Subframe: Service and Repair
Subframe, removing and installing
Special tools, testers and auxiliary items required
^ Engine support bridge 10 - 222 A
^ Support 10 - 222 A /1
^ Testing mandrel 3393
^ Torque wrench V.A.G 1331
^ Torque wrench V.A.G 1332
^ Engine/transmission jack V.A.G 1383 A
Removing
- Support engine entirely with engine support bridge.
- Remove wheel covers, remove cover cap on light-alloy wheels (removal hook in vehicle tool kit).
- Remove wheels.
- Secure brake disc with a wheel bolt.
- Remove sound insulation.
Convertible only
- Remove front diagonal brace.
Continued for all vehicles
- Before removing subframe, check whether holes - 1 - and - 2 - are aligned using special tool 3393.
If this is not the case, a vehicle alignment must be performed after carrier is installed.
- Remove nuts - arrows - at transmission mounts if necessary.
- Remove nuts - 1 -
- On vehicles with headlight range control, remove vehicle level sensor link from link.
- Remove ABS speed sensor screw - 5 -.
- Remove ABS speed sensor wiring from wheel bearing housing bracket.
Vehicles with brake caliper HP-2
- Remove hex bolt - 2 - and remove brake line bracket.
- Remove bolts - 1 - from brake caliper and remove brake caliper.
- Reinstall brake line bracket. Reinstall hex bolt - 2 - and tighten.
- Secure brake caliper to body so that caliper weight does not bend or damage brake line.
Continued for all vehicles
- Remove brake caliper and secure to body so that weight of caliper does not stress or damage brake hose or brake line.
To avoid damaging upper link joints, wheel bearing housing must be braced against a rebound that is too strong, e.g. using engine/transmission jack V.A.G 1383 A
- Remove bolt - 1 -
- Remove bolt - 4 -
- Remove bolt - 3 -
- Loosen guide link/subframe connection.
- Remove tunnel crossmember if necessary.
- Place engine/transmission jack V.A.G 1383 A with wooden block under subframe and press lightly against.
- Remove hex bolts - 1 -.
- Remove hex bolts - 2 - and lower rear subframe.
- Remove guide link hex bolts.
- Remove guide links from subframe.
Note:
^ To prevent link and guide link pins from being over flexed, they should be secured with a wire or something similar during removal.
- Remove power steering line - arrow - from console.
- Remove bolt - 3 -.
- Loosen hex bolts - 2 - until subframe can be removed.
Installing
- Insert subframe and install hex bolts - 5 - and - 6 -.
- Insert suspension strut hex bolts at link.
- Guide control arms and guide links into subframe.
Before tightening subframe, it must be fixed to body using Testing Mandrel 3393.
- Holes - 1 - and - 2 - of subframe and hole - 3 - of aluminum bracket must line up on both sides.
Note:
^ This attachment only replaces subsequent vehicle alignment measurements when:
^ The subframe is removed completely and installed.
^ Holes - 1 - and - 2 - lined up before the repair.
- Position hex bolts - 1 - and - 2 -.
- Protect holes in body for mounting Testing Mandrel 3393 against corrosion.
- Install nut - 1 -.
- Install transmission mount nuts - arrