Remove the front undersheets -2 & 3-.
Remove the front subframe brace. Refer to

–

"Brace front subframe - To remove and fit".→
Rep.-Gr.40

For vehicles equipped with "EAWS", remove the
–

two fixings -arrows- (10 Nm), detach the 48 volt
steering connector block -1- from the body and
move to one side.

–

Remove the three fixings -arrows- (10 Nm) and the
upper heatshield -1-.

–

Remove the fixing -1- from lower
steering coupling (20 + 90).
Detach the steering column -2-

–

from the rack -3- and push
upwards to gain access to the
transmission mount fixings.
Detach the electrical connection arrow- to the transmission mount.

Caution
Prior to removing ANY of the fixings -arrows-, mark the position
of the transmission mounting bracket -1- against the automatic
transmission housing in order to retain the correct height settings
of the bracket -1-. Failure to do so will result in premature mount
failure!

From the underside of the vehicle, remove the
–

rearmost fixing -arrow- (20 Nm) from the
transmission mount -1-.

–
–
–

Remove the two fixings -1- (20 Nm) securing the
transmission mount -2-.
Remove the outer fixing -3- (55 Nm) securing the
transmission mount -2- to the body.
Carefully manoeuvre the transmission mount assembly out
from beneath vehicle.

Note
Access is tight.

Replacement of the transmission mount

–

Remove the three fixings -arrows- (10 Nm) and the
heatshield -1-.

–
–

Remove the "Multispline" fixing -arrow- (55 Nm)
and detach the top bracket.
Using a soft-faced mallet, carefully tap the lower
bracket from the transmission mount.

Installation – RH side
Installation is the reverse of removal procedure, noting the
following.

Caution
When refitting the transmission mounting bracket, the mounting
bracket MUST be positioned to the corresponding markings
previously made prior to tightening the fixings -arrows-.
–

Refit all previously removed components.

–

Torque tighten all remaining fixings.→ Rep.-Gr.00

Kovomo and Diesel Lower suspension lever - Rear - To remove and fit
General Information

The following procedure is for the LH lower rear lever. The procedure for the RH lever is the same except where
stated.
Special tools and workshop equipment required



Ball joint puller -T10444-



Vehicle tester



21 mm Ring insert -VAG 1332/7-



Torque tightening values
Unless otherwise shown, standard torque values apply.
→ Rep.-Gr.00

Single use items
Within this procedure there are single use items which
must be replaced and not reused. Ensure that new
replacements are available prior to starting this
procedure.

Removal
Set the car in "Jack" mode and position on a ramp.
–

Refer to "Raising and supporting the car". → Rep.Gr.99
Discharge the air from the air spring dampers.

–

Refer to "Air suspension system - To discharge and
charge".→ Rep.-Gr.43

Caution
Ensure the air is evacuated from the suspension
strut prior to carrying out this procedure. The air


is under high pressure and must only be
discharged via the Vehicle tester.
Once the air has been discharged from the air
suspension struts, the car must NEVER be
lowered and allowed to rest on its wheels and



compressing the discharged air suspension
struts. Failure to comply may result in internal
damage of the air bellows leading to catastrophic
failure of the air suspension strut.

–

Remove the foremost under sheet. Refer to "Front
undersheets - To remove and fit". → Rep.-Gr.66
Remove the foremost transmission mount

–

assembly. Refer to "Automatic transmission mounts
- Front - To remove and fit ". → Rep.-Gr.37

–

Remove the fixings -arrows- (10 Nm) and detach
the heatshield -2-.

Note
The LH side has an additional coolant pipe stay bracket
-1-. Remove this fixing also where applicable -arrow(10 Nm).

On the outer section of the lower lever and using 21
–

mm Ring insert -VAG 1332/7-, release the nut arrow- (140 Nm) until it is flush with the end of the
thread of the ball joint.

–
–

–
–

Using Ball joint puller -T10444-, "break" the taper
pin of the ball joint.
Remove the Ball joint puller -T10444- , remove and
DISCARD the nut -arrow-.

Remove and DISCARD the fixings -2 and 3- (70
Nm + 180°.
Manoeuvre the lower lever -1- out from the sub
frame and wheel bearing housing.

Installation
Installation is the reverse of removal procedure, noting
the following.

Note
The lower lever -1- MUST be fitted into the wheel
bearing housing first.
Secure the outer section of the lower lever -1- to the
–

wheel bearing housing with a NEW fixing -arrowbut do NOT yet torque tighten.

Secure the inner section of the lower lever -1- to the
–

sub frame with NEW fixings -2 and 3- but do NOT
yet torque tighten.

Caution
There is a requirement that any suspension
component with bonded rubber bushes, all levers
and the bearing housing MUST be set at standard
ride height before tightening the fixings.
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.
Failure to comply will result in the lever bushes
undertaking excessive torsional twist, resulting in
rupture and complete failure of the rubber inserts.
The suspension must be set to a specific angle prior to
torque tightening the fixings.

Position the Hydraulic support stand ASE40611000000 or VAG 1383-A- beneath the
–

wheel bearing housing and jack until the
suspension levers are at the correct ride height
level. Refer to "Raising the wheel bearing housing To tighten bolts".→ Rep.-Gr.40

With the wheel bearing housing in the raised
–

position, torque tighten the fixing -3- to 70 Nm + 180
° using a suitable "crow ring" spanner.

–

Remove the Hydraulic support -ASE40611000000
or VAG 1383-A-.

Using 21 mm Ring insert -VAG 1332/7- , torque
–

tighten the nut -arrow- securing the ball joint on the
outer section of the lower lever -1- to the wheel
bearing housing to 140 Nm.

–
–

Take the car out of "Jack" mode.→ Rep.-Gr.99
Charge the air suspension. Refer to "Air suspension
system - To discharge and charge".→ Rep.-Gr.43

Lower front suspension lever (rear) bush - To replace
General Information
Bush — Lower suspension lever rear — To remove and fit
–

Removing and installing bonded rubber bush for guide link

Special tools and workshop equipment required



Thrust plate — VW 402




Press tool — VW 412





Removal sleeve



Workshop press VAS 6654



Assembly lubricant -G 294 421 A1-
















Removal

–
–

Remove rear lower suspension lever. Refer to "Lower
suspension lever — Rear — To remove and fit".→ Rep.-Gr.40
Mark installation depth on bonded rubber bush using a
waterproof felt-tip pen or similar.

–

Set up special tools as shown in illustration



-1- Workshop press -VAS 6654



-2- Press tool guide



-3- Suitable spacer



-4- Press tool T40048/7



-5- Bonded rubber bush



-6- Suspension arm



-7- Separating device VAS 251413



Note
Hold the suspension arm when pressing the bonded rubber bush
in or out.
–

Press bonded rubber bush out of guide link.

Installation
Installation is the reverse of removal procedure, noting the
following.
–
–

Transfer marking for installation depth from old bonded rubber
bush to new bush.
Lightly lubricate new bush with assembly lubricant.

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.
Fit bonded rubber bush into guide link using previous setup of

–

special tools.
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.
Note

l Dimension -a- = 23 mm
–
–



Press bonded rubber bush in further if specification is not
met.
Refit rear lower suspension lever.