Subframe, Removing and Installing

Subframe, removing and installing

Special tools, testers and auxiliary items required:

^ Engine support bridge 10 - 222 A
^ Bracket with spindle and hook 10 - 222 A/10
^ Adapter 10 - 222 A/18
^ Testing mandrel 3393
^ Torque wrench V.A.G 1332
^ Engine/transmission jack V.A.G 1383 A

Removing





^ Install support bridge 10 - 222 A together with supports 10 - 222 A/1.

Vehicles with 8-cylinder engine
^ Remove oil filler pipe from engine.





^ Install support bridge 10 - 222 A together with bracket for engine 10 - 222 A/1 and the adapter 10 - 222 A/18.

The longer side of adapter 10 - 222 A/18 faces forward.
^ Secure third spindle 10 - 222 A/10 with additional hook 10 - 222 A/2 on lifting eye T40016 at left rear of engine.
^ Hook second additional hook 10 - 222 A/2 on lifting eye at right rear of engine.

Continued for all vehicles
^ Take weight of engine/transmission assembly on the spindles.
^ Remove wheels.
^ Remove noise insulation tray.

Vehicles with automatic headlight range control





^ Unclip clamp for coupling rod - 1 - for left front level control system sensor G78 from control arm - 2 -.

Continued for all vehicles





^ Before loosening subframe, check that at least holes - 1 - and - 2 - align using testing mandrel 3393.

If this is not the case, perform axle alignment measurements after installing the sub-frame!





^ Remove hex bolt - 5 -.
^ Remove hex nuts - 3 - and - 4 - and take out coupling link.
^ Remove hex nut - 2 - for track-control link on subframe and remove hex bolt.
^ Loosen hex bolt - 1 -.





^ Remove hex bolts - arrows - from transmission mounting - 1 -.

Vehicles with all-wheel drive
^ Unbolt driveshaft from transmission.

Continued for all vehicles





Place engine/transmission jack V.A.G 1383 A with V.A.G 1359/2 under subframe and apply slight counter pressure.
^ Remove bolts - 1 - and - 2 - at rear of subframe on both sides of vehicle.

A - Supporting wood blocks
^ Lower subframe slightly with the engine/transmission jack V.A.G 1383 A.
^ Remove hex bolts for control arm and guide control arm.
^ Disconnect ABS speed sensor wiring out from retainer on brake caliper.





^ Pull both control arm and guide control arm out of subframe.





^ Remove hex bolts - A -.
^ Loosen hex bolts - B - until subframe can be taken out.

Installing





^ Install subframe and start hex bolts - A - and - B -.





^ Guide both control arm and guide control arm into subframe.
^ Install bolts into inner holes - arrows -.
^ Lift rear of subframe slightly using engine/transmission jack V.A.G 1383 A.

The subframe must be attached to the body with the help of testing mandrel 3393 before tightening.





^ Hole - 1 -, sub-frame hole - 2 - and aluminium console hole - 3 -must align on both sides.

Note:
^ This attachment only replaces subsequent axle alignment measurements when:
^ The sub-frame is removed completely and installed.
^ Holes - 1 - and - 2 - align before repairs are made.





^ Tighten bolts - 1 - and - 2 - to specified torque at rear of subframe on both sides of vehicle and.

Note:
^ The screws may only be tightened to additional turn angle after vehicle alignment.

A - Supporting block of wood

^ Protect holes in structure for mounting testing mandrel 3393 against corrosion.





^ Tighten hex bolts - A - and - B - and.





^ Tighten hex bolts - arrows - at transmission mounting - 1 -.





^ Insert new hex bolts for guide control arm - 1 - and control arm - 2 - and tighten new hex nuts and.

Note:
^ Push track-control and guide links inward while tightening.

^ Tighten hex nuts - 3 - and - 4 - and.
^ Tighten hex bolt - 5 -.

Vehicles with automatic headlight range control
^ Install clamp for connecting rod for left front level control system sensor G78 to control arm.

During installation, observe installing position of clamp on control arm.

Continued for all vehicles
^ Connect ABS vehicle speed sensor wiring into retainer on brake caliper.

Vehicles with all-wheel drive
^ Bolt driveshaft to transmission.

Continued for all vehicles
^ Attach oil filler line to engine.
^ Install wheels and tighten.

Check front axle, alignment must take place on a VW recommended alignment stand.

Note:
^ The screws for subframe must only be tightened to additional turn angle after vehicle alignment.