Engine Accessory Bracket: Service and Repair

Accessory Bracket

Special tools, testers and auxiliary items required

• Mount (T40093/5) , from Engine Support Supplement Set (T40093)

• Moveable Joint (T40091/3) (Qty: 2), from Engine Support Basic Set (T40091)

• Moveable Joint (T40093/4) (Qty: 2), from Engine Support Supplement Set (T40093)

• Rail with Holes (T40091/2) , from Engine Support Basic Set (T40091)

• Square Pipe (T40091/1) (Qty: 2), from Engine Support Basic Set (T40091)

• Engine Support Bridge (10-222 A)

• Adapter (10-222 A/28-2) (Qty: 2)

• Adapter (10-222 A/28)

• Shackle (10-222 A/12)

• Bracket with Spindle and Hook (10-222 A/10)

• Torque Wrench (5-50 Nm) (V.A.G 1331)

• The accessory bracket can be removed and installed without having to open the refrigerant circuit.






1 Bolt, M8 x 110

• 25 Nm

2 Bolt, M8 x 60

• 25 Nm

3 Bolt, M8 x 30

• 25 Nm

4 Bolt, M8 x 30

• 25 Nm

5 Bolt, M8 x 30

• 25 Nm

6 Bolt, M8 x 30

• 25 Nm

When doing any repair work, especially in the engine compartment, pay attention to the following due to clearance issues:

• Route lines of all types (for example, fuel, hydraulic, Evaporative Emission (EVAP), coolant, refrigerant, brake fluid and vacuum) and electrical wiring so that the original path is followed.

• To prevent damage to the lines, make sure there is sufficient clearance to all moving or hot components.

Removing

• The bracket can be removed without removing the battery and the battery tray.

Danger of causing damage to the flex coupling element:

• Do not bend the flex coupling element more than 10°.

• Do not stretch the flex coupling element.

• Do not damage the wire mesh on the flex coupling element.

- Remove the exhaust system suspended mount bolts - arrows - from the subframe.






- Remove the pendulum support bolt - 1 -.






- Then, remove the bolts - 2 and 3 - and the pendulum support.

- Remove the air filter (engine cover). Refer to => [ Air Filter and Engine Cover ] Air Filter and Engine Cover.

- Remove the plenum chamber cover.

- Remove the bolts - arrows - from the left and right sides of the lock carrier brackets.






- Remove the lower mount from the adapter (10-222 A/28) and replace it with adapter (10-222 A/28-2).






- Remove the bolts - arrows - from the adapter (10-222 A/28-2).

- Use the bolts from the adapter (10-222 A /28-2) to install the adapter (10-222 A/28). Do not use the bolts for the lock carrier brackets.






- Bolt - arrows - tightening specification: 8 Nm.

A second technician is needed to install the engine support bridge (10-222 A) to the vehicle in order to prevent the engine support bridge from tipping.

- Install the adapter (10-222 A/31-2) - 1 - to the inner hole in the engine support bridge (10-222 A) and install the 2 moveable joints (T40091/3) - 2 - from the left side.

• The bolts in the moveable joints (T40091/3) face in the direction of travel.

- Install the adapter (10-222 A/31-1) - 3 -, but do not tighten the bolts yet.






1. Adapter (10-222 A/31-2)

2. Moveable joint (T40091/3)

3. Adapter (10-222 A/31-1)

4. Moveable joint (T40093/4)

5. Square pipe (T40091/1)

6. Adapter (10-222 A/28) with adapter (10-222 A/28-2)

7. Bracket with spindle and hook (10-222 A/10).


- Push the two brackets with spindles and hooks (10 - 222 A /10) onto the right square pipe - 5 -.

- Install the engine support bridge (10-222 A) and attach the adapter (10-222 A/31-1) - 3 - in the correct position.

- Slide the left and right square pipes (T40091/1) - 5 - through the adapters (10-222 A/28) - 6 - from the front and mount the moveable joint (T40093/4) - 4 - to the rail with holes on each side.

- Slide both brackets with spindles and hooks (10-222 A/10) - 7 - in front of and behind the moveable joint (T 40093/4) - 4 - on the right side.

- Slide the square pipe (T40091/1) - 5 - through the moveable joint (T40091/3) - 2 -.






