1.2 Basic setting of electronic damper control”, page 205
⇒ “1.3 Removing and installing running gear control unit J775 ”,
page 206

1.1 Overview of fitting locations - electronic damping control

1 - Front vehicle level sender

♦ Front left vehicle level
sender - G78-
♦ Front right vehicle level
sender - G289-
❑ Exploded view
⇒ page 208
2 - Shock absorber with front
right shock absorber damper
adjustment valve - N337-
❑ Exploded view
⇒ page 63
3 - Running gear control unit -
J775-
❑ Installation position: On
centre tunnel
❑ Removing and installing
⇒ page 206
4 - Shock absorber with rear
right shock absorber damper
adjustment valve - N339-
❑ Exploded view
⇒ page 163
5 - Shock absorber with rear
left shock absorber damper
adjustment valve - N338-
❑ Exploded view
⇒ page 163
6 - Rear vehicle level sender
♦ Rear left vehicle level send‐
er - G76-
♦ Rear right vehicle level
sender - G77-
❑ Exploded view ⇒ page 209
7 - Shock absorber with front left shock absorber damper adjustment valve - N336-
❑ Exploded view ⇒ page 63

204 Rep. gr.43 - Self-levelling suspension

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Running gear control unit - J775- - tightening torque

– Tighten nuts -arrows- to 8 Nm.

1.2 Basic setting of electronic damper con‐

trol
Adapting stops for level sensor system
Perform this basic setting if:
♦ The bolts for one of the vehicle level senders were unscrewed.
♦ One of the vehicle level senders was removed and installed.
♦ One of the shock absorbers (front or rear) was renewed.
Requirement:
• The vehicle must be raised on a lifting platform until the wheels
are off the ground; this will move the shock absorbers to their
stops.
Adapting zero position for level sensor system
Perform this basic setting if:
♦ The bolts for one of the vehicle level senders were unscrewed.
♦ One of the vehicle level senders was removed and installed.
♦ The running gear control unit - J775- has been removed and
installed.
Requirements:
• The vehicle must be standing on a level surface.
• The vehicle must be unladen.
Calibrating the inertia sensor system (sensors in control unit)
Perform this basic setting if:
♦ The running gear control unit - J775- has been renewed.
Requirements:
• The vehicle must be standing on a level surface.
• The vehicle must be unladen.
Note:
The basic settings can be performed individually or several at a
time.
Procedure
– Connect vehicle diagnostic tester .
– Switch on ignition.
– Select and start Diagnosis mode.

1. Electronic damping control 205

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– Select Test plan tab.

– Choose Select own test and select following options one
after the other:
♦ Systems with diagnostic capability
♦ 0074 - Suspension control system J775
♦ 0074 - Suspension control system, functions
♦ 0074 - Basic setting
– Start selected program and follow instructions shown on dis‐
play of vehicle diagnostic tester.
The following steps must be carried out after performing a basic
setting:
• Adjust headlights ⇒ Electrical system; Rep. gr. 94 ; Head‐
lights; Adjusting headlights .
• Calibrate front camera for driver assist systems ⇒ Driver as‐
sist systems; Rep. gr. 98 ; Front camera for driver assist
systems; Calibrating front camera for driver assist systems .

1.3 Removing and installing running gear

control unit - J775-
Special tools and workshop equipment required
♦ Vehicle diagnostic tester
Removing
– Remove centre console ⇒ General body repairs, interior; Rep.
gr. 68 ; Centre console; Removing and installing centre con‐
sole .
– Depending on equipment version: Remove air duct (rear) ⇒
Heating, air conditioning; Rep. gr. 87 ; Air duct system; Ex‐
ploded view - routing of air flow and air distribution in passen‐
ger compartment .
– Unscrew nuts -arrows B- and -arrows C-.
– Move electrical wiring harness -arrow A- clear and detach
cover -1-.

206 Rep. gr.43 - Self-levelling suspension

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– Remove nuts -arrows- and detach running gear control unit -

J775- -item 1-.
– Unplug electrical connector -2-.
Installing
Installation is carried out in reverse order; note the following:
– Depending on equipment version: Install air duct (rear) ⇒
Heating, air conditioning; Rep. gr. 87 ; Air duct system; Ex‐
ploded view - routing of air flow and air distribution in passen‐
ger compartment .
– Install centre console ⇒ General body repairs, interior; Rep.
gr. 68 ; Centre console; Removing and installing centre con‐
sole .
Activate new electronically controlled damping control unit -J250-
after installing:
– Connect vehicle diagnostic tester .
– Switch on ignition.
– Select and start Diagnosis mode.
– Select Test plan tab.
– Choose Select own test and select following options one
after the other:
♦ Systems with diagnostic capability
♦ 0074 - Suspension control system J775
♦ 0074 - Suspension control system, functions
♦ 0074 - Replace control unit
– Start selected program and follow instructions shown on dis‐
play of vehicle diagnostic tester.
Tightening torques
♦ ⇒ Fig. ““ Running gear control unit -J775- - tightening torque”“ ,
page 205

1. Electronic damping control 207

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2 Vehicle level senders

⇒ “2.1 Exploded view - front vehicle level senders”, page 208
⇒ “2.2 Exploded view - rear vehicle level senders”, page 209
⇒ “2.3 Removing and installing front vehicle level senders G78 /
G289 ”, page 209
⇒ “2.4 Removing and installing rear vehicle level senders G76 /
G77 ”, page 210

2.1 Exploded view - front vehicle level senders

1 - Bolt
❑ 8 Nm
2 - Front vehicle level sender
♦ Front left vehicle level
sender - G78-
♦ Front right vehicle level
sender - G289-
❑ With coupling rod and
retaining plate
❑ Removing and installing
⇒ page 209
❑ Installation position:
coupling rod of sender
faces outwards
3 - Subframe
4 - Track control link
5 - Nut
❑ Self-locking
❑ Renew after removing
❑ 8 Nm

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2.2 Exploded view - rear vehicle level senders

1 - Rear vehicle level sender

♦ Rear left vehicle level send‐
er - G76-
♦ Rear right vehicle level
sender - G77-
❑ With coupling rod and
retaining plate
❑ Removing and installing
⇒ page 210
❑ Installation position:
coupling rod of sender
faces towards rear
2 - Bolt
❑ Not available separately
❑ 3 Nm
3 - Bracket
❑ For vehicle level sender
4 - Upper transverse link (front)
5 - Nut
❑ Self-locking
❑ Renew after removing
❑ 8 Nm

2.3 Removing and installing front vehicle

level senders -G78- / -G289-
Special tools and workshop equipment required
♦ Torque wrench - V.A.G 1410-

2. Vehicle level senders 209

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Removing
– Unplug electrical connector -3- and move wiring clear.
– Unscrew nut -2- for coupling rod.
– Remove bolt -1- and detach vehicle level sender.
Installing
Installation is carried out in reverse order; note the following:
Equipment version with coil springs:
• Adjust headlights ⇒ Electrical system; Rep. gr. 94 ; Head‐
lights; Adjusting headlights .
• Calibrate front camera for driver assist systems ⇒ Driver as‐
sist systems; Rep. gr. 98 ; Front camera for driver assist
systems; Calibrating front camera for driver assist systems .
• Depending on equipment version: Perform basic setting for
electronic damping control ⇒ page 205 .
Equipment version with air suspension:
• Re-adapt normal level ⇒ page 219 .
Tightening torques
♦ ⇒ “2.1 Exploded view - front vehicle level senders”,
page 208

2.4 Removing and installing rear vehicle

level senders -G76- / -G77-
Special tools and workshop equipment required
♦ Torque wrench - V.A.G 1410-

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Removing
– Unplug electrical connector -1-.
– Unscrew nut -2- for coupling rod.
– Remove bolts -arrows- and detach vehicle level sender.
Installing
Installation is carried out in reverse order; note the following:
Equipment version with coil springs:
• Adjust headlights ⇒ Electrical system; Rep. gr. 94 ; Head‐
lights; Adjusting headlights .
• Depending on equipment version: Perform basic setting for
electronic damping control ⇒ page 205 .
Equipment version with air suspension:
• Re-adapt normal level ⇒ page 219 .
Tightening torques
♦ ⇒ “2.2 Exploded view - rear vehicle level senders”, page 209

2. Vehicle level senders 211

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3 Air suspension
⇒ “3.1 Overview of fitting locations - electrical components”, page
212
⇒ “3.2 Overview of fitting locations - air suspension”, page 214
⇒ “3.3 Exploded view - air pipes”, page 215
⇒ “3.4 Exploded view - pressure accumulator”, page 217
⇒ “3.5 Exploded view - air supply unit”, page 218
⇒ “3.6 Setting normal level and permanently disabling control”,
page 219
⇒ “3.7 Re-adapting normal level”, page 219
⇒ “3.8 Bleeding and charging air spring system”, page 220
⇒ “3.9 Checking air suspension for leaks”, page 221
⇒ “3.10 Removing and installing adaptive suspension compres‐
sor electronics J1135 ”, page 223
⇒ “3.11 Servicing air pipe”, page 224
⇒ “3.12 Renewing connection piece”, page 226
⇒ “3.13 Removing and installing air supply unit”, page 228
⇒ “3.14 Removing and installing filter”, page 231
⇒ “3.15 Removing and installing solenoid valve block”,
page 232
⇒ “3.16 Removing and installing accumulator”, page 233

3.1 Overview of fitting locations - electrical components

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1 - Running gear control unit -

J775-
❑ Installation position: On
centre tunnel
❑ Removing and installing
⇒ page 206
2 - Front vehicle level sender
♦ Front left vehicle level
sender - G78-
♦ Front right vehicle level
sender - G289-
❑ Exploded view
⇒ page 208
3 - Rear vehicle level sender
♦ Rear left vehicle level send‐
er - G76-
♦ Rear right vehicle level
sender - G77-
❑ Exploded view
⇒ page 209
4 - Adaptive suspension com‐
pressor electronics - J1135-
❑ Removing and installing
⇒ page 223
5 - Adaptive suspension com‐
pressor motor - V66-
❑ With integrated adap‐
tive suspension drain
valve - N111-
❑ Adaptive suspension
drain valve - N111- can‐
not be renewed sepa‐
rately; if defective renew
adaptive suspension compressor motor - V66-
❑ Exploded view ⇒ page 218
6 - Valve block for adaptive suspension - NX7-
❑ With the following integrated components:
♦ Pressure sender for adaptive suspension - G291-
♦ Front left suspension strut valve - N148-
♦ Front right suspension strut valve - N149-
♦ Rear left suspension strut valve - N150-
♦ Rear right suspension strut valve - N151-
♦ Adaptive suspension pressure accumulator valve - N311-
❑ Components cannot be renewed separately
❑ Renew valve block for adaptive suspension if any components are defective
❑ Exploded view ⇒ page 215
❑ When unscrewing the air pipe from a component, check whether the cutting ring is seated on the air pipe
❑ Cutting ring must be fitted to ensure that air pipe is fitted securely

3. Air suspension 213

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3.2 Overview of fitting locations - air suspension

1 - Air supply unit with adaptive

suspension compressor motor
- V66-
❑ Exploded view
⇒ page 218
2 - Air pipe “black”
3 - Air spring (rear left)
❑ Exploded view
⇒ page 161
4 - Air pipe “purple”
5 - Accumulator (left-side)
❑ In wheel housing (rear
left)
❑ Exploded view
⇒ page 217
6 - Air pipe “red”
7 - Air spring (front left)
❑ With front left shock ab‐
sorber damping adjust‐
ment valve - N336-
❑ Exploded view
⇒ page 60
8 - Air spring (front right)
❑ With front right shock
absorber damping ad‐
justment valve - N337-
❑ Exploded view
⇒ page 60
9 - Air pipe “green”
10 - Accumulator (right-side)
❑ In wheel housing (rear
right)
❑ Exploded view ⇒ page 217
11 - Air pipe “yellow”
12 - Air spring (rear right)
❑ Exploded view ⇒ page 161
13 - Air pipe “blue”

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3.3 Exploded view - air pipes

1 - Air pipe “yellow”

❑ To accumulator (right-
side)
❑ Renew O-ring after re‐
moval
❑ Tightening torque of
connection piece:
5.5 Nm
2 - Air pipe “purple”
❑ From solenoid valve
block
❑ Renew O-ring after re‐
moval
❑ Tightening torque of
connection piece:
5.5 Nm
3 - Air pipe
❑ From solenoid valve
block
♦ Red on left side
♦ Green on right side
❑ Renew O-ring after re‐
moval
❑ Routing ⇒ page 216
❑ Tightening torque of
connection piece:
2.3 Nm
4 - Air pipe
❑ From solenoid valve
block
♦ Black on left side
♦ Blue on right side
❑ Renew O-ring after removal
❑ Tightening torque of connection piece: 2.7 Nm
5 - Air pipe “yellow”
❑ From accumulator (left-side)
❑ Renew O-ring after removal
❑ Tightening torque of connection piece: 5.5 Nm
6 - Air pipe “brown”
❑ From air supply unit
❑ Renew O-ring after removal
❑ Tightening torque of connection piece: 3.5 Nm
7 - Air pipe “green”
❑ To air spring (front right)
❑ Renew O-ring after removal
❑ Tightening torque of connection piece: 2 Nm
8 - Air pipe “blue”
❑ To air spring (rear right)
❑ Renew O-ring after removal

3. Air suspension 215

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❑ Tightening torque of connection piece: 2 Nm

9 - Air pipe “black”
❑ To air spring (rear left)
❑ Renew O-ring after removal
❑ Tightening torque of connection piece: 2 Nm
10 - Air pipe “purple”
❑ To accumulator (left-side)
❑ Renew O-ring after removal
❑ Tightening torque of connection piece: 3.5 Nm
11 - Air pipe “red”
❑ To air spring (front left)
❑ Renew O-ring after removal
❑ Tightening torque of connection piece: 2 Nm

Routing of air pipe to air spring (front)

– Integrate air pipe -2- into wiring harness -5- at clip -4-.
1 - Residual pressure valve - must not be loosened
3 - Air spring (front)

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3.4 Exploded view - pressure accumulator

1 - Air pipe “yellow”

