Volkswagen ID.3: Rear suspension, drive shaft. Suspension strut, shock absorber, spring

• Removing and installing shock absorber
• Renewing shock absorber
• Assembly overview – spring
• Exploded view - shock absorber
• Removing and installing spring
• Renewing spring

Removing and installing shock absorber

Removing and installing shock absorber

Special tools and workshop equipment required

♦ engine and gearbox jack -VAS 6931-

Removing

Removal and installation are described for the left side of vehicle as an example.

– Remove wheel → Rep. gr.44; Removing and installing wheel.

– → Rep. gr.42; Secure vehicle to support arms of lifting platform.

– Unbolt rear left vehicle level sender -G76- from spring control arm → Rep. gr.43; Removing and installing rear vehicle level sender [G76]/[G77].

Vehicles with adaptive chassis control

– Disconnect electrical connector -3- on rear left shock absorber damping adjustment valve -N338-.

– Pull electrical wire -arrow- off retainer on shock absorber -2-.

All vehicles (continued)

– Position engine and gearbox jack -VAS 6931- under spring control arm, and push upwards.

– Unscrew bolts -arrows- for shock absorber -1-.

– Unscrew nut -4-.

– Pull out bolt -2-.

– Press together shock absorber -1-.

– Guide shock absorber -1- out of spring control arm -3-.

Installing

Install in reverse order of removal, observing the following:

Important

● The shock absorber must be bolted to the spring control arm only in unladen position → Rep. gr.42; Raising wheel bearing assembly to unladen position.

– Carry out required function/functions using → Vehicle diagnostic tester → Rep. gr.00; Access to diagnoses.

Tightening torques

♦ → Rep. gr.42; Assembly overview – shock absorber

♦ → Rep. gr.43; Assembly overview – rear vehicle level senders

Renewing shock absorber

Renewing shock absorber

Special tools and workshop equipment required

♦ Extension -T10001/14-

♦ Extension -T10001/3-

♦ Ratchet -T10001/11-

♦ Suspension strut support clamp -V.A.G 1752/20-

♦ Torque wrench -V.A.G 1331-

♦ shock absorber set -T10001-

♦ suspension strut support clamp -V.A.G 1752/20-

Remove shock absorber → Rep. gr.42; Removing and installing shock absorber.

Dismantling shock absorber

– Clamp suspension strut support clamp -V.A.G 1752/20- in a vice.

– Clamp shock absorber into suspension strut support clamp -V.A.G 1752/20-.

– Lever cover -1- off shock absorber mounting -2-.

– Fit tools from shock absorber set -T10001- as shown in illustration, and loosen threaded connection for shock absorber mounting.

1 - Commercially available ratchet

2 - Ratchet -T10001/11-

3 - Shock absorbers

4 - Suspension strut support clamp -V.A.G 1752/20-

5 - Extension -T10001/3-

6 - Extension -T10001/14-

– Open cable tie -5-.

– Unscrew nut -3-.

– Pull shock absorber mounting -2- off shock absorber -1-.

– Remove protective tube -1- from shock absorber mounting -2-.

– Remove protective tube -1-.

Assembling shock absorber

– Fit tools from shock absorber set -T10001- as shown in illustration, and tighten threaded connection. When doing this, counterhold using ratchet.

1 - Tool insert -T10001/14-

2 - Commercially available ratchet

3 - Torque wrench -V.A.G 1331-

4 - Nut

5 - Shock absorber mounting

6 - Piston rod

7 - Extension -T10001/3-

8 - Ring spanner insert AF 21, commercially available

– Insert stop buffer -1- to stop into shock absorber mounting -2-.

– Make sure that seal -3- is firmly seated.

– Push protective tube -1- to stop onto shock absorber mounting -2-.

– Fit and secure cable tie -3-.

Important

● The fastener -arrow- of the cable tie -3- must be located within area -a-.

● Closure -arrow- of cable tie must point outwards when shock absorber is installed.

– Install cover -1- to shock absorber mounting -2-, and ensure that it is seated firmly.