1. Rail with holes (T40091/2)

2. Bracket with spindle and hook (10-222 A/10)

3. Spindle (10-222 A/11)

4. Shackle (10-222 A/12)


- Slide the rail with holes (T40091/2) - 1 - through the moveable joint (T40093/4) from the right side.

- Slide the rail with holes (T40091/2) - 1 - into the moveable joint on the other side and secure it.

- Tighten all the threaded connectors hand tight.

- Lengthen the right bracket and spindle and hook (10-222 A/10) using the adapter (10-222 A/7).

- Install the adapter (10-222 A/7) to the cylinder block, see the illustration below.






- Position the spindles and support the engine. Do not lift.

- Remove the bolt - 2 - and move the windshield washer filler tube forward - 1 -.






- Remove the bolts - 5 - and place the coolant expansion tank on top of the engine with the hoses connected.

- Remove the engine mount bolts - 2 -.






• The rear bolts - 2 - are accessible through a hole in the wheel housing.

Risk of destroying due to a reversed running direction of a used ribbed belt:

• Before removing the ribbed belt, marking the running direction with chalk or a felt-tip pen for reinstallation later.

- Remove the ribbed belt. Refer to => [ Ribbed Belts ] Ribbed Belts.

- Remove the Air Conditioning (A/C) compressor ribbed belt tensioner. Refer to => [ Ribbed Belt Tensioner, A/C Compressor Belt ] Ribbed Belt Tensioner, A/C Compressor Belt.

- Remove the generator, power steering pump and coolant pump ribbed belt tensioner. Refer to => [ Ribbed Belt Tensioner, Generator, Power Steering Pump and Coolant Pump Belt ] Ribbed Belt Tensioner, Generator, Power Steering Pump and Coolant Pump Belt.

- Remove the generator.

Refrigerant can cause serious personal injury.

• Do not open the A/C refrigerant circuit.

- Remove the A/C compressor from the bracket.

Securing the A/C Compressor to the Body:





Risk of damaging refrigerant lines and hoses.

• Do not stretch, kink or bend refrigerant lines and hoses.

- Remove the clamps for the power steering pressure line from the transmission.

- Remove the nuts - 1 - and the power steering pump hose.






- Remove the power steering pump from the bracket and set it down at the front.

• The power steering lines remain connected to the power steering pump.

• Note the different bolt lengths.

- Remove the accessory bracket bolts - 1 through 6 - and then remove the bracket from the cylinder block.






Installing

Installation is performed in the reverse order of removal. When doing this note the following:

• Note the different bolt lengths.

- Install the accessory bracket and the bolt - 5 -.

- Install the bolts - 1, 2, 3, 4 and 6 -. Tighten all the bolts in 3 stages in sequence - 1 through 6 - as follows:

- Tighten the bolts by hand.

- Tighten the bolts to 20 Nm.

- Tighten the bolts an additional 90° (1/4) turn.

- Install the engine mount. Refer to => [ Engine Mount ] Engine Mount.

- Install the generator.

- Install the A/C compressor to the bracket.

- Install the generator, power steering pump and coolant pump ribbed belt tensioner. Refer to => [ Ribbed Belt Tensioner, Generator, Power Steering Pump and Coolant Pump Belt ] Ribbed Belt Tensioner, Generator, Power Steering Pump and Coolant Pump Belt.

- Install the A/C compressor ribbed belt tensioner. Refer to => [ Ribbed Belt Tensioner, A/C Compressor Belt ] Ribbed Belt Tensioner, A/C Compressor Belt.

- Install the power steering pump to the accessory bracket.

Risk of destroying due to a reversed running direction of a used ribbed belt:

• Before removing the ribbed belt, mark the running direction with chalk or a felt-tip pen for reinstallation later.

- Install the ribbed belts. Refer to => [ Ribbed Belts ] Ribbed Belts.

Ribbed Belt Routing:





1. Power steering pump pulley

2. Ribbed belt, for the generator, power steering pump and coolant pump

3. Generator pulley

4. Idler pulley

5. A/C compressor pulley

6. Ribbed belt, for the A/C compressor

7. Vibration damper

8. Belt tensioner, for the A/C compressor ribbed belt

9. Belt tensioner, for the generator, power steering pump and coolant pump ribbed belt

10. Coolant pump pulley


• Remove the adapter (10-222 A/7) from the cylinder block.