❑ To accumulator (right-
side)
❑ Cutting ring must be fit‐
ted to ensure that air
pipe is fitted securely
❑ Tightening torque for
connection piece
⇒ Item 1 (page 215)
2 - O-rings
❑ Renew after removing
3 - Air pipe “purple”
❑ From solenoid valve
block
❑ Cutting ring must be fit‐
ted to ensure that air
pipe is fitted securely
❑ Tightening torque for
connection piece
⇒ Item 2 (page 215)
4 - Accumulator
❑ Shown for left side of ve‐
hicle
❑ Removing and installing
⇒ page 233
5 - Bracket
6 - Bolt
❑ 10 Nm
7 - Nut
❑ 80 Nm
8 - Bolt
❑ 8 Nm

3. Air suspension 217

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3.5 Exploded view - air supply unit

1 - Bolt
❑ 9 Nm
2 - Spacer sleeve
3 - Nut
❑ 20 Nm
4 - Bracket
5 - Bracket
6 - Bolt
❑ 8 Nm
7 - Grommet
8 - Hose
9 - Nut
❑ 2.5 Nm
10 - Silencer
❑ Fitting location: in wheel
housing (left-side)
11 - Retaining clip
12 - Adaptive suspension com‐
pressor electronics - J1135-
❑ Removing and installing
⇒ page 223
13 - Solenoid valve block
❑ Identification of pipes
⇒ page 215
❑ Removing and installing
⇒ page 232
14 - Bolt
❑ 4 Nm
15 - Bracket
16 - Retaining clip
17 - Hose
❑ With bonded clip
18 - Bracket
19 - Bolt
❑ 9 Nm
20 - Grommet
21 - Spring
22 - Flange nut
❑ 7.5 Nm
23 - Filter
❑ Removing and installing ⇒ page 231
24 - Air supply unit with adaptive suspension compressor motor - V66-
❑ Removing and installing ⇒ page 230

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25 - Grommet
26 - Bracket
27 - Spacer sleeve
28 - Bolt
❑ 9 Nm
29 - Bolt
❑ Tightening torque ⇒ Engine; Rep. gr. 26 ; Exhaust pipes/silencers; Exploded view - silencers
30 - Heat shield
31 - Nut
❑ 9 Nm

3.6 Setting normal level and permanently

disabling control
Special tools and workshop equipment required
♦ Vehicle diagnostic tester
Procedure
• Determine correct type of running gear ⇒ page 241 .
– Connect vehicle diagnostic tester .
– Switch on ignition.
– Select and start Diagnosis mode.
– Select Test plan tab.
– Choose Select own test and select following options one
after the other:
♦ Systems with diagnostic capability
♦ 0074 - Suspension control system J775
♦ 0074 - Suspension control system, functions
♦ 0074 - Basic setting - set normal level and perma-
nently disable control

– Start selected program and follow instructions shown on dis‐

play of vehicle diagnostic tester.
• If “0074 - Basic setting - set normal level and permanently dis‐
able control” has been activated, carry out “0074 - Basic
setting - activate control” after work is completed.

3.7 Re-adapting normal level

The normal level must be re-adapted if:
♦ The coupling rod of a vehicle level sender has been detached
from the track control link.
♦ A vehicle level sender has been removed and re-installed or
renewed.
♦ A shock absorber with shock absorber damping adjustment
valve on the front or rear axle has been renewed.
♦ An air spring strut on the front or rear axle has been renewed.
♦ The running gear control unit - J775- has been loosened and
re-secured, removed and re-installed, or renewed.

3. Air suspension 219

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Requirements:
• The vehicle must be standing on a level surface.
• The vehicle must be unladen.
Procedure
– Connect vehicle diagnostic tester .
– Switch on ignition.
– Select and start Diagnosis mode.
– Select Test plan tab.
– Choose Select own test and select following options one
after the other:
♦ Systems with diagnostic capability
♦ 0074 - Suspension control system J775
♦ 0074 - Suspension control system, functions
♦ 0074 - Basic setting complete
– Start selected program and follow instructions shown on dis‐
play of vehicle diagnostic tester.
• The suspension will adjust to the normal level.

3.8 Bleeding and charging air spring system

Bleeding
– Connect vehicle diagnostic tester .
– Switch on ignition.
– Select and start Diagnosis mode.
– Select Test plan tab.
– Choose Select own test and select following options one
after the other:
♦ Systems with diagnostic capability
♦ 0074 - Suspension control system J775
♦ 0074 - Suspension control system, functions
♦ 0074 - Basic setting
– Start selected program and follow instructions shown on dis‐
play of vehicle diagnostic tester.
Charging
– Charging is performed in the same way by selecting:
♦ Systems with diagnostic capability
♦ 0074 - Suspension control system J775
♦ 0074 - Suspension control system, functions
♦ 0074 - Basic setting

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NOTICE
Risk of irreparable damage to rear air springs due to incorrect
handling when charging.
– Guide empty or newly installed air springs into correct posi‐
tion at rear axle during charging process.

– Procedure for charging air spring system ⇒ page 163 .

3.9 Checking air suspension for leaks

Special tools and workshop equipment required
♦ Air suspension leak tester - VAS 751 001-

The air suspension leak tester - VAS 751 001- is used to check
the air spring struts, solenoid valve block, accumulators and air
pipes for leaks.
Procedure
– Disconnect air pipe of component to be checked, e.g. suspen‐
sion strut (front left), at solenoid valve block ⇒ page 214 .
– Connect adapter -1- to solenoid valve block -2-.
– Connect adapter -3- to relevant air pipe -4-.
– Connect connecting pipe -5- of tester to adapter -1-.

3. Air suspension 221

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– Switch tester -1- on.

– Open both shut-off valves -A and B- of air suspension leak
tester - VAS 751 001- .
– Charge air spring system ⇒ page 220 .
– Set normal level and permanently disable control
⇒ page 219 .
– Check pressure gauge to determine whether there is a drop
in pressure.
– If a drop in pressure is determined, close shut-off valve in di‐
rection of solenoid valve block.
• If the pressure does not continue to drop, the problem is in the
direction of the solenoid valve block ⇒ page 215 .
– If pressure continues to drop, check connection of air pipe on
affected component, e.g. suspension strut (front left), for
leaks.
– Disconnect air pipe directly at affected component, e.g. sus‐
pension strut (front left).
• Observe rules for cleanliness ⇒ page 6 .
• Take care to prevent indentations forming in boot on air spring
during assembly work.
• When unscrewing the air pipe from a component, check
whether the cutting ring is seated on the air pipe.

– Unscrew air pipe -2- from residual pressure valve -3-. This will
allow air to escape.

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– Connect tester -1- between component to be checked and air

pipe.
– Open both shut-off valves -A and B- of air suspension leak
tester - VAS 751 001- .
– Charge air spring system ⇒ page 220 .
– Check pressure gauge to determine whether there is a drop
in pressure.
– If a drop in pressure is determined, close shut-off valve in di‐
rection of solenoid valve block.
• If the pressure continues to drop, the component being
checked is the cause ⇒ page 215 .
• If the pressure does not continue to drop, the air pipe is the
cause ⇒ page 224 .

3.10 Removing and installing adaptive sus‐

pension compressor electronics -
J1135-
Special tools and workshop equipment required
♦ Hook - 3438-

Removing
– Switch off ignition.
– Remove rear wheel ⇒ page 234 .
– Unfasten rear section of wheel housing liner (rear left) and
press towards front ⇒ General body repairs, exterior; Rep. gr.
66 ; Wheel housing liners; Exploded view - wheel housing liner
(rear) .
– Unplug electrical connectors -1-.
– Release fasteners carefully using hook - 3438- -arrows- and
detach control unit -2- from bracket towards rear.
Installing
Installation is carried out in reverse sequence.
Tightening torques
♦ ⇒ General body repairs, exterior; Rep. gr. 66 ; Wheel housing
liners; Exploded view - wheel housing liner (rear)
♦ ⇒ “1 Wheels, tyres”, page 234

3. Air suspension 223

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3.11 Servicing air pipe

Air pipes are routed through electrical wiring harness; it is per‐
missible to repair them.
Special tools and workshop equipment required
♦ Torque wrench - V.A.G 1783-

♦ Open end spanner insert (10 mm) - V.A.G 1783/1-

♦ Cutting pliers - VAS 6228-

♦ Repair kit for air pipes ⇒ Electronic parts catalogue

Repair scenario 1
• The defective section of an air pipe in the wiring harness is not
larger than the coupling and is not in a bend in the pipe.
– Move affected air pipe clear out of the wiring harness.
– Cut out defective section.
– Connect ends of original pipe using a coupling from the repair
kit.
– Put wiring harness back together after servicing.

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Repair scenario 2
• The defective section of an air pipe in the wiring harness is
larger than the coupling.
– Open wiring harness at location of defect.
– Remove defective part of air pipe.
– Fit new section of pipe parallel to original wiring harness going
away from solenoid valve block, suspension strut or accumu‐
lator.
– Connect ends of pipes using coupling from repair kit.
• To avoid leaks, air pipe must run straight for a distance of 100
mm before and after coupling.
Procedure
• A maximum of two repair locations are permissible per pipe.
• On integrated pipe sections, only one repair location per pipe
is permissible.
• The repair location must be recorded and added to the vehi‐
cle's documentation.
• Clean the area around the cutting point before cutting the air
pipe.
• Any dirt entering the connections can cause malfunctions or
failure of the system.
– Clean sections in vicinity of connection piece and relevant cut‐
ting location; for an overview of cutting points, refer to
⇒ page 215 .
– Cut through air pipe at cutting location (at a right angle) using
cutting pliers - VAS 6228- .
– Unscrew connection piece and remove air pipe.
– Use waterproof pen to mark end of air pipe in vehicle and both
ends of new air pipe.
• Use 17 mm/22 mm marks to check whether air pipe has been
properly inserted in connection piece.
– Fit sponge rubber insulation onto both pipes.
– Fit new pipe connectors.
Note:
The connection pieces in the pipe connector are already tightened
to torque. The air pipes only need to be pushed in.
– Remove transport protection cap.

– Push old air pipe through seals -1, 2-.

– Push air pipe through sealing edges -3, 4- of cutting ring in
pipe connector as far as stop -5-, exerting more force as re‐
quired.
– Fit sponge rubber insulation onto connection pieces.
– Repeat procedure with new air pipe.
– Renew connection piece ⇒ page 226 .

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Cutting location on air pipe for air spring (front)

– Service air pipe -4- ⇒ page 225 .
– Secure sheathed pipe connector -3- and new air pipe -2- to
wiring harness -1- with a cable tie -arrow-.

Cutting location on air pipe for air spring (rear)

– Release original air pipe -2- from wiring harness -1-.
– Sheathe wiring harness again in the proper manner.
– Service air pipe ⇒ page 225 .
– Secure sheathed pipe connector -3- and new air pipe -4- to
wiring harness with a cable tie -arrow-.

3.12 Renewing connection piece

Special tools and workshop equipment required
♦ Torque wrench - V.A.G 1783-

♦ Open end spanner insert (10 mm) - V.A.G 1783/1-

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♦ Cutting pliers - VAS 6228-

Procedure
In the event of leakage at the connection, the air pipe can be
shortened by 10 mm (if sufficient length is available) and a new
connection piece fitted.
Note:
It must be ensured that the routing of the air pipe is not changed
significantly if the air pipe is shortened.
• Always renew connecting piece if removed.
• Clean the area around the cutting point before cutting the air
pipe.
• Any dirt entering the connections can cause malfunctions or
failure of the system.
– Unscrew connection piece and detach air pipe.
– Detach cutting ring from air pipe.
– Use cutting tool - VAS 6228- to cut through air pipe at a right
angle behind impression made by cutting ring.
– Then use waterproof felt-tip pen to mark end of air pipe in ve‐
hicle.
Note:
Use 17 mm/22 mm marks to check whether air pipe has been
properly inserted in connection piece.
– Screw in and tighten new connection piece by hand.

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– Only remove transport protection caps -2- and -3- immediately

prior to attachment of air pipe -4-.
– Install and secure air pipe in vehicle with appropriate clips and/
or grommets. Renew cable ties that have been cut open as
required.
– Remove transport protection caps.
– Exerting moderate pressure, push air pipe -4- all the way into
connection piece -1-.
• Air pipes have been properly fitted if only one of the two marks
is visible -arrow A-.
Tightening torques
♦ ⇒ “3.3 Exploded view - air pipes”, page 215
♦ ⇒ Engine; Rep. gr. 26 ; Exhaust pipes/silencers; Exploded
view - silencers

3.13 Removing and installing air supply unit

⇒ “3.13.1 Removing and installing air supply unit with bracket”,
page 228
⇒ “3.13.2 Removing and installing air supply unit”, page 230

3.13.1 Removing and installing air supply unit

with bracket
Special tools and workshop equipment required
♦ Torque wrench - V.A.G 1783-

♦ Open end spanner insert (10 mm) - V.A.G 1783/1-

Removing
• Observe rules for cleanliness ⇒ page 6 .

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• When unscrewing the air pipe from a component, check

whether the cutting ring is seated on the air pipe.
– Bleed air spring system ⇒ page 220 .
– Switch off ignition.
– Remove silencers ⇒ Engine; Rep. gr. 26 ; Exhaust pipes/
silencers; Removing and installing silencers .
– Remove rear left wheel ⇒ page 234 .
– Unfasten rear section of wheel housing liner (rear left) and
press towards front ⇒ General body repairs, exterior; Rep. gr.
66 ; Wheel housing liners; Exploded view - wheel housing liner
(rear) .
– Unscrew nuts -arrows- and move silencer -1- clear.

– Unplug electrical connector -arrow-.

– Unplug electrical connectors -4-.

– Unscrew air pipe -3- and protect from dirt.
– Unscrew bolt -1- and tie up solenoid valve block -2- towards
front.

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– Unscrew nuts -1, 2- and detach air supply unit together with
bracket.
Installing
Installation is carried out in reverse order; note the following:
Note:
Cutting ring must be fitted to ensure that air pipe is fitted securely.
– Charge air spring system ⇒ page 220 .
Tightening torques
♦ ⇒ “3.5 Exploded view - air supply unit”, page 218
♦ ⇒ Engine; Rep. gr. 26 ; Exhaust pipes/silencers; Exploded
view - silencers
♦ ⇒ General body repairs, exterior; Rep. gr. 66 ; Wheel housing
liners; Exploded view - wheel housing liner (rear)
♦ ⇒ “1 Wheels, tyres”, page 234

3.13.2 Removing and installing air supply unit

Special tools and workshop equipment required
♦ Torque wrench - V.A.G 1783-

♦ Hose clip pliers - VAS 6362-

Removing
• Observe rules for cleanliness ⇒ page 6 .
• When unscrewing the air pipe from a component, check
whether the cutting ring is seated on the air pipe.
– Remove silencer(s) ⇒ Engine; Rep. gr. 26 ; Exhaust pipes/
silencers; Exploded view - silencers .