Tightening torques

♦ → Rep. gr.42; Assembly overview – shock absorber

Assembly overview – spring

Assembly overview – spring

The overview is shown for the left side of vehicle as an example.

1 - Spring

❏ Depending on equipment/version

❏ Allocation → Electronic parts catalogue (ETKA)

❏ → Rep. gr.42; Removing and installing spring

2 - Spring seat

3 - Support

4 - Spring seat

5 - Spring control arm

❏ → Rep. gr.42; Assembly overview – spring control arm

❏ → Rep. gr.42; Removing and installing spring control arm

6 - Retaining clip

7 - Guides

Exploded view - shock absorber

Exploded view - shock absorber

The exploded view here applies to the left side of the vehicle.

1 - Shock absorber

❏ → Rep. gr.42; Removing and installing shock absorber

2 - Bolt

❏ 2x

❏ Renew after removing

❏ M 10 x 35

❏ 50 Nm +90°

3 - Cover

4 - Nut

❏ Renew after removing

❏ M10

❏ 25 Nm

5 - Shock absorber mounting

6 - Bump stop

7 - Cable tie

❏ Renew after removing

8 - Protective tube

9 - Nut

❏ Renew after removing

❏ M 12 x 1.5

❏ 70 Nm +180°

10 - Bolt

❏ Renew after removing

❏ M 12 x 1.5 x 90

Removing and installing spring

Removing and installing spring

Special tools and workshop equipment required

♦ Spreader device -VAS 6274/8-

♦ Supplement set -VAS 6274/12-

♦ Supplement set -VAS 6274/15A-

♦ Thrust plates -VAS 6274/16-

♦ spring compressing system -VAS 6274-

Removal and installation are described for the left side of vehicle as an example.

Removing

– Remove wheel → Rep. gr.44; Removing and installing wheel.

– → Rep. gr.42; Secure vehicle to support arms of lifting platform.

– Remove stone deflector for spring control arm → Rep. gr.42; Removing and installing stone deflector for spring control arm.

– Remove rear centre underbody cladding → General body repairs, exterior; Rep. gr.66; Underbody cladding; Removing and installing rear centre underbody cladding.

– Remove rear underbody cladding → General body repairs, exterior; Rep. gr.66; Underbody cladding; Removing and installing rear underbody cladding.

Vehicles with rear left vehicle level sender -G76-

– Unbolt rear left vehicle level sender -G76- from spring control arm → Rep. gr.43; Removing and installing rear vehicle level sender [G76]/[G77].

All vehicles (continued)

Preparing spreader device for rear suspension link:

– Screw threaded spindle -1- from spreader device -VAS 6274/8- into plastic-padded plate -2- from spreader device -VAS 6274/8-.

– Screw support plate -VAS 6274/15-8- -A- onto threaded spindle -1-.

– Screw in gripping rod included with spreader device -VAS 6274/8- -C-.

Important

● Please pay attention to the relevant side of the vehicle.

All vehicles (continued)

– Position support plate -A- on longitudinal member -1-.

– Fit support plate -B- onto suspension link at upper front -2-.

– Align tools between upper front suspension link -2- and longitudinal member -1- via gripping rod -1-.

– Turn threaded spindle until both support plates make contact.

– Push slide lock -2- in direction of -arrow-.

– Secure locating element -4- to thrust plate with slide lock -VAS 6274/16-2- -1- using bolts -3-.

Important

● Tighten bolts -3- to 10 Nm.

– Insert thrust plate with slide lock -VAS 6274/16-2- -F- into spring -1- at bottom.

Important

● Plastic support must face downwards.

– Turn thrust plate with slide lock -F- upwards at spring -1-.

– Insert 69 mm piston -VAS 6274/12-6- -D- into thrust plate with slide lock -F-.

Important

● Markings on piston -D- and thrust plate with slide lock -F- must be offset relative to one another by 90°.

– Push piston -D- through thrust plate with slide lock -F-.

– Turn piston -D- by 90°.

