Table of contents: Removal and installation ↓ Fixing the subframe ↓
Removal and installation
1. Subframe installation details are shown on illustrations 1.1a. The subframe is removed on the mounting platform along with the steering gear, front final drive, lower arms and steering knuckles. The suspension struts with the upper arms and their brackets remain on the car.
2. Place the car on a lift.
3. Remove the front wheels, sound insulation panels under the engine compartment (see Section 19 of Chapter 1) and the left front wheel arch liner (see chapter 10).
4. Unscrew the fasteners of the refrigerant line holders (see illustration 5.8 Chapter 2). After this, the refrigerant lines can be slightly moved to the side for installation on the side members of supports No. 10-222A/19.
5. Select the weight of the power unit. To do this, remove the upper engine cover and follow the steps described in paragraphs 6-8 (for 3.0 TDI engines) or 9-11 (for 4.2 TDI engines). After this, go to paragraph 12.
6. Remove the air cleaner (see chapter 4) and the air intake hose (see illustration 4.16 Chapter 2).
7. Remove the drive belt and its tensioner (see Chapter 2).
8. Follow the steps described in paragraphs 9-12 of Section 5 of Chapter 2, and evenly rotate the lifting device spindles 3 turns.
9. Remove the air cleaner (see Chapter 4).
10. Loosen the bolt (1 in illustration 36.15 Chapter 2), unscrew the bolt (2) and remove it together with the nut. Slide the coolant pipe off the rear right engine lifting eye. Remove the hood seals (see illustration 36.9 Chapter 2) on both sides.
11. Install the lifting devices as shown in the illustrations and turn their spindles evenly through 3 turns.
3.11a. Installation of lifting equipment, part 1 of 2.
3.11b. Installing Lifting Equipment, Part 2 of 2.
12. Remove the ABS sensor and brake pad wear sensor wiring brackets from the steering knuckles. Disconnect the connectors of these sensors. Remove the brake calipers and hang them on the body so that the brake hoses are not damaged.
13. Clamp the suction and return hoses at the power steering fluid reservoir with No. 3094 clamps with a diameter of 25 mm (see illustration).
3.13. Pinched power steering fluid lines.
Note: Do not pinch the hose directly at the non-return valve located in the return line.
14. Unscrew the fasteners (1 in illustration 3.27 Chapter 7) power steering line bracket, disconnect the power steering pressure and return lines from the steering gear (2).
15. Set the coolant hoses aside (see illustration 15.30 Chapter 2). Release the power steering fluid line from the bracket on the left subframe.
16. Separate the front propeller shaft from the front final drive and hang it on a wire.
17. Remove the heat shield (And in illustration 4.43 of Chapter 2) steering mechanism. Set the front wheels in the straight ahead position and secure the steering wheel with tape to prevent it/steering column from changing position. Remove the hinge mounting bolt (B) and separate it from the steering gear.
18. Disconnect the steering gear wiring connector (see illustration 4.42 Chapter 2).
19. Loosen the upper control arm nut and press the arm out of the steering knuckle (see Figure 7.9 in Chapter 7).
20. Install the required supports from the VAS6131/10, -/11, and -/13 kits onto the VAS6131 alignment table. Tighten the support fasteners on the table by hand, install the alignment table on a transmission jack, and position it horizontally under the powertrain. The supports from the VAS6131/10 and -/11 kits must be positioned on the front side of the subframe as shown in illustrations 4.49 Chapter 2. Make sure the threaded spindles are screwed in completely.
21. Install the supports from the VAS6131/10 and -/13 kits under the suspension struts and the rear side of the subframe as shown in illustrations 4.50b-c Chapter 2. Drive the spindles of all the supports upwards so that their centering projections touch the support points. Tighten the support plates of the supports on the coordinate table with a torque of 20 Nm.
22. On both sides, unscrew the bolts (1 and 2 in Illustration 7.7 of Chapter 7) and fix the position of the subframe (see subsection below).
23. Remove the bolts (4 in illustration 4.51 Chapter 2), lower the subframe by approximately 50 mm and carefully disconnect the ventilation line (And in the illustration) from the front main gear.
3.23. Ventilation line (A).
Release and disconnect the power steering fluid line from the subframe. Lower the subframe completely.
24. Installation is carried out in reverse order.
Fixing the subframe
25. Some repair procedures require removal of the subframe or the entire front suspension. The original position of the subframe relative to the body can be achieved by installing T10300 centering pins before lowering the subframe or the entire front suspension.
26. Remove the bolts (2 in illustration 4.51 Chapter 2) and screw in the T10300 centering pins instead by hand up to the marks (In the illustration).
3.26. Markings on the centering pin.
Then tighten them to 30 Nm, holding the bushing flats with an open-end wrench to prevent them from turning.
27. Removal of the centering pins is carried out in reverse order.
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