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– Remove nuts -arrows- and detach heat shield -3-.

– Unplug electrical connectors -2-.

– Unscrew air pipe -1- and protect from dirt.
– Unclip filter -4- from bracket and move it clear.
– Unscrew flange nuts -arrows- and carefully detach air supply
unit.
– Release clip -3- and mark installation position of hose for re-
installation.
– Disconnect hose and protect it immediately from dirt.
Installing
Installation is carried out in reverse order; note the following:
Note:
Cutting ring must be fitted to ensure that air pipe is fitted securely.
– If renewing air supply unit, transfer the marking.
Tightening torques
♦ ⇒ “3.5 Exploded view - air supply unit”, page 218
♦ ⇒ Engine; Rep. gr. 26 ; Exhaust pipes/silencers; Exploded
view - silencers

3.14 Removing and installing filter

Special tools and workshop equipment required
♦ Torque wrench - V.A.G 1783-

Removing
• Observe rules for cleanliness ⇒ page 6 .
– Remove silencer(s) ⇒ Engine; Rep. gr. 26 ; Exhaust pipes/
silencers; Exploded view - silencers .

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– Remove nuts -arrows- and detach heat shield -3-.

– Unclip filter -1- from bracket and detach it downwards.

– Release hose clips -arrows- and mark installation position of
hoses for re-installation.
– Disconnect hoses and protect them immediately from dirt.
Installing
Installation is carried out in reverse order; note the following:
• Secure all hose connections with correct type of hose clips (as
original equipment) ⇒ Electronic parts catalogue .
– If renewing filter, transfer the markings.
Tightening torques
♦ ⇒ “3.5 Exploded view - air supply unit”, page 218
♦ ⇒ Engine; Rep. gr. 26 ; Exhaust pipes/silencers; Exploded
view - silencers

3.15 Removing and installing solenoid valve

block
Special tools and workshop equipment required
♦ Torque wrench - V.A.G 1783-

Removing
• Observe rules for cleanliness ⇒ page 6 .
– Bleed air spring system ⇒ page 220 .
– Switch off ignition.
– Remove rear left wheel ⇒ page 234 .
– Unfasten rear section of wheel housing liner (rear left) and
press towards front ⇒ General body repairs, exterior; Rep. gr.
66 ; Wheel housing liners; Exploded view - wheel housing liner
(rear) .

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– Unplug electrical connector -3-.

– Unscrew air pipes -arrows- and protect from dirt.
– Remove bolts -1- and detach solenoid valve block -2- from
bracket.
Installing
Installation is carried out in reverse order; note the following:
Note:
Cutting ring must be fitted to ensure that air pipe is fitted securely.
– Charge air spring system ⇒ page 220 .
Tightening torques
♦ ⇒ “3.5 Exploded view - air supply unit”, page 218
♦ ⇒ General body repairs, exterior; Rep. gr. 66 ; Wheel housing
liners; Exploded view - wheel housing liner (rear)
♦ ⇒ “1 Wheels, tyres”, page 234

3.16 Removing and installing accumulator

Special tools and workshop equipment required
♦ Torque wrench - V.A.G 1783-

Removing
• Observe rules for cleanliness ⇒ page 6 .
– Discharge accumulator ⇒ page 17 .
– Accumulator (left-side): Unbolt air pipe -2- from accumulator
-4-.
– Remove bolts -arrows- and detach accumulator.
– If necessary, unscrew nut -1- and bolt -3- and detach accu‐
mulator from retaining plate (illustration shows accumulator on
left side).
Installing
Installation is carried out in reverse order; note the following:
Note:
Cutting ring must be fitted to ensure that air pipe is fitted securely.
– Charge system ⇒ page 220 .
Tightening torques
♦ ⇒ “3.4 Exploded view - pressure accumulator”, page 217

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44 – Wheels, tyres, vehicle geometry

1 Wheels, tyres
This information is contained in the Workshop Manual on Wheels
and tyres ⇒ Wheels and tyres; Rep. gr. 44 ; Fitting wheels / tyres /
Tyre Pressure Monitoring System / Tyre Pressure Loss Indicator .

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2 Wheel alignment
⇒ “2.1 Notes on wheel alignment”, page 235
⇒ “2.2 Test requirements for wheel alignment”, page 235
⇒ “2.3 Preparations for measurement”, page 236
⇒ “2.4 When does wheel alignment have to be checked?”,
page 238
⇒ “2.5 Wheel alignment procedure”, page 240
⇒ “2.6 Explanatory notes on production control numbers (PR
numbers)”, page 241
⇒ “2.7 Wheel runout compensation”, page 241
⇒ “2.8 Checking full steering lock”, page 242
⇒ “2.9 Checking unladen position for wheel alignment - vehicles
with coil springs”, page 242
⇒ “2.10 Checking normal level for wheel alignment - vehicles with
air suspension”, page 244
⇒ “2.11 Wheel alignment specifications”, page 245
⇒ “2.12 Adjusting camber at rear wheels”, page 249
⇒ “2.13 Adjusting toe setting at rear wheels”, page 249
⇒ “2.14 Centralising camber at front wheels”, page 250
⇒ “2.15 Adjusting toe setting at front wheels”, page 252
⇒ “2.16 Basic setting for steering angle sender G85 ”, page 253

2.1 Notes on wheel alignment

• Wheel alignment must always be performed using a wheel
alignment unit approved by VW/Audi.
• The alignment check must always include both the front and
the rear axles. This is important to achieve proper handling
and road behaviour.
• To allow running gear to fully settle, wheel alignment should
not be checked before the vehicle has completed 1000 to 2000
km.
• When making adjustments, try to obtain the specified settings
as accurately as possible.

CAUTION
Risk of accident if bolts/nuts are not tightened as specified.
– Always tighten bolts/nuts as specified before driving the ve‐
hicle on public roads.

2.2 Test requirements for wheel alignment

• Please refer to general information on wheel alignment
⇒ page 235 .
• Before driving the vehicle onto the wheel alignment unit, make
sure there is sufficient space between the vehicle and the set‐
ting device. The distance between the setting device and the
vehicle must be 120 cm ± 2.5 cm.
• If the available space is not adequate, drive the vehicle back‐
wards onto the wheel alignment unit as required.
• Allow the vehicle to cool down.

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• Check suspension, steering and steering linkage for excessive

play or damage and service if necessary.
• Tread depth difference of no more than 2 mm on one axle.
• Tyres inflated to correct pressures.
• Ensure that the sliding plates and turntables are not touching
the end stop when checking the alignment.
• Sensors must be properly attached and adjusted; refer to op‐
erating instructions of equipment manufacturer.
• Wheel alignment units and computer measuring equipment
can lose their original levelling setting and calibration over a
period of time, and they should therefore be serviced and cali‐
brated at least once a year.
• Precision equipment should be treated with appropriate care.
• If necessary, contact the manufacturer for familiarisation with
the proper use of the wheel alignment equipment.

2.3 Preparations for measurement

⇒ “2.3.1 Preparations for calibration/adjustment of driver assist
systems - quick-start mode”, page 236
⇒ “2.3.2 Preparations for wheel alignment - full wheel alignment
mode”, page 236

2.3.1 Preparations for calibration/adjustment

of driver assist systems - quick-start
mode
Select “Quick-start” mode on the wheel alignment computer if the
driver assist systems need to be calibrated/adjusted, or if a basic
setting needs to be performed for the dynamic steering.
• Connect battery charger for backup power supply ⇒ Electrical
system; Rep. gr. 27 ; Battery; Charging battery .
• Bring front wheels into straight-ahead position.
• Interrogate event memory before starting calibration/adjust‐
ment. Work through all entries that are displayed.
• Vehicle accurately aligned, suspension bounced and rocked
several times.
• Exterior lighting switched off.
• All vehicle doors closed.

2.3.2 Preparations for wheel alignment - full

wheel alignment mode
Select “Full wheel alignment” mode on the wheel alignment com‐
puter if wheel alignment needs to be performed together with an
adjustment/calibration of the driver assist systems.
Special tools and workshop equipment required
♦ Wheel alignment computer approved by VW/Audi
♦ Vehicle diagnostic tester

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♦ Brake pedal actuator - V.A.G 1869/2-

♦ Steering wheel balance - VAS 6458A-

Preparations for measurement

• 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.
• Do not switch ignition off until vehicle is stationary.
• Vehicle accurately aligned, suspension bounced and rocked
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
6458A- .
• Ensure that the sliding plates and turntables are not touching
the end stop when checking the alignment.
• Sensors must be properly attached and adjusted; refer to op‐
erating instructions of equipment manufacturer.
• Perform compensation of wheel rim runout: A certain amount
of axial runout at the wheel rims is permissible, but this may
already exceed the specified toe-in tolerance. In such cases it
is not possible to set the toe-in correctly without first compen‐
sating for the wheel runout.
• Wheel alignment units and computer measuring equipment
can lose their original levelling setting and calibration over a
period of time, and they should therefore be serviced and cali‐
brated at least once a year.
• Precision equipment should be treated with appropriate care.
• If necessary, contact the manufacturer for familiarisation with
the proper use of the wheel alignment equipment.

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2.4 When does wheel alignment have to be

checked?
Wheel alignment must be checked:
♦ In the event of handling problems
♦ Following accident damage
♦ If suspension components have been reinstalled or renewed.
♦ If tyres are worn unevenly.
After REMOVING AND REINSTALLING components
Front axle Wheel alignment Rear axle Wheel alignment
check required check required
Yes No Yes No
Upper link (front) X Upper transverse link X
(front)
Upper link (rear) X Upper transverse link (rear) X
Guide link (bottom) X Lower transverse link X
(front)
Track control link (bottom) X Lower transverse link (rear) X
Swivel joint X
Suspension strut X Suspension strut X
Shock absorber fork X Shock absorber fork X
Wheel bearing housing X Wheel bearing housing X
Track rod X Track rod X
Track rod ball joint X
Steering rack X Rear wheel steering rack X
Subframe cross brace X Steering adapter X
Subframe X1) Subframe X2)
Anti-roll bar X
Anti-roll bar X
Coupling rod X
Coupling rod X
• 1) A wheel alignment check may still be required, even if the position of the subframe has been fixed
using locating pins: perform a road test ⇒ page 27 .
• 2)A wheel alignment check may still be required, even if the position of the subframe has been fixed
using locating pins: perform a road test ⇒ page 132 .

After RENEWING components

Front axle Wheel alignment Rear axle Wheel alignment
check required check required
Yes No Yes No
Upper link (front) X Upper transverse link X
(front)
Upper link (rear) X Upper transverse link (rear) X
Guide link (bottom) X Lower transverse link X
(front)
Track control link (bottom) X Lower transverse link (rear) X
Bonded rubber bush for X Bonded rubber bush for X
subframe subframe
Swivel joint X
Suspension strut X Suspension strut X

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Front axle Wheel alignment Rear axle Wheel alignment

check required check required
Yes No Yes No
Shock absorber fork X Shock absorber fork X
Wheel bearing housing X Wheel bearing housing X
Track rod X Track rod X
Track rod ball joint X
Steering rack X Rear wheel steering rack X
Subframe cross brace X Steering adapter X
Subframe X Subframe X
Anti-roll bar X Anti-roll bar X
Coupling rod X Coupling rod X

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2.5 Wheel alignment procedure

Select “Full wheel alignment” mode on the wheel alignment com‐
puter if wheel alignment needs to be performed as well as an
adjustment/calibration of the driver assist systems.
Always keep to the sequence of operations.
1- Drive vehicle onto wheel alignment unit (vehicle must be positioned straight). Do not switch ignition off
until vehicle is stationary.
2 - Equipment version with air suspension: Bring suspension to normal level and permanently disable con‐
trol ⇒ “3.6 Setting normal level and permanently disabling control”, page 219 .
3 - Bring rear wheel steering rack into zero position
⇒ “4.3 Bringing rear wheel steering rack into zero position”, page 293 .
4 - Only align rear wheel steering rack if bolts of rear wheel steering rack have been loosened
⇒ “4.2 Aligning rear wheel steering rack”, page 291
5 - Carry out wheel rim runout compensation ⇒ “2.7 Wheel runout compensation”, page 241 .
6 - Check full steering lock ⇒ “2.8 Checking full steering lock”, page 242 .
7 - Check camber at rear wheels and adjust if necessary
⇒ “2.12 Adjusting camber at rear wheels”, page 249 .
8 - Check toe setting at rear wheels and adjust if necessary
⇒ “2.13 Adjusting toe setting at rear wheels”, page 249 .
9 - Check camber at front wheels and centralise if necessary
⇒ “2.14 Centralising camber at front wheels”, page 250 .
10 - Check toe setting at front wheels and adjust if necessary
⇒ “2.15 Adjusting toe setting at front wheels”, page 252 .
11 - If suspension settings have been changed:
♦ Calibrate steering angle sender - G85-
⇒ “2.16 Basic setting for steering angle sender G85 ”, page 253 .
♦ Perform basic setting of dynamic steering ⇒ “3.3 Basic setting for dynamic steering”, page 256 .

12 - The driver assist systems must be adjusted/calibrated if rear axle settings have been changed. Due to
the distance between the vehicle and the setting device - VAS 6430- , keep to the following order of
operations:
♦ Adjust radar sensor (adaptive cruise control unit -J428-) ⇒ Driver assist systems; Rep. gr. 98 ;
Adaptive cruise control; Adjusting adaptive cruise control .
♦ Calibrate night vision system ⇒ Driver assist systems; Rep. gr. 98 ; Night vision system; Calibrating
night vision system .
♦ Adjust laser sensor (control unit for laser distance control -J428-) ⇒ Driver assist systems; Rep. gr.
98 ; Adaptive cruise control; Adjusting adaptive cruise control .
♦ Calibrate front camera for driver assist systems ⇒ Driver assist systems; Rep. gr. 98 ; Front camera
for driver assist systems; Calibrating front camera for driver assist systems .
♦ Calibrate reversing camera system ⇒ Driver assist systems; Rep. gr. 98 ; Reversing camera system;
Calibrating reversing camera system .