– Pull piston -D- downwards into guides on thrust plate with slide lock -F-.

Important

● Markings -arrows- must align properly.

– Push slide lock -2- to stop in direction of -arrow A-. This will fix piston -D- in position.

– Turn thrust plate with slide lock -F- as far as possible upwards on spring coils -1-.

– Make sure when doing this that plastic support rests against spring coils -1-.

NOTICE

Risk of damage to spindle due to lacking or wrong grease.

– Apply a thin coat of molybdenum disulfide to the front area of the spindle.

– Apply a thin coat of molybdenum disulfide -1- to the front area of the spindle -2-. For allocation, refer to → Operating manual of spring compressing system VAS 6274.

– Guide spindle -VAS 6274/15-1A- -E- into spring -1-, and screw into piston -D-.

– Insert thrust plate with swivel mounting -VAS 6274/16-1- -M- into spring -1-.

Important

● Plastic support must face upwards.

– Turn thrust plate with swivel mounting -M- upwards at spring -1-.

– Guide hexagon of spindle -E- through hole in thrust plate with swivel mounting -M-.

– Guide spindle -E- with socket with ball head (AF8) -VAS 6274/15-3-.

– Unscrew spindle -E- as far as possible.

Important

● Shank – without spindle threads – -E- must be located below thrust plate with swivel mounting -M-.

– Position spindle attachment -VAS 6274/15-2A- -G- on spindle -E-.

– Turn thrust plate with swivel mounting -M- as far as possible downwards at spring -1-.

– Turn thrust plate with swivel mounting -M- upwards at spring coil -1-.

– Align spindle attachment -G- in thrust plate with swivel mounting -M-.

Important

● Make sure that spindle attachment -G- makes proper contact with guide of thrust plate with swivel mounting -M-.

– Align thrust plate with slide lock -F- and thrust plate with swivel mounting -M-.

Important

● Arrow on thrust plate with swivel mounting -M- must face in direction of travel.

Important

● Make sure that spring is properly seated in thrust plates.

– Secure locating element -3- with bracket -7- to thrust plate with swivel mounting -M- -5-.

Important

● Tighten bolts -6- to 10 Nm.

– Connect thrust plate with swivel mounting -M- and thrust plate with slide lock -F- via brackets -5- and bolts -4-.

Important

● Tighten bolts -4- to 10 Nm.

– Position socket with ball head (AF8) -VAS 6274/15-3- -K- at spindle -E-.

Important

● Make sure that spindle attachment -G- is correctly seated in swivel mounting of thrust plate -M-.

● Make sure that spring -1- is properly seated in thrust plate with swivel mounting -M-.

– Tighten spindle -E- by hand.

– Insert counter-hold tool -VAS 6274/7- -N- into thrust plate with swivel mounting -M-.

– Tension spring -1- using socket wrench -K- while counter-holding with counter-hold tool -N-.

– Compress spring -1- until support -2- can be removed.

– Carefully lever spring -1- with spring seat -2- off spring control arm -3-.

– Remove spring -1- with tools.

Installing

Install in reverse order of removal, observing the following:

– Insert lug of spring seat -2- into hole in spring control arm -3-.

Renewing spring

Renewing spring

Special tools and workshop equipment required

♦ Spreader device -VAS 6274/8-

♦ Supplement set -VAS 6274/12-

♦ Supplement set -VAS 6274/15A-

♦ Thrust plates -VAS 6274/16-

♦ foot pump -VAS 6179-

♦ hydraulic tensioning device -VAS 6274/9-

Removing

– Remove spring → Rep. gr.42; Removing and installing spring.

– Connect foot pump -VAS 6179- to hydraulic tensioning device -VAS 6274/9-.

– Check nuts -arrows- on hydraulic tensioning device -VAS 6274/9- -L- for secure fit.

– Attach centring disc of spring mounting -VAS 6274/15-6A- -I- to tensioning device -L-.

Important

● Make sure that recess of centring disc -I- faces towards vehicle side L or R, respectively, and that locating element is fitted at top.

