With Anti-Theft Protection

With Anti-Theft Protection

Special tools, testers and auxiliary items required

• Electric Knife (V.A.G 1561 A) with Saw Set (V.A.G 1561/14)

• Hot Air Gun from the Wiring Harness Repair Set (VAS 1978)

• Vehicle Diagnostic Tester, for example, Vehicle Diagnosis, Testing and Information System (VAS 5051 B)

• Locking Pliers

• Protective Gloves

• If the Engine Control Module (ECM) is to be replaced, connect the vehicle diagnostic tester and perform the "Guided Functions, Replacing Engine Control Module".

Conditions

• Ignition is turned off.

Removing

- Remove the windshield wiper arms and the plenum chamber cover.

- Remove the plenum chamber bulkhead.

• The threads of the shear bolts are equipped with locking compound. By heating the shear bolts using the hot air gun, the inhibition effect of the locking compound is lowered.


Cover the wires, the harness connectors and the control modules in close vicinity of the ECM to prevent damage from burning.

Set the hot air gun - 4 - as shown:






- Turn the temperature adjuster - 2 - to maximum heat output (600 °C (1112 °F)).

- Move the two stage switch for air quantity - 3 - to position 3.


By heating the shear bolts, parts of the protective housing are heated intensely. Wear protective gloves to prevent injuries.

- Guide the nozzle of the hot air gun onto the shear bolt.

- Turn on the hot air gun and heat the shear bolt for approximately 20 to 25 seconds.

- Remove the shear bolt using pliers on the bolt head.

The procedure for the second shear bolt is exactly the same.

If the bolts cannot be removed:

- Cut into the heads of the shear bolts so that two parallel surfaces are formed - arrows - and remove the bolts.






- Insert a screwdriver - A - between the protective housing and retaining plate - arrow -.






- Pry the protective housing upward using the screwdriver - A - and pull it off sideways from the retaining plate - arrow -.






- Disconnect the front connector - 1 - from the ECM.






- Pry up the locking mechanism - 2 - slightly.

- Push the ECM in the - direction of the arrow - out of the retaining plate.

- Release the rear connector from the ECM and remove it.

Installing

- Connect the rear connector to the ECM and lock it into place.

- Slide the ECM onto the retaining plate.

- Now connect the front connector - 1 - to the ECM and secure it.






- Slide the protective housing onto the retaining plate.

- Tighten the shear bolts - 1 - uniformly until the bolt heads shear off.






- Install the plenum chamber bulkhead.

- Install the windshield wiper arms and the plenum chamber cover.

- If the ECM was replaced, connect the vehicle diagnostic tester and perform "Guided Functions, Replacing Engine Control Module".

- Read the ECM Diagnostic Trouble Code (DTC) memory and erase all DTC entries. refer to "Guided Functions" in the vehicle diagnostic tester.

- Perform a test drive.

• Observe safety precautions that apply to road tests. Refer to => [ If special testing equipment is required during road test, note the following: ] Diesel Fuel Injection.

- Again, check the ECM DTC memory.