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2.6 Explanatory notes on production control

numbers (PR numbers)
Vehicle data sticker
The corresponding PR number on the vehicle data sticker indi‐
cates which running gear version is installed in the vehicle.
Example of a vehicle data sticker:
♦ 1BK -arrow- = PR number
1BA - Standard running gear, coil springs
1BB - Standard running gear, coil springs (country-specific ver‐
sion)
1BE - Sports running gear, coil springs
1BL - Standard running gear (regulated), coil springs
1BQ - Sports running gear (regulated), coil springs
1BR - Heavy-duty running gear, coil springs
1BK - Standard running gear, air springs
1BY - Standard running gear, air springs (model variant)
Location of vehicle data sticker ⇒ Maintenance ; Booklet 450 ;
General information; Vehicle data sticker

ELSA/Vehicle-specific notes
The required information on the type of running gear, the spring/
shock absorber combination and driver assist systems can be
found in ELSA in the ⇒ Vehicle-specific notes in the document
“Vehicle data”.
-Arrow-: example of a PR number for a given spring/shock ab‐
sorber combination

2.7 Wheel runout compensation

♦ The toe-in cannot be set correctly without performing wheel
runout compensation.
♦ The existing lateral runout of the wheel rims must be compen‐
sated accordingly; otherwise the measurement will be incor‐
rect.
♦ A certain amount of axial runout at the wheel rims is permis‐
sible, but this may already exceed the specified toe-in toler‐
ance. In such cases it is not possible to set the toe-in correctly
without first compensating for the wheel runout.
♦ Please observe the operating instructions provided by the
manufacturer of the wheel alignment unit.
♦ The vehicle is equipped with an electronically controlled au‐
tomatic gearbox. Please therefore note the following when
performing wheel runout compensation: If the engine is
switched off with the selector lever in position N , the gearbox
will remain in N for about 30 minutes before automatically se‐
lecting P . P is engaged immediately if the driver's door is
opened. Please observe the instructions in the ⇒ Owner's
Manual .

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2.8 Checking full steering lock

The wheel alignment computer is used to determine the full steer‐
ing lock.
– If the value was outside the tolerance when determining the
full steering lock on the wheel alignment unit, inspect the
steering and suspension for any damage or distortion and
check the symmetry of the track rods. If necessary, shorten
the “longer” track rod ball joint (by screwing it further onto the
track rod) and renew any damaged components.
– If the steering wheel was found to be out of alignment when
checking the centre position of the steering on the wheel align‐
ment unit, inspect the steering and suspension for damage or
distortion and renew any damaged parts. Also check the sym‐
metry of the track rods.
– Measure dimension -a- on “shorter” track rod ball joint. Short‐
en the “longer” track rod ball joint to the same dimension. To
do so, screw track rod ball joint -1- further onto track rod -2-.
• Specification: Dimension -a- on right track rod ball joint = di‐
mension -a- on left track rod ball joint.
• Maximum permissible difference between right and left <
2.5 mm.
– When returning steering to centre position, allow steering
wheel to “settle” by rocking it evenly back and forth past centre
position a few times.

2.9 Checking unladen position for wheel

alignment - vehicles with coil springs
⇒ “2.9.1 Checking unladen position for wheel alignment - vehicles
with coil springs, A6 Saloon/Avant”, page 242
⇒ “2.9.2 Checking unladen position for wheel alignment - vehicles
with coil springs, A7 Sportback”, page 243

2.9.1 Checking unladen position for wheel

alignment - vehicles with coil springs, A6
Saloon/Avant
Before checking the wheel alignment on vehicles with coil springs,
the unladen position must be checked. “Unladen" means: the
weight of the vehicle ready for the road (full tank, full windscreen
washer/headlight washer fluid reservoir, spare wheel, vehicle
tools and vehicle jack), without driver.
Determining dimension -a-
– Determine dimension -a- between centre of wheel and bottom
edge of wing/wheel housing, as shown.

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Overview of dimension -a-

Running Distance between centre of wheel and bottom edge of wing/wheel housing
gear
Front axle Rear axle Tolerance between
Nominal di‐ Tolerance Nominal dimen‐ Tolerance left and right
mension sion
1BA 413 mm ± 10 mm 414 mm ± 10 mm <= 10 mm
1BB 413 mm ± 10 mm 414 mm ± 10 mm <= 10 mm
1BE 393 mm ± 10 mm 394 mm ± 10 mm <= 10 mm
1BL 403 mm ± 10 mm 404 mm ± 10 mm <= 10 mm
1BQ 393 mm ± 10 mm 394 mm ± 10 mm <= 10 mm
1BR 426 mm ± 10 mm 427 mm ± 10 mm <= 10 mm

2.9.2 Checking unladen position for wheel

alignment - vehicles with coil springs, A7
Sportback
Before checking the wheel alignment on vehicles with coil springs,
the unladen position must be checked. “Unladen" means: the
weight of the vehicle ready for the road (full tank, full windscreen
washer/headlight washer fluid reservoir, spare wheel, vehicle
tools and vehicle jack), without driver.
Determining dimension -a-
– Determine dimension -a- between centre of wheel and bottom
edge of wing/wheel housing, as shown.

Overview of dimension -a-

Running Distance between centre of wheel and bottom edge of wing/wheel housing
gear
Front axle Rear axle Tolerance between
Nominal di‐ Tolerance Nominal dimen‐ Tolerance left and right
mension sion
1BA 404 mm ± 10 mm 401 mm ± 10 mm <= 10 mm
1BE 394 mm ± 10 mm 391 mm ± 10 mm <= 10 mm
1BL 404 mm ± 10 mm 401 mm ± 10 mm <= 10 mm
1BQ 394 mm ± 10 mm 391 mm ± 10 mm <= 10 mm

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2.10 Checking normal level for wheel align‐

ment - vehicles with air suspension
⇒ “2.10.1 Checking normal level for wheel alignment - vehicles
with air suspension, A6 Saloon/Avant”, page 244
⇒ “2.10.2 Checking normal level for wheel alignment - vehicles
with air suspension, A7 Sportback”, page 244

2.10.1 Checking normal level for wheel align‐

ment - vehicles with air suspension, A6
Saloon/Avant
Checking normal level for wheel alignment
Before checking the wheel alignment on vehicles with air sus‐
pension, the normal level must be checked and, if necessary, re-
adapted.
– Set normal level and permanently disable control
⇒ “3.6 Setting normal level and permanently disabling control”,
page 219 .
Determining dimension -a-
– Determine dimension -a- between centre of wheel and bottom
edge of wing/wheel housing, as shown.

Overview of dimension -a-

Running Distance between centre of wheel and bottom edge of wing/wheel housing
gear
Front axle Rear axle Tolerance between
Nominal di‐ Tolerance Nominal dimen‐ Tolerance left and right
mension 4), sion 4),
1BK 393 mm ± 10 mm 394 mm ± 10 mm <= 10 mm
1BY 407 mm ± 10 mm 407 mm ± 10 mm <= 10 mm
4) The specified dimension applies to the normal level.

2.10.2 Checking normal level for wheel align‐

ment - vehicles with air suspension, A7
Sportback
Checking normal level for wheel alignment
Before checking the wheel alignment on vehicles with air sus‐
pension, the normal level must be checked and, if necessary, re-
adapted.
– Set normal level and permanently disable control
⇒ “3.6 Setting normal level and permanently disabling control”,
page 219 .

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Determining dimension -a-

– Determine dimension -a- between centre of wheel and bottom
edge of wing/wheel housing, as shown.

Overview of dimension -a-

Running Distance between centre of wheel and bottom edge of wing/wheel housing
gear
Front axle Rear axle Tolerance between
Nominal di‐ Tolerance Nominal dimen‐ Tolerance left and right
mension 5) sion 5)
1BK 394 mm ± 10 mm 391 mm ± 10 mm <= 10 mm
5) The specified dimension applies to the normal level.

NOTICE
Risk of incorrect wheel alignment.
– Never perform wheel alignment when the vehicle suspen‐
sion is not at normal level.

– Set normal level and permanently disable control

⇒ “3.6 Setting normal level and permanently disabling control”,
page 219 .

2.11 Wheel alignment specifications

⇒ “2.11.1 Wheel alignment specifications - A6 Saloon/Avant”,
page 245
⇒ “2.11.2 Wheel alignment specifications - A7 Sportback”,
page 247

2.11.1 Wheel alignment specifications - A6 Sa‐

loon/Avant
Important
• The alignment values given here apply to the unladen position
⇒ page 242 or normal level ⇒ page 244 of the vehicle. The
unladen position/normal level is calculated using dimension
-a- between the wheel centre and the lower edge of the wing/
wheel housing.

2. Wheel alignment 245

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Front axle Standard running gear Standard running Sports running gear
1BA gear 1BB 1BE
Version Coil spring Coil spring Coil spring
Camber
Specification when - 50′ ± 23′ - 50′ ± 23′ - 67′ ± 23′
making adjustment
Specification when - 50′ ± 25′ - 50′ ± 25′ - 67′ ± 25′
checking adjustment
Maximum permissible 30′ 30′ 30′
difference between left
and right
Toe-in for each wheel
Specification when + 10 ± 5′ + 10 ± 5′ + 10 ± 5′
making adjustment
Specification when + 10 ± 7′ + 10 ± 7′ + 10 ± 7′
checking adjustment
Total toe-in + 20 ± 10′ + 20 ± 10′ + 20 ± 10′
Toe-out on turns at 20° 9) -1° 29‘ 24‘‘ ± 30′ -1° 29‘ 24‘‘ ± 30′ -1° 29‘ 24‘‘ ± 30′
Outer wheel steering angle at full 33° 5‘ 24‘‘ ± 1° 30′ 33° 5‘ 24‘‘ ± 1° 30′ 33° 5‘ 24‘‘ ± 1° 30′
lock
Inner wheel steering angle at full 39° 24‘ 36‘‘ ± 1° 30′ 39° 22‘ 12‘‘ ± 1° 30′ 39° 24‘ 36‘‘ ± 1° 30′
lock

Front axle Standard running gear Sports running gear Heavy-duty running
1BL6) 1BQ 6) gear 1BR
Version Coil spring Coil spring Coil spring
Camber
Specification when - 58′ ± 23′ - 68′ ± 23′ - 40′ ± 23′
making adjustment
Specification when - 58′ ± 25′ - 68′ ± 25′ - 40′ ± 25′
checking adjustment
Maximum permissible 30′ 30′ 30′
difference between left
and right
Toe-in for each wheel
Specification when + 10 ± 5′ + 10 ± 5′ + 10 ± 5′
making adjustment
Specification when + 10 ± 7′ + 10 ± 7′ + 10 ± 7′
checking adjustment
Total toe-in + 20 ± 10′ + 20 ± 10′ + 20 ± 10′
Toe-out on turns at 20° 9) -1° 29‘ 24‘‘ ± 30′ -1° 29‘ 24‘‘ ± 30′ -1° 29‘ 24‘‘ ± 30′
Outer wheel steering angle at full 33° 5‘ 24‘‘ ± 1° 30′ 33° 5‘ 24‘‘ ± 1° 30′ 33° 5‘ 24‘‘ ± 1° 30′
lock
Inner wheel steering angle at full 39° 24‘ 36‘‘ ± 1° 30′ 39° 22‘ 12‘‘ ± 1° 30′ 39° 24‘ 36‘‘ ± 1° 30′
lock

Front axle Standard running gear Standard running

1BK gear 1BY
Version Air spring Air spring
Camber
Specification when - 67′ ± 23′ - 56′ ± 23′
making adjustment

246 Rep. gr.44 - Wheels, tyres, vehicle geometry

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Front axle Standard running gear Standard running

1BK gear 1BY
Specification when - 67′ ± 25′ - 56′ ± 25′
checking adjustment
Maximum permissible 30′ 30′
difference between left
and right
Toe-in for each wheel
Specification when + 10 ± 5′ + 10 ± 5′
making adjustment
Specification when + 10 ± 7′ + 10 ± 7′
checking adjustment
Total toe-in + 20 ± 10′ + 20 ± 10′
Toe-out on turns at 20° 7) -1° 29‘ 24‘‘ ± 30′ -1° 29‘ 24‘‘ ± 30′
Outer wheel steering angle at full 33° 5‘ 24‘‘ ± 1° 30′ 33° 5‘ 24‘‘ ± 1° 30′
lock
Inner wheel steering angle at full 39° 22‘ 12‘‘ ± 1° 30′ 39° 22‘ 12‘‘ ± 1° 30′
lock
6) Electronic damping control
7) The wheel on the outside of a curve is turned in less than the inside wheel. This value shows the difference in the steering angles. It
may be displayed as a negative value on the wheel alignment computer, depending on the manufacturer.

Rear axle Running gear Running gear

1BA, 1BB, 1BE, 1BL, 1BQ, 1BR 1BK, 1BY
Version Coil spring Air spring
Camber - 50’ ± 25′ - 50’ ± 25′
Maximum permissible 30′ 30′
difference between left
and right
Toe-in + 20 ± 10′ + 20 ± 10′
Maximum permissible deviation in 10′ 10′
direction of travel relative to longi‐
tudinal axis of vehicle

2.11.2 Wheel alignment specifications - A7

Sportback
Important
• The alignment values given here apply to the unladen position
⇒ page 242 or normal level ⇒ page 244 of the vehicle. The
unladen position/normal level is calculated using dimension
-a- between the wheel centre and the lower edge of the wing/
wheel housing.

Front axle Standard running gear Sports running gear Standard running
1BA 1BE gear 1BL8)
Version Coil spring Coil spring Coil spring

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Front axle Standard running gear Sports running gear Standard running
1BA 1BE gear 1BL8)
Camber
Specification when - 58′ ± 23′ - 68′ ± 23′ - 58′ ± 23′
making adjustment
Specification when - 58′ ± 25′ - 68′ ± 25′ - 58′ ± 25′
checking adjustment
Maximum permissible 30′ 30′ 30′
difference between left
and right
Toe-in for each wheel
Specification when + 10 ± 5′ + 10 ± 5′ + 10 ± 5′
making adjustment
Specification when + 10 ± 7′ + 10 ± 7′ + 10 ± 7′
checking adjustment
Total toe-in + 20 ± 10′ + 20 ± 10′ + 20 ± 10′
Toe-out on turns at 20° 9) -1° 29‘ 24‘‘ ± 30′ -1° 29‘ 24‘‘ ± 30′ -1° 29‘ 24‘‘ ± 30′
Outer wheel steering angle at full 33° 5‘ 24‘‘ ± 1° 30′ 33° 5‘ 24‘‘ ± 1° 30′ 33° 5‘ 24‘‘ ± 1° 30′
lock
Inner wheel steering angle at full 39° 24‘ 36‘‘ ± 1° 30′ 39° 22‘ 12‘‘ ± 1° 30′ 39° 24‘ 36‘‘ ± 1° 30′
lock

Front axle Sports running gear Standard running

1BQ 8) gear 1BK
Version Coil spring Air spring
Camber
Specification when - 68′ ± 23′ - 68′ ± 23′
making adjustment
Specification when - 68′ ± 25′ - 68′ ± 25′
checking adjustment
Maximum permissible 30′ 30′
difference between left
and right
Toe-in for each wheel
Specification when + 10 ± 5′ + 10 ± 5′
making adjustment
Specification when + 10 ± 7′ + 10 ± 7′
checking adjustment
Total toe-in + 20 ± 10′ + 20 ± 10′
Toe-out on turns at 20° 9) -1° 29‘ 24‘‘ ± 30′ -1° 29‘ 24‘‘ ± 30′
Outer wheel steering angle at full 33° 5‘ 24‘‘ ± 1° 30′ 33° 5‘ 24‘‘ ± 1° 30′
lock
Inner wheel steering angle at full 39° 22‘ 12‘‘ ± 1° 30′ 39° 22‘ 12‘‘ ± 1° 30′
lock
8) Electronic damping control
9) The wheel on the outside of a curve is turned in less than the inside wheel. This value shows the difference in the steering angles. It
may be displayed as a negative value on the wheel alignment computer, depending on the manufacturer.

Rear axle Running gear Running gear 1BK

1BA, 1BE, 1BL, 1BQ
Version Coil spring Air spring
Camber - 50’ ± 25′ - 50’ ± 25′

248 Rep. gr.44 - Wheels, tyres, vehicle geometry

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Rear axle Running gear Running gear 1BK

1BA, 1BE, 1BL, 1BQ
Maximum permissible 30′ 30′
difference between left
and right
Toe-in + 20 ± 10′ + 20 ± 10′
Maximum permissible deviation in 10′ 10′
direction of travel relative to longi‐
tudinal axis of vehicle

2.12 Adjusting camber at rear wheels

Special tools and workshop equipment required
♦ Fine-tooth ratchet (commercially available)
♦ 12-point socket AF 21 mm (commercially available)
Procedure
– Unscrew nut -1- joining subframe and lower transverse link,
and screw on new nut as far as stop.
– Adjust camber by turning adjuster screw -2-.
Note:
Adjuster screw can also be turned via hexagon flats at tip of
screw.
• Wheel alignment specifications ⇒ page 245
Note:
• The maximum adjustment range is 135° to the left or right of
the centre position.
• When the end position of the adjuster screw -2- is reached, do
not turn further; otherwise components will be damaged.
– Tighten nut -1-.
– Then check camber settings again ⇒ page 245 .
Tightening torques
♦ ⇒ “4.1 Exploded view - transverse links”, page 146

2.13 Adjusting toe setting at rear wheels

Special tools and workshop equipment required
♦ Fine-tooth ratchet (commercially available)
♦ 12-point socket AF 21 mm (commercially available)

2. Wheel alignment 249

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Procedure
– Unscrew nut -1- at track rod/rear wheel steering assembly,
and screw on new nut as far as stop.
– Adjust toe setting by turning eccentric bolt -2-.
• Wheel alignment specifications ⇒ page 245
Note:
♦ The maximum adjustment range is 90° to the left or right of the
centre position.
♦ Adjusting the individual toe settings automatically alters the
geometric running direction of the axle.
– Tighten nut -1- using 12-point socket, 21 mm.
– Then check toe setting again ⇒ page 245 .
Tightening torques
♦ ⇒ “4.1 Exploded view - transverse links”, page 146

2.14 Centralising camber at front wheels

Note:
♦ The camber cannot be adjusted.
♦ By moving the subframe, it is possible to centralise the camber
setting symmetrically within the specified tolerance range.
Procedure
– Remove noise insulation ⇒ General body repairs, exterior;
Rep. gr. 66 ; Noise insulation; Exploded view - noise insula‐
tion .
– Remove wheel spoilers (front) on both sides ⇒ General body
repairs, exterior; Rep. gr. 66 ; Wheel housing liners; Exploded
view - wheel housing liner (front) .
– Unfasten rear section of front wheel housing liner (both sides)
and press to one side ⇒ General body repairs, exterior; Rep.
gr. 66 ; Wheel housing liners; Exploded view - wheel housing
liner (front) .
– Release front section of underbody trim panels on both sides
and lower slightly ⇒ General body repairs, exterior; Rep. gr.
66 ; Underbody trim; Exploded view - underbody trim .
– Remove bolts -arrows- at rear of bracket for subframe cross
brace.

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NOTICE
Risk of damage to threads in body due to improper handling.
– Never use an impact wrench to loosen or tighten.
– Fit bolts by hand only; make the first few turns by hand.

– Remove and renew subframe bolts -1- and -arrow- one after
the other on both sides.
– Screw in new bolts by hand until they make contact.
• When moving the subframe (in order to centralise the camber
setting), the vehicle must be raised at the front by positioning
the axle lift under the jacking points for the lifting platform.

– Use plastic-coated lever or similar to move subframe to re‐

quired position -arrow-.
– To do so, apply lever in centre of subframe close to track con‐
trol link between subframe and longitudinal member of body.
Note:
If a plastic-coated lever is not available, wrap a normal assembly
lever with adhesive tape.
– Before checking the camber values, the vehicle must be
bounced several times at the front axle.
• Wheel alignment specifications ⇒ page 245

2. Wheel alignment 251

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Equipment version with 3.0 ltr. TDI engine with electric compres‐
sor:

CAUTION
Risk of damage to electric compressor when vehicle is driven if
compressor comes into contact with longitudinal member.
– Ensure minimum clearance between electric compressor
and longitudinal member is maintained.

– Observe minimum clearance -a- between electric compressor

-1- and longitudinal member (left-side) -2-.
• Distance -a- = min. 19 mm
All versions (continued):
– Tighten subframe bolts (left and right) in several stages in di‐
agonal sequence.
– Then check camber settings again ⇒ page 245 .

NOTICE
Risk of incorrect wheel alignment.
– Check all wheel alignment values after any changes to cam‐
ber setting.

Tightening torques
♦ ⇒ “2.1 Exploded view - subframe”, page 20
♦ ⇒ General body repairs, exterior; Rep. gr. 66 ; Wheel housing
liners; Exploded view - wheel housing liner (front)
♦ ⇒ General body repairs, exterior; Rep. gr. 66 ; Noise insula‐
tion; Exploded view - noise insulation
♦ ⇒ General body repairs, exterior; Rep. gr. 66 ; Underbody
trim; Exploded view - underbody trim

2.15 Adjusting toe setting at front wheels

Procedure
– Measure and note down dimension -a- between track rod ball
joint -1- and track rod -2- on both sides. Dimension -a- should
be the same on the left and right prior to and after adjustment.

252 Rep. gr.44 - Wheels, tyres, vehicle geometry

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– Loosen union nut -B- (counterhold track rod ball joint -C-).
– Adjust toe setting at left and right wheels via hexagon flats
-A-.

NOTICE
Risk of premature wear if boot is twisted.
– Make sure that boot is not twisted when it is installed.

– Tighten lock nut -B- ⇒ Item 5 (page 278) and check toe setting
again.
Note:
♦ The setting may change slightly after tightening lock nut -B-.
♦ However, the adjustment is correct if the measured toe value
is still inside the tolerance.

2.16 Basic setting for steering angle sender -

G85-
Select this basic setting after the following types of work have
been performed:
♦ Changes have been made to the suspension settings.
♦ The control unit for steering column electronics - J527- has
been renewed.
♦ The active steering control unit - J792- has been renewed.
♦ The steering column has been renewed.
Special tools and workshop equipment required
♦ Vehicle diagnostic tester
♦ Steering wheel balance - VAS 6458A-

Procedure
– Connect vehicle diagnostic tester .
– Switch on ignition.
– Select and start Diagnosis mode.
– Select Test plan tab.
– Choose Select own test and select following options one
after the other:
♦ Systems with diagnostic capability
♦ 0016 - Steering column electronics control unit
J527

2. Wheel alignment 253

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♦ 0016 - Steering column electronics control unit,

functions

♦ 0016 - Calibration of steering angle sender G85

– Start selected program and follow instructions shown on dis‐
play of vehicle diagnostic tester.

254 Rep. gr.44 - Wheels, tyres, vehicle geometry

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3 Dynamic steering
⇒ “3.1 Exploded view - dynamic steering”, page 255
⇒ “3.2 Removing and installing active steering control unit J792
”, page 256
⇒ “3.3 Basic setting for dynamic steering”, page 256

3.1 Exploded view - dynamic steering

1 - Steering rack
❑ With:
♦ Electromechanical power
steering motor - V187-
♦ Power steering control unit
- J500-
2 - Bolt
❑ 6 Nm
3 - Bolt
❑ 6 Nm
4 - Bolt
❑ 6 Nm
5 - Bracket
❑ For active steering con‐
trol unit - J792-
6 - Active steering control unit
- J792-
❑ Installation position: In
front of driver's seat
❑ Removing and installing
⇒ “3.2 Removing and in‐
stalling active steering
control unit J792 ”, page
256
❑ Perform basic setting
following renewal
⇒ page 256
7 - Steering column
❑ Exploded view
⇒ page 264
❑ Perform basic setting
following renewal
⇒ page 256
8 - Active steering motor - V477-
❑ If defective, renew steering column ⇒ page 268
9 - Active steering safety lock actuator - F437-
❑ Removing and installing ⇒ page 271

3. Dynamic steering 255

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3.2 Removing and installing active steering

control unit - J792-
Removing
– Remove infotainment system display ⇒ Communication; Rep.
gr. 91 ; Infotainment system; Removing and installing info‐
tainment system display .
– Remove bolts -arrows-.
– Remove active steering control unit - J792- -item 2- and unplug
electrical connector -1-.
Installing
Installation is carried out in reverse order; note the following:
– Install infotainment system display ⇒ Communication; Rep.
gr. 91 ; Infotainment system; Removing and installing info‐
tainment system display .
– Activate new active steering control unit -J792- after installing.
– Connect vehicle diagnostic tester .
– Switch on ignition.
– Select and start Diagnosis mode.
– Select Test plan tab.
– Choose Select own test and select following options one
after the other:
♦ Systems with diagnostic capability
♦ 001B - Active steering J792
♦ 001B - Active steering, functions
♦ 001B - Replace control unit
– Start selected program and follow instructions shown on dis‐
play of vehicle diagnostic tester.
– Basic setting must be performed if active steering control unit
- J792- has been renewed ⇒ page 256 .
Tightening torques
♦ ⇒ “3.1 Exploded view - dynamic steering”, page 255

3.3 Basic setting for dynamic steering

There are two options for performing the basic setting:
Full wheel alignment
This procedure (wheel alignment and basic setting) should be
selected if:
♦ The rear axle toe setting has been changed.
♦ The running gear of the vehicle has been modified in any way
– e.g. conversion from standard running gear to sports running
gear.
Quick-start
This procedure (basic setting only) should be selected if:
♦ The steering angle sender - G85- has been calibrated.
♦ The active steering control unit - J792- has been renewed.

256 Rep. gr.44 - Wheels, tyres, vehicle geometry

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♦ The steering wheel is not straight when driving in a straight

line.
Note:
♦ The two procedures are programmed on the wheel alignment
computer. Each procedure runs automatically. All you have to
do is select the relevant program.
♦ To perform only the basic setting, select “Quick-start” mode on
the wheel alignment computer.
♦ The procedure in “Quick-start” mode is described below.
Special tools and workshop equipment required
♦ Wheel alignment computer approved by VW/Audi
♦ Vehicle diagnostic tester
Procedure
• Observe test requirements
⇒ “2.2 Test requirements for wheel alignment”, page 235 .
• Please note preparations required before calibration/adjust‐
ment of driver assist systems
⇒ “2.3.1 Preparations for calibration/adjustment of driver as‐
sist systems - quick-start mode”, page 236 .
– Drive vehicle onto wheel alignment unit (vehicle must be posi‐
tioned straight). Do not switch ignition off until vehicle is sta‐
tionary.
– Equipment version with air suspension: bring suspension to
normal level and permanently disable control
⇒ “3.6 Setting normal level and permanently disabling control”,
page 219 .
– Using vehicle diagnostic tester , move rear wheel steering into
zero position
⇒ “4.3 Bringing rear wheel steering rack into zero position”,
page 293 .
• This is the only way to ensure that rear wheel steering rack is
in straight-ahead position.
– Carry out wheel rim runout compensation.
– Calibrate steering angle sender - G85- ⇒ page 253 .
The remaining steps are now performed via the vehicle diagnostic
tester .
– Connect vehicle diagnostic tester .
– Switch on ignition.
– Select and start Diagnosis mode.
– Select Test plan tab.
– Choose Select own test and select following options one
after the other:
♦ Systems with diagnostic capability
♦ 001B - Active steering J792
♦ 001B - Active steering, functions
♦ 001B - Basic setting (Rep. Gr. 48)
♦ 001B - Basic setting complete
– Start selected program and follow instructions shown on dis‐
play of vehicle diagnostic tester.

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4 Adaptive cruise control

⇒ “4.1 Adjusting adaptive cruise control”, page 258

4.1 Adjusting adaptive cruise control

All notes and instructions for this chapter can be found in ⇒ Driver
assist systems; Rep. gr. 98 ; Adaptive cruise control; Adjusting
adaptive cruise control .

258 Rep. gr.44 - Wheels, tyres, vehicle geometry

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5 Front camera for driver assist sys‐

tems
⇒ “5.1 Calibrating front camera for driver assist systems”,
page 259

5.1 Calibrating front camera for driver assist

systems
All notes and instructions for this chapter can be found in ⇒ Driver
assist systems; Rep. gr. 98 ; Front camera for driver assist sys‐
tems; Calibrating front camera for driver assist systems .