– Secure centring disc -9- with bolt -1-.

– Place adapter plate with magnets -VAS 6274/15-5- -H- onto flexible mounting, making sure that magnetic holder is correctly seated.

– Insert spring -1- with tools into tensioning device -L-.

Important

● Make sure that guides on mounting -1- are located in holes of centring disc -I-.

– Hold spring in this position.

– Connect foot pump -L- to tensioning device.

– Withdraw piston of tensioning device -L- until spring -1- is securely fitted.

Important

● Do not tension spring -1-.

● Spring -1- must be seated correctly at guide of adapter plate -H-.

– Determine and make note of dimension -a-.

– Mark installation position of thrust plate with slide lock -VAS 6274/16-2- -F- and thrust plate with swivel mounting -VAS 6274/16-1- -M- on spring -1-.

– Fit centring sleeve -VAS 6274/15-7- -J- in position.

– Position socket with ball head (AF8) -VAS 6274/15-3- -K- on spindle 130 mm (AF19) -VAS 6274/15-1A- -E-.

– Relieve tension from spring -1- via socket -K- at tensioning device -L-.

– Move back piston of tensioning device -L- using foot pump.

– Make sure that spring -1- is properly seated in tensioning device -L-.

– Relieve tension from spring -1- via socket -K- in tensioning device -L-.

– Move piston of tensioning device -L- further back via foot pump.

– Detach tools.

Installing

Install in reverse order of removal, observing the following:

– Insert spring -1- into tensioning device -L-.

Important

● Markings must be transferred to new coil spring.

● Make sure that guides on mounting -1- are located in holes of centring disc -I-.

– Hold spring in this position.

– Connect foot pump -L- to tensioning device.

– Withdraw piston of tensioning device -L- as far as spring -1-.

Important

● Spring -1- must NOT be tensioned.

– Make sure that spring -1- is properly seated on guide of adapter plate -M-.

– Retract piston of tensioning device -L- until spring -1- is securely fitted.

– Insert thrust plate -F- in installation position.

– Move 69 mm piston -VAS 6274/12-6- -D- through thrust plate -F-.

– Insert piston -D- into thrust plate -F-.

Important

● Markings -arrow- on piston -D- and thrust plate -F- must be offset 90°relative to one another.

– Turn piston -D- by 90°.

– Pull piston -D- downwards into guides on thrust plate -F-.

Important

● Markings -arrows- must align properly.

– Insert thrust plate -M- observing markings for orientation.

– Screw spindle -E- into piston -D- using socket with ball head (AF8) -VAS 6274/15-3-.

– Attach locating element.

Important

● Tighten bolts to 10 Nm.

– Push slide lock -2- to stop in direction of -arrow A-. This will fix piston -D- in position.

– Push spindle attachment -VAS 6274/15-2A- -G- onto spindle -E-.

– Screw spindle -E- further into piston -D-.

– Screw in spindle -E- until spindle attachment -G- rests against thrust plate -M-.

– Make sure that spindle attachment -G- is correctly seated in hole of thrust plate -M-.

– Fit centring sleeve -VAS 6274/15-7- -J- in position.

– Bring socket -K- in position on spindle -E-.

Important

● Spring -1- must be properly seated in tensioning device -L-.

– Turn socket -K- 2 turns.

– Turn socket -K- far enough to make sure that spring -1- cannot slip out of tensioning device -L-.

Important

● Spring -1- and tools must be seated correctly.

–

– Operate foot pump, and slightly tighten spring -1- via piston of tensioning device -L-.

– Tension spring -1- via spindle -E-. Keep retracting piston of tensioning device -L- over and over again.

– Tension spring -1- until dimension a determined beforehand is obtained.

– Move back piston of tensioning device -L- via foot pump.

– Hold spring -1- in place.

– Remove spring -1- with tools from tensioning device -L-.

– Install spring → Rep. gr.42; Removing and installing spring.

Rear suspension, drive shaft. Suspension link, track rodRear suspension, drive shaft. Wheel bearing assembly, trailing arm