5. Front camera for driver assist systems 259

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6 Night vision system

⇒ “6.1 Calibrating night vision system”, page 260

6.1 Calibrating night vision system

All notes and instructions for this chapter can be found in ⇒ Driver
assist systems; Rep. gr. 98 ; Night vision system; Calibrating
night vision system .

260 Rep. gr.44 - Wheels, tyres, vehicle geometry

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48 – Steering
1 Steering wheel
⇒ “1.1 Exploded view - steering wheel”, page 261
⇒ “1.2 Removing and installing steering wheel”, page 262

1.1 Exploded view - steering wheel

1 - Multifunction buttons on left

in steering wheel - E440-
❑ Exploded view ⇒ Com‐
munication; Rep. gr.
91 ; Multi-function steer‐
ing wheel; Exploded
view - multi-function
steering wheel
2 - Steering wheel
❑ Depending on equip‐
ment version: with heat‐
ed steering wheel send‐
er - G428- and heated
steering wheel - Z36-
❑ Removing and installing
⇒ page 262
3 - Bolt
❑ Tightening torque ⇒
Communication; Rep.
gr. 91 ; Multi-function
steering wheel; Explo‐
ded view - multi-function
steering wheel
4 - Tiptronic switch (shift down)
- E480-
❑ Exploded view ⇒ Com‐
munication; Rep. gr.
91 ; Multi-function steer‐
ing wheel; Exploded
view - multi-function
steering wheel
5 - Tiptronic switch (shift up) -
E479-
❑ Exploded view ⇒ Com‐
munication; Rep. gr.
91 ; Multi-function steer‐
ing wheel; Exploded view - multi-function steering wheel
6 - Multifunction buttons on right in steering wheel - E441-
❑ Exploded view ⇒ Communication; Rep. gr. 91 ; Multi-function steering wheel; Exploded view - multi-
function steering wheel
7 - Bolt
❑ Tightening torque ⇒ Communication; Rep. gr. 91 ; Multi-function steering wheel; Exploded view - multi-
function steering wheel
8 - Trim
❑ For steering wheel
9 - Bolt
❑ 1.2 Nm

1. Steering wheel 261

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10 - Driver's airbag unit

❑ Safety precautions for working on airbags ⇒ General body repairs, interior; Rep. gr. 00 ; Safety pre‐
cautions; Safety precautions when working with pyrotechnic components
❑ Removing and installing ⇒ General body repairs, interior; Rep. gr. 69 ; Airbag (driver side); Removing
and installing airbag unit with igniters
11 - Bolt
❑ Renew after removing
❑ 30 Nm +90°

1.2 Removing and installing steering wheel

Special tools and workshop equipment required
♦ Torque wrench - V.A.G 1331-

Removing
– Turn wheels to straight ahead position.
– Move steering wheel rearwards and down as far as possible,
using full range of steering column adjuster.
– Switch off ignition.
– Remove airbag unit ⇒ General body repairs, interior; Rep. gr.
69 ; Airbag (driver side); Removing and installing airbag unit
with igniters .

262 Rep. gr.48 - Steering

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– Turn wheels to straight ahead position.

– Remove bolt -2-.
– Mark position of steering wheel -1- relative to steering column
-3- -arrow- for re-installation.
– Pull steering wheel off steering column.
Installing
Installation is carried out in reverse order; note the following:
• Front wheels in straight-ahead position
– If re-installing old steering wheel, observe marks showing po‐
sition of steering wheel/steering column.
– Install airbag unit ⇒ General body repairs, interior; Rep. gr.
69 ; Airbag (driver side); Removing and installing airbag unit
with igniters .
– Road-test vehicle.
– If the steering wheel is not correctly centred, it must be re‐
moved again and re-fitted onto the splines of the steering
column.
• Re-adapting end stops of steering rack
⇒ “3.7 Re-adapting end stops of steering rack”, page 290
Tightening torques
♦ ⇒ “1.1 Exploded view - steering wheel”, page 261

1. Steering wheel 263

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2 Steering column
⇒ “2.1 Exploded view - steering column”, page 264
⇒ “2.2 Checking steering column for damage”, page 267
⇒ “2.3 Handling and transporting steering column”, page 267
⇒ “2.4 Removing and installing steering column”, page 268
⇒ “2.5 Removing and installing safety lock for active steering
(locking solenoid)”, page 271
⇒ “2.6 Removing and installing intermediate steering shaft”, page
272
⇒ “2.7 Removing and installing control unit for electronic steering
column lock J764 ”, page 274
⇒ “2.8 Removing and installing control unit for electrically adjust‐
able steering column J866 ”, page 275

2.1 Exploded view - steering column

⇒ “2.1.1 Exploded view - steering column (with manual adjust‐
ment)”, page 264
⇒ “2.1.2 Exploded view - steering column (with electrical adjust‐
ment)”, page 266

2.1.1 Exploded view - steering column (with manual adjustment)

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1 - Nut
❑ 4.5 Nm
2 - Bolt
❑ Renew after removing
❑ Clean threaded hole
(e.g. with a thread tap)
before fitting new bolt
❑ Start by screwing in bolt
a few turns by hand. Try
to pull off intermediate
steering shaft to check
that it is correctly seat‐
ed. Then tighten bolt.
❑ 20 Nm +90°
3 - Intermediate steering shaft
❑ Removing and installing
⇒ page 272
4 - Cross member
❑ For dash panel
5 - Bolt
❑ 4.5 Nm
6 - Control unit for electronic
steering column lock - J764-
❑ Removing and installing
⇒ page 274
7 - Steering column
❑ Removing and installing
⇒ page 268
❑ Handling and transpor‐
tation ⇒ page 267
❑ Checking for damage
⇒ page 267
8 - Bolt
❑ 4x
❑ Tightening torque and tightening sequence ⇒ page 266
9 - Handle
❑ For steering column adjustment
10 - Bolt
❑ 5 Nm
11 - Bolt
❑ Renew after removing
❑ Clean threaded hole (e.g. with a thread tap) before fitting new bolt
❑ Start by screwing in bolt a few turns by hand. Try to pull off intermediate steering shaft to check that it is
correctly seated. Then tighten bolt.
❑ 20 Nm +90°

2. Steering column 265

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Steering column - tightening torque and tightening sequence

– Tighten bolts for steering column -arrow- to 20 Nm in the se‐
quence -1 ... 4-.

2.1.2 Exploded view - steering column (with electrical adjustment)

1 - Bolt
❑ Renew after removing
❑ Clean threaded hole
(e.g. with a thread tap)
before fitting new bolt
❑ Start by screwing in bolt
a few turns by hand. Try
to pull off intermediate
steering shaft to check
that it is correctly seat‐
ed. Then tighten bolt.
❑ 20 Nm +90°
2 - Intermediate steering shaft
❑ Removing and installing
⇒ page 272
3 - Steering column
❑ Removing and installing
⇒ page 268
❑ Handling and transpor‐
tation ⇒ page 267
❑ Checking for damage
⇒ page 267
4 - Cross member
❑ For dash panel
5 - Bolt
❑ 4.5 Nm
6 - Control unit for electronic
steering column lock - J764-
❑ Removing and installing
⇒ page 274
7 - Bolt
❑ 4x
❑ Tightening torque and tightening sequence ⇒ page 266

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8 - Bolt
❑ 4.5 Nm
9 - Active steering safety lock actuator - F437-
❑ Removing and installing
⇒ “2.5 Removing and installing safety lock for active steering (locking solenoid)”, page 271
10 - Control unit for electrically adjustable steering column - J866-
❑ Removing and installing ⇒ page 275
11 - Bolt
❑ 4.5 Nm
12 - Bolt
❑ Renew after removing
❑ Clean threaded hole (e.g. with a thread tap) before fitting new bolt
❑ Start by screwing in bolt a few turns by hand. Try to pull off intermediate steering shaft to check that it is
correctly seated. Then tighten bolt.
❑ 20 Nm +90°
13 - Nut
❑ 4.5 Nm

2.2 Checking steering column for damage

Visual inspection
• The components of the steering column must not be damaged.
Checking function
• The steering column must turn smoothly and easily.
• It must be possible to easily adjust the steering column for
height and reach (this check can only be performed when the
steering column is installed).

2.3 Handling and transporting steering col‐

umn
CAUTION
Risk of damage to steering column if handled incorrectly.
Malfunctions in the steering can cause a safety risk.
– Observe the following instructions for handling the steering
column.

Incorrect handling of steering column

Carrying the steering column by the following parts will cause
damage and can lead to injuries:
• Motors, spindles, connectors and wiring harness
The steering column must not be put under mechanical load:
♦ A steering column that has been dropped onto a hard surface
or shows signs of damage must not be installed in the vehicle.
♦ The steering column must not be put down on the shafts at
either end -1, 2-.
♦ The ends of the shafts must not be subjected to any impact.

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Improper handling of steering column with dynamic steering

• The steering column with dynamic steering must not be rota‐
ted.

Correct handling and transportation of steering column

– Use both hands to carry the steering column.
– Take hold of the steering column by the upper column tube
-1- and the upper universal joint close to the end of the shaft
-2-.

2.4 Removing and installing steering col‐

umn
Special tools and workshop equipment required
♦ Torque wrench - V.A.G 1331-

Additionally for equipment version with mechanical anti-theft de‐

vice:

♦ Steering column repair set ⇒ Electronic parts catalogue

♦ Bolt extractor set - VAS 5514- (not illustrated)
♦ Protector set - VAS 871 009- (not illustrated)
♦ Hand-held drill
♦ Drill bit, ∅ 4.5 mm
♦ Safety goggles
Removing
– Remove footwell vent (driver side) ⇒ Heating, air conditioning;
Rep. gr. 87 ; Air duct system; Removing and installing footwell
vent (driver side) .

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– Remove dash panel cover (driver side) ⇒ General body re‐

pairs, interior; Rep. gr. 68 ; Storage compartments/covers/trim
panels; Removing and installing dash panel cover (driver
side) .
– Remove steering column switch module ⇒ Electrical system;
Rep. gr. 94 ; Steering column switch module; Removing and
installing steering column switch module .
– Remove bolt -2- and detach universal joint -1- of intermediate
steering shaft from steering column.
– Equipment version with dynamic steering: Unplug electrical
connectors -arrows-.
– Detach wiring retainer and move electrical wiring clear.

– Equipment version with steering column with electrical adjust‐

ment: Unplug electrical connector -arrow-.

Equipment version with mechanical anti-theft device:

– Fit protector set - VAS 871 009- .

CAUTION
Risk of injury caused by flying metal shavings.
Eyes and skin can suffer irritation or injuries.
– Put on safety goggles.
– Put on protective gloves.

– Punch anti-theft device three times at intervals of 120° in

groove of top and bottom sections so that top section of me‐
chanical anti-theft device -1- cannot turn while you are drilling.

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– Centre-punch mechanical anti-theft device (top section) -1-

and drill through punch marking using carbide drill from repair
kit (4.5 mm ∅).
– Working through drilled hole -arrow- in mechanical anti-theft
device (top section) -1-, drill approx. 8 mm into bolt -2- using
a ∅ 4.5 mm bit (commercially available).
– Drill through mechanical anti-theft device (top section) -1- us‐
ing carbide drill from repair kit (7.0 mm ∅).
– Unscrew bolt (with anti-theft device) using bolt extractor no. 4
from bolt extractor set - VAS 5514- .
– Vacuum up all swarf.

All versions (continued):

– Unscrew bolts in the sequence -4 ... 1-, supporting steering
column -arrow- by hand from below.
Equipment version without control unit for electronic steering col‐
umn lock - J764- :
– Detach steering column towards rear and remove it.

Equipment version with control unit for electronic steering column

lock - J764- :
– Detach steering column towards rear and lower it slightly.
– Unplug electrical connector -3- for control unit for electronic
steering column lock - J764- -item 1- and move it clear.
– Remove steering column.

Installing
Installation is carried out in reverse order; note the following:
– Bring steering column into installation position; to do so, en‐
gage retaining hook -1- in centre tunnel -2- -arrow-.

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Equipment version with mechanical anti-theft device:

– Locate bolt -2- with anti-theft device (bottom section) -1- in in‐
stallation position.
– Tighten bolts ⇒ page 266 .
– Using a plastic hammer, drive mechanical anti-theft device
(top section) -3- into bottom section, making sure it is flush.
All versions (continued):
– Install intermediate steering shaft ⇒ page 272 .
– Install steering column switch module ⇒ Electrical system;
Rep. gr. 94 ; Steering column switch module; Removing and
installing steering column switch module .
– Install dash panel cover (driver side) ⇒ General body repairs,
interior; Rep. gr. 68 ; Storage compartments/covers/trim pan‐
els; Removing and installing dash panel cover (driver side) .
– Install footwell vent (driver side) ⇒ Heating, air conditioning;
Rep. gr. 87 ; Air duct system; Removing and installing footwell
vent (driver side) .
• Re-adapt end stops of steering rack ⇒ page 290 .
• Calibrate steering angle sender - G85- ⇒ page 253 .
Tightening torques
♦ ⇒ “2.1 Exploded view - steering column”, page 264

2.5 Removing and installing safety lock for

active steering (locking solenoid)
Special tools and workshop equipment required
♦ Vehicle diagnostic tester
♦ Torque wrench - V.A.G 1783-

Removing
• To prevent the steering wheel from being skewed, it must not
be turned, and the straight-ahead position or the steering an‐
gle of the front wheels must not be altered when the actuator
has been removed.
• Observe rules for cleanliness ⇒ page 6 .
– Turn steering wheel to straight ahead position.
– Switch off ignition.
– Remove dash panel cover (driver side) ⇒ General body re‐
pairs, interior; Rep. gr. 68 ; Storage compartments/covers/trim
panels; Removing and installing dash panel cover (driver
side) .

2. Steering column 271

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– Mark installation position of active steering safety lock actuator

-F437- -arrow- for subsequent installation.
– Unplug electrical connector -4-.
– Clean any paint residue from bolt heads.
– Remove bolts -1, 2- (use bit included in repair set) and detach
safety lock -3- from steering column.
Installing
Installation of a new actuator/re-installation of marked actuator is
carried out in reverse sequence; note the following:
– Position marked actuator according to marking made during
removal and secure with bolts (use bit provided in repair set).
– Install dash panel cover (driver side) ⇒ General body repairs,
interior; Rep. gr. 68 ; Storage compartments/covers/trim pan‐
els; Removing and installing dash panel cover (driver side) .
– Connect vehicle diagnostic tester .
– Switch on ignition.
– Select and start Diagnosis mode.
– Select Test plan tab.
– Choose Select own test and select following options one
after the other:
♦ Systems with diagnostic capability
♦ 001B - Active steering J792
♦ 001B - Active steering, functions
♦ 001B - Basic setting (Rep. Gr. 48)
♦ 001B - Basic setting complete
– Start selected program and follow instructions shown on dis‐
play of vehicle diagnostic tester.
Tightening torques
♦ ⇒ “2.1 Exploded view - steering column”, page 264

2.6 Removing and installing intermediate

steering shaft
Special tools and workshop equipment required
♦ Torque wrench - V.A.G 1331-

Removing
– Turn wheels to straight ahead position.

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– Move driver's seat back as far as possible.

– Move steering wheel rearwards and down as far as possible,
using full range of steering column adjuster.
– Switch off ignition.
– To prevent unintentional turning, secure steering wheel in
straight-ahead position with adhesive tape -arrows-.
• Use adhesive tape that can be completely removed afterwards
without leaving marks.
• Do not turn steering wheel while performing repair work, as
otherwise airbag coil connector and return ring with slip ring -
F138- could be damaged.
– Remove noise insulation ⇒ General body repairs, exterior;
Rep. gr. 66 ; Noise insulation; Exploded view - noise insula‐
tion .

– Remove bolt -2-.

– Detach universal joint -1- of intermediate steering shaft from
steering rack -3-.
– Remove dash panel cover (driver side) ⇒ General body re‐
pairs, interior; Rep. gr. 68 ; Storage compartments/covers/trim
panels; Removing and installing dash panel cover (driver
side) .

– Push floor covering slightly towards rear.

– Remove nuts -1, 4- and detach intermediate steering shaft
-3- with sealing lip -2-.

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– Remove bolt -arrow- and detach universal joint -1- of inter‐

mediate steering shaft from steering column -2-.
– Detach intermediate steering shaft.
Installing
Installation is carried out in reverse order; note the following:
• Always renew bolts after removal.
• Clean threaded holes for bolts on universal joints using a
thread tap or similar.

– Move intermediate steering shaft -3- into installation position

as shown; ensure that sealing lip -2- is positioned on insula‐
tion.
• The -arrow- should point upwards.
– Tighten nuts -1, 4-.

CAUTION
Incorrect installation of intermediate steering shaft can cause
an accident.
An interruption in power to the steering can cause a safety risk.
– Note the following instructions for installation.

– Push universal joint -4- of intermediate steering shaft onto

steering column -2-/steering rack as far as stop -arrow B-.
• The recess -3- on the steering column/steering rack must align
exactly with the hole -arrow A- for the bolt -1- on the universal
joint, as shown.
– Screw in new bolt by hand until it makes contact.
– Try to pull off intermediate steering shaft to check that it is
correctly seated. Then tighten bolt.
– Repeat procedure for lower universal joint connecting to steer‐
ing rack.
• Re-adapting end stops of steering rack ⇒ page 290
Tightening torques
♦ ⇒ “2.1 Exploded view - steering column”, page 264
♦ ⇒ General body repairs, exterior; Rep. gr. 66 ; Noise insula‐
tion; Exploded view - noise insulation

2.7 Removing and installing control unit for

electronic steering column lock - J764-
Special tools and workshop equipment required

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♦ Torque wrench - V.A.G 1783-

Removing
– Detach steering column from central tube for dash panel and
place it in driver's footwell with intermediate steering shaft at‐
tached ⇒ page 268 .
– Remove bolts -2- and detach control unit for electronic steer‐
ing column lock - J764- .
Installing
Installation is carried out in reverse order; note the following:
– Install steering column ⇒ page 268 .
• Calibrate steering angle sender - G85- ⇒ page 253 .
Tightening torques
♦ ⇒ “2.1 Exploded view - steering column”, page 264

2.8 Removing and installing control unit for

electrically adjustable steering column -
J866-
Removing
– Remove dash panel cover (driver side) ⇒ General body re‐
pairs, interior; Rep. gr. 68 ; Storage compartments/covers/trim
panels; Removing and installing dash panel cover (driver
side) .

2. Steering column 275

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– Unplug electrical connectors -1, 2-.

– Unscrew bolt -arrow- and detach control unit for electrically
adjustable steering column - J866- -item 3- towards left side.
Installing
Installation is carried out in reverse order; note the following:
– Activate control unit for electrically adjustable steering column
-J866- (if a new control unit has been installed).
– Connect vehicle diagnostic tester .
– Switch on ignition.
– Select and start Diagnosis mode.
– Select Test plan tab.
– Choose Select own test and select following options one
after the other:
♦ Systems with diagnostic capability
♦ 0009 - Electronic central electrics J519
♦ 0009 - Control unit for electrically adjustable
steering column J866

♦ 0009 - Control unit for electrically adjustable

steering column, replace

– Start selected program and follow instructions shown on dis‐

play of vehicle diagnostic tester.
Tightening torques
♦ ⇒ “2.1 Exploded view - steering column”, page 264

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3 Steering rack
⇒ “3.1 Exploded view - steering rack”, page 277
⇒ “3.2 Handling and transporting steering rack”, page 280
⇒ “3.3 Removing and installing steering rack”, page 281
⇒ “3.4 Removing and installing boot”, page 284
⇒ “3.5 Removing and installing track rod”, page 286
⇒ “3.6 Removing and installing track rod ball joint”, page 288
⇒ “3.7 Re-adapting end stops of steering rack”, page 290

3.1 Exploded view - steering rack

Steering rack

1 - Steering rack with track

rods
❑ With integrated power
steering control unit -
J500-
❑ Power steering control
unit - J500- cannot be
renewed separately. If
defective, renew steer‐
ing rack
❑ Removing and installing
⇒ page 281
❑ Servicing ⇒ page 277
2 - Bolt
❑ Renew after removing
❑ 80 Nm +180°
3 - Subframe
4 - Nut
❑ Inserted into subframe
❑ Renew after removing
5 - Intermediate steering shaft
❑ Removing and installing
⇒ page 272
6 - Wheel bearing housing
❑ Removing and installing
⇒ page 179
7 - Nut
❑ Renew after removing
❑ After loosening, remove
any remaining adhesive
from thread
❑ 140 Nm
8 - Bolt
❑ Tightening torque ⇒ Item 11 (page 265)

Steering rack, track rods

3. Steering rack 277

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1 - Hose clip
❑ Renew after removing
❑ Do not open new hose
clip
❑ Tightening ⇒ page 280
2 - Track rod
❑ Grease joint with steer‐
ing rack grease - G 052
168 A1-
❑ Removing and installing
⇒ page 286
❑ If track rod is deformed,
track control link must
be renewed additionally
on same side of vehicle
❑ 140 Nm
3 - Steering rack
❑ Grease rack on both
sides with steering rack
grease - G 052 168 A1-
❑ Removing and installing
⇒ page 281
4 - Track rod ball joint
❑ Check that dust cap is
seated correctly and not
damaged
❑ Specified dimension
⇒ page 279
❑ Removing and installing
⇒ page 288
❑ If track rod ball joint is
deformed, track control
link must be renewed
additionally on same
side of vehicle
5 - Nut
❑ Counterhold at track rod ball joint when loosening and tightening
❑ 80 Nm
6 - Spring-type clip
❑ Renew after removing
❑ Installing spring-type clip ⇒ page 280
7 - Boot
❑ Check for damage
❑ Renew after removing
❑ Must not be twisted when adjusting toe setting
❑ Do not crush folds
❑ Do not allow to come into contact with hard or sharp objects
❑ Grease seal seat with steering rack grease - G 052 168 A1-
❑ Must be installed correctly ⇒ page 280
❑ Renewing ⇒ page 284
8 - Hose clip
❑ Renew after removing
❑ Do not open new hose clip

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❑ Tightening ⇒ page 280

9 - Track rod
❑ Grease joint with steering rack grease - G 052 168 A1-
❑ Removing and installing ⇒ page 286
❑ If track rod is deformed, track control link must be renewed additionally on same side of vehicle
❑ 140 Nm
10 - Track rod ball joint
❑ Check that dust cap is seated correctly and not damaged
❑ Specified dimension ⇒ page 279
❑ Removing and installing ⇒ page 288
❑ If track rod ball joint is deformed, track control link must be renewed additionally on same side of vehicle
11 - Nut
❑ Counterhold at track rod ball joint when loosening and tightening
❑ 80 Nm
12 - Spring-type clip
❑ Renew after removing
❑ Installing spring-type clip ⇒ page 280
13 - Boot
❑ Check for damage
❑ Renew after removing
❑ Must not be twisted when adjusting toe setting
❑ Do not crush folds
❑ Do not allow to come into contact with hard or sharp objects
❑ Grease seal seat with steering rack grease - G 052 168 A1-
❑ Installation position ⇒ page 280
❑ Must be installed correctly ⇒ page 280
❑ Renewing ⇒ page 284

Specified dimension for track rod ball joint

• Apply steel ruler -2- to track rod ball joint -1- and slide as far
as rolled edge -arrow- on end of track rod ball joint.
• The entire steering rack with track rod, track rod ball joint and
track rod control link (on the corresponding side) must be re‐
newed if dimension -a- is less than 190 mm.
• Renew entire steering rack if it is damaged or if it makes un‐
usual noises.

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Installation position of outer boot

• Dimension -a- = 2 mm

Tightening inner hose clip with clamp tensioner - V.A.G 1682 A-

– Apply clamp tensioner - V.A.G 1682 A- as shown.
• Tips of tool must be applied centrally -arrow- to clip -2-.
• The thread of the spindle should move freely; if necessary,
lubricate with MoS2 grease.
Note:
If the thread is stiff (e.g. due to dirt), the required clamping force
will not be attained at the hose clip when the specified tightening
torque is applied.
– Tighten hose clip by turning spindle -1- with torque wrench
(take care to keep clamp tensioner straight).

Tightening torques
Type of hose clip Clamp tensioner - V.A.G 1682 A- Clamp tensioner - V.A.G 1682-
(Hazet) with adapter -V.A.G 1682 (Ötiker) with adapter -V.A.G
A/1- 1682 A/1-
Hose clip ∅ 85 mm (passenger side) 7 Nm 9 Nm
⇒ Item 8 (page 278)
Hose clip ∅ 59 mm (driver side) 10 Nm 12 Nm
⇒ Item 1 (page 278)

3.2 Handling and transporting steering rack

Special tools and workshop equipment required
♦ Protective gloves

CAUTION
Risk of damage to steering rack if it is handled incorrectly.
Malfunctions in the steering can cause a safety risk.
– Observe the following instructions for handling the steering
rack.

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Incorrect handling and transport of the steering rack

Carrying the steering rack by the parts shown in red will cause
damage:
• Boots: Can be damaged if compressed, grasped or placed on
a hard surface.
• Motor: Electrical connectors and wiring can be damaged if
grasped or placed on a hard surface.
The steering rack must not be put under mechanical load:
♦ Do not install a steering rack that has been dropped onto a
hard surface or shows signs of damage.
Correct handling and transport of the steering rack
– Use both hands to carry the steering rack.
– Hold the steering rack only at the areas shown in green.

3.3 Removing and installing steering rack

Special tools and workshop equipment required
♦ Torque wrench - V.A.G 1331-

♦ Torque wrench - V.A.G 1332-

3. Steering rack 281

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♦ Ball joint ejector - VAS 251 805-

Removing
– Turn wheels to straight ahead position.
– Switch off ignition.
– To prevent unintentional turning, secure steering wheel in
straight-ahead position with adhesive tape -arrows-.
• Use adhesive tape that can be completely removed afterwards
without leaving marks.
• Do not turn steering wheel while performing repair work, as
otherwise coil connector - F350- could be damaged.
– Remove front wheels ⇒ page 234 .
– Remove noise insulation ⇒ General body repairs, exterior;
Rep. gr. 66 ; Noise insulation; Exploded view - noise insula‐
tion .
– Remove wheel spoilers (front) on both sides ⇒ General body
repairs, exterior; Rep. gr. 66 ; Wheel housing liners; Exploded
view - wheel housing liner (front) .

– To protect thread, unscrew nut -arrow- on joint pin of track rod

ball joint until nut is flush with thread of joint pin.

CAUTION
Track rod ball joint is released abruptly when it is pressed out -
risk of injury.
Risk of contusions.
– Secure tools by placing engine and gearbox jack under‐
neath.

• To prevent damage to ball joint puller, make sure the two lever
arms of the puller are parallel when maximum force is exerted.
– Press track rod ball joint off wheel bearing housing using ball
joint ejector - VAS 251 805- .
– Then unscrew nut; if necessary, counterhold at joint pin with
a 6 mm hexagon socket.
– Repeat procedure on opposite side.

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– Unscrew nuts -arrows- and lower anti-roll bar.

– Remove bolt -2-.

– Detach universal joint -1- of intermediate steering shaft from
steering rack -3-.
– Lower subframe cross brace ⇒ page 40 .

NOTICE
Risk of damage to components due to improper handling.
Lowering the vehicle onto its wheels can damage components
if the assembly mountings, steering rack or subframe cross
brace are not fitted as specified.
– Never lower vehicle onto its wheels with suspension com‐
ponents unfastened or detached.
– Never support weight of vehicle on subframe or subframe
cross brace with suspension components unfastened or de‐
tached.

– Unplug electrical connectors -1, 2- from power steering control

unit - J500- ; to do so, release retainer and push catch down‐
wards.

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– Remove bolts -1, 2-.

NOTICE
Risk of damage to boots if handled incorrectly.
– Do not hold steering rack by boots.

CAUTION
Risk of accident caused by high weight of steering rack.
– Perform the following work with the assistance of a second
mechanic.

– Push steering rack slightly to the side -arrow A- and take out
from below -arrow B-.
Installing
Installation is carried out in reverse order; note the following:
– Install subframe cross brace ⇒ page 43 .
– Install intermediate steering shaft ⇒ page 272 .
If a new steering rack has been installed with a power steering
control unit - J500- , activate control unit:
– Connect vehicle diagnostic tester .
– Switch on ignition.
– Select and start Diagnosis mode.
– Select Test plan tab.
– Choose Select own test and select following options one
after the other:
♦ Systems with diagnostic capability
♦ 0044 - Power steering control unit J500
♦ 0044 - Power steering control unit, functions
♦ 0044 - Replace control unit
– Start selected program and follow instructions shown on dis‐
play of vehicle diagnostic tester.
• Overview table: when does wheel alignment have to be
checked? ⇒ page 238
Tightening torques
♦ ⇒ “3.1 Exploded view - steering rack”, page 277
♦ ⇒ General body repairs, exterior; Rep. gr. 66 ; Noise insula‐
tion; Exploded view - noise insulation
♦ ⇒ General body repairs, exterior; Rep. gr. 66 ; Wheel housing
liners; Exploded view - wheel housing liner (front)
♦ ⇒ “1 Wheels, tyres”, page 234

3.4 Removing and installing boot

Special tools and workshop equipment required

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♦ Torque wrench - V.A.G 1331-

♦ Hose clip pliers - VAS 6362-

Removing
• Observe rules for cleanliness ⇒ page 6 .
• When cleaning the steering rack and surrounding compo‐
nents, removing steering rack components and lubricating the
steering rack, ensure that no dirt enters the steering rack
through the defective rubber boot.
– Turn wheels to straight ahead position.
– Remove noise insulation ⇒ General body repairs, exterior;
Rep. gr. 66 ; Noise insulation; Exploded view - noise insula‐
tion .
– Remove track rod ball joint ⇒ page 288 .
– Clean steering rack and subframe in area of rubber boot.
– Unscrew nut from track rod.

3. Steering rack 285

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– Release spring-type clip -3- using hose clip pliers - VAS 6362-
and detach.
– Detach hose clip -1- and pull boot -2- outwards off steering
rack.

NOTICE
A defective boot can cause irreparable damage to steering rack.
Risk of moisture and dirt entering.
– Check that there is a visible film of lubricant on splines of
steering rack.
– Renew steering rack if no film of lubricant is present.

Installing
Installation is carried out in reverse order; note the following:
• Always renew boot if removed

NOTICE
Risk of damage to boot if it is handled incorrectly.
– Do not crush folds of boot.
– Do not allow boot to come into contact with hard or sharp
objects.

– Check seat of boot on steering rack housing for damage. Re‐

new steering rack if seal seat is damaged.
– Grease evenly all round inside of boot seating surfaces with
steering rack grease - G 052 168 A1- .
– Grease rack on both sides with steering rack grease - G 052
168 A1- (turn steering to full lock in both directions to do so).

– Turn wheels to straight ahead position.

– Fit rubber boot with new hose clip onto steering rack housing.
– Ensure that boot is seated correctly.
• Boot must engage in groove and make contact with contour of
steering rack.
– Tighten inner hose clip -1- ⇒ page 280 .
– Secure spring-type clip -3- on boot -2- with hose clip pliers -
VAS 6362- , paying attention to installation position
⇒ page 280 .
• Overview table: when does wheel alignment have to be
checked? ⇒ page 238
Tightening torques
♦ ⇒ “3.1 Exploded view - steering rack”, page 277
♦ ⇒ General body repairs, exterior; Rep. gr. 66 ; Noise insula‐
tion; Exploded view - noise insulation

3.5 Removing and installing track rod

Special tools and workshop equipment required

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♦ Torque wrench - V.A.G 1332-

♦ Open-end spanner attachment - V.A.G 1923-

Removing
• Observe rules for cleanliness ⇒ page 6 .
– Remove rubber boot ⇒ page 284 .
– Turn the front wheels as follows:
♦ Turn steering to full left lock for left track rod
♦ Turn steering to full right lock for right track rod
– Unscrew track rod using open-end spanner attachment -
V.A.G 1923- -item 2-; to do so, counterhold with an open-end
spanner -1- at teeth of steering rack.

NOTICE
A defective boot can cause irreparable damage to steering rack.
Risk of moisture and dirt entering.
– Check that there is a visible film of lubricant on splines of
steering rack.
– Renew steering rack if no film of lubricant is present.

Installing
Installation is carried out in reverse order; note the following:
– Install rubber boot ⇒ page 284 .
• Overview table: when does wheel alignment have to be
checked? ⇒ page 238
Tightening torques
♦ ⇒ “3.1 Exploded view - steering rack”, page 277

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3.6 Removing and installing track rod ball

joint
Special tools and workshop equipment required
♦ Torque wrench - V.A.G 1332-

♦ Ring spanner insert - V.A.G 1332/7-

♦ Ball joint ejector - VAS 251 805-

Removing
– Remove front wheel ⇒ page 234 .
– Measure and note down dimension -a- between track rod ball
joint -1- and track rod -2- on both sides.
• Dimension -a- should be the same on both sides after instal‐
lation.

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– To protect thread, unscrew nut -arrow- on joint pin of track rod

ball joint until nut is flush with thread of joint pin.

CAUTION
Track rod ball joint is released abruptly when it is pressed out -
risk of injury.
Risk of contusions.
– Secure tools by placing engine and gearbox jack under‐
neath.

• To prevent damage to ball joint puller, make sure the two lever
arms of the puller are parallel when maximum force is exerted.
– Press track rod ball joint off wheel bearing housing using ball
joint ejector - VAS 251 805- .
– Unscrew nut; if necessary, counterhold at joint pin with a 6 mm
hexagon socket.

– Loosen nut -2- but do not remove (counterhold track rod ball
joint -3-).
– Unscrew track rod ball joint; if necessary, counterhold at hex‐
agon flats of track rod -1-.

Installing
Installation is carried out in reverse order; note the following:
– Screw track rod ball joint -1- onto track rod -2- until dimension
-a- measured on removal is obtained.
– Align track rod so that pin of track rod ball joint is in installation
position.
– Insert track rod ball joint all the way into wheel bearing hous‐
ing.

– To tighten nut -1- counterhold at joint pin with a 6 mm hexagon

socket if necessary.

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– Tighten nut -2-.

• Overview table: when does wheel alignment have to be
checked? ⇒ page 238
Tightening torques
♦ ⇒ “3.1 Exploded view - steering rack”, page 277
♦ ⇒ “1 Wheels, tyres”, page 234

3.7 Re-adapting end stops of steering rack

• If any connections between the steering rack and steering
wheel have been detached, the end stops of the steering rack
must be re-adapted.
Special tools and workshop equipment required
♦ Vehicle diagnostic tester
Procedure
– Connect vehicle diagnostic tester .
– Switch on ignition.
– Select and start Diagnosis mode.
– Select Test plan tab.
– Choose Select own test and select following options one
after the other:
♦ Systems with diagnostic capability
♦ 0044 - Power steering control unit J500
♦ 0044 - Power steering control unit, functions
♦ 0044 - Basic setting
– Start selected program and follow instructions shown on dis‐
play of vehicle diagnostic tester.

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4 Rear wheel steering rack

⇒ “4.1 Exploded view - rear wheel steering rack”, page 291
⇒ “4.2 Aligning rear wheel steering rack”, page 291
⇒ “4.3 Bringing rear wheel steering rack into zero position”, page
293
⇒ “4.4 Removing and installing rear wheel steering rack”,
page 293

4.1 Exploded view - rear wheel steering rack

1 - Heat shield
2 - Nut
❑ Tightening torque
⇒ Item 11 (page 147)
3 - Eccentric washer
4 - Track rod
❑ Removing and installing
⇒ page 158
❑ If track rod is deformed,
rear wheel steering rack
must be renewed addi‐
tionally
5 - Eccentric bolt
6 - Subframe
7 - Rear wheel steering rack
❑ With integrated rear
wheel steering control
unit - J1019-
❑ Rear wheel steering
control unit - J1019-
cannot be renewed sep‐
arately. If defective, re‐
new rear wheel steering
rack
❑ Removing and installing
⇒ page 293
8 - Bolt
❑ Renew after removing
❑ 90 Nm +180°
9 - Bolt
❑ 9 Nm

4.2 Aligning rear wheel steering rack

♦ Locking tool - 40326- is only used to align the rear wheel
steering rack at the workshop.
♦ If the rear wheel steering rack was installed at the factory,
locking tool - 40326- may not fit in the guides provided. In this
case, the steering rack is still fitted and aligned correctly.
The rear wheel steering rack only has to be aligned if the bolts
fitted at the factory have been loosened or in the event of any of
the following problems:

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• Poor handling
• Increased or uneven tyre wear
Special tools and workshop equipment required
♦ Locking tool - 40326- (not illustrated)
Procedure
– Unscrew and renew bolts -arrow- for rear wheel steering rack
one after the other.
– Fit bolts loosely by hand.
– Fit locking tool - T40326- :

Right side of vehicle:

• Note marking -2- “right”.
• “Arrow” points in direction of travel.
• Rear wheel steering -1- makes contact on pin of locking tool
at points -3-.
• Pin of locking tool must engage in hole -4- on subframe.

Left side of vehicle:

• Note marking -3- “left”.
• “Arrow” points in direction of travel.
• Semi-circular mountings -2- of rear wheel steering rack -4-
must make contact with pin of locking tool.
• Pin of locking tool must engage in hole -1- on subframe.
– Tighten bolted connections for rear wheel steering rack.
– Detach locking tool - T40326- .
– After alignment is completed, drive vehicle onto wheel align‐
ment unit.
– Then check wheel alignment ⇒ page 235 .
Tightening torques
♦ ⇒ “4.1 Exploded view - rear wheel steering rack”, page 291

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4.3 Bringing rear wheel steering rack into

zero position
The steering can be turned to an angle of up to 4.8° when the
vehicle is stationary. For this reason, the rear wheel steering rack
must be brought into the zero position before performing wheel
alignment or adjusting one of the driver assist systems.
• This is the only way to ensure that rear wheel steering rack is
in straight-ahead position.
– Switch on ignition.
– Select and start Diagnosis mode.
– Select Test plan tab.
– Choose Select own test and select following options one
after the other:
♦ Systems with diagnostic capability
♦ 00CB - Rear axle steering J1019
♦ 00CB - Rear wheel steering control unit, functions
♦ 00CB - Adaption
– Start selected program and follow instructions shown on dis‐
play of vehicle diagnostic tester.
• The rear wheel steering can be deactivated (rear wheel steer‐
ing rack fixed) and activated (rear wheel steering rack not
fixed) via the “Adaption” function. If the rear wheel steering
was deactivated via the “Adaption” function, it must be reacti‐
vated after the work is complete.

4.4 Removing and installing rear wheel

steering rack
Special tools and workshop equipment required
♦ Engine and gearbox jack - VAS 6931-

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♦ Gearbox support - T10337-

♦ Locking tool - 40326- (not illustrated)

Removing
Before commencing work:
– Do not switch ignition off until vehicle is stationary.
– Using vehicle diagnostic tester , move rear wheel steering into
zero position
⇒ “4.3 Bringing rear wheel steering rack into zero position”,
page 293 .
• This is the only way to ensure that rear wheel steering rack is
in straight-ahead position.
– Equipment version with coil springs: ascertain unladen posi‐
tion ⇒ page 242 .
– Equipment version with air suspension: ascertain normal level
⇒ page 244 .
– Depending on equipment version: Loosen diagonal strut (left-
side) ⇒ General body repairs, exterior; Rep. gr. 66 ; Under‐
body trim; Exploded view - underbody struts .
– Vehicles with 3.0 ltr. TFSI engine: Remove silencers ⇒ En‐
gine; Rep. gr. 26 ; Exhaust pipes/silencers; Exploded view -
silencers .
– Unplug electrical connectors -arrows- on rear wheel steering
control unit - J1019- and move electrical wiring clear.

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– Remove bolts -arrows- and detach heat shield -1-.

• The rear part of the subframe is lowered in order to remove
the rear wheel steering rack. The subframe does not have to
be removed.
• Do not lower the subframe more than 20 mm.

– Fit gearbox support - T10337- onto engine and gearbox jack

- VAS 6931- and position underneath subframe.

– Remove bolts -2- on subframe (rear) on both sides.

– Lower subframe by a maximum of 20 mm.

– Remove bolts -1, 2-.

– Remove bolts -arrows- and detach rear wheel steering rack.
Installing
Installation is carried out in reverse order; note the following:
– Bring rear wheel steering into installation position and fit lock‐
ing tool - T40326- :

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Right side of vehicle:

• Note marking -2- “right”.
• “Arrow” points in direction of travel.
• Rear wheel steering -1- makes contact on pin of locking tool
at points -3-.
• Pin of locking tool must engage in hole -4- on subframe.

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Left side of vehicle:

• Note marking -3- “left”.
• “Arrow” points in direction of travel.
• Semi-circular mountings -2- of rear wheel steering rack -4-
must make contact with pin of locking tool.
• Pin of locking tool must engage in hole -1- on subframe.
– Tighten bolted connections for rear wheel steering rack.
– Detach locking tool - T40326- .
– Install track rods ⇒ page 158 .
• Observe steps required after installing rear wheel steering
rack.
Steps required after installing old rear wheel steering rack
– After installation is completed, drive vehicle onto wheel align‐
ment unit.
– Then check wheel alignment ⇒ page 235 .
Steps required after installing a new rear wheel steering rack
If a new rear wheel steering rack has been installed, activate rear
wheel steering control unit - J1019- :
– Connect vehicle diagnostic tester .
– Switch on ignition.
– Select and start Diagnosis mode.
– Select Test plan tab.
– Choose Select own test and select following options one
after the other:
♦ Systems with diagnostic capability
♦ Rear axle steering J1019

♦ 00CB - Rear wheel steering control unit, functions

♦ 00CB - Replace control unit
– Start selected program and follow instructions shown on dis‐
play of vehicle diagnostic tester.
– Then drive vehicle onto wheel alignment unit.
– Check wheel alignment ⇒ page 235 .
Tightening torques
♦ ⇒ “4.1 Exploded view - rear wheel steering rack”, page 291
♦ ⇒ Engine; Rep. gr. 26 ; Exhaust pipes/silencers; Exploded
view - silencers
♦ ⇒ General body repairs, exterior; Rep. gr. 66 ; Underbody
trim; Exploded view - underbody struts

4. Rear wheel steering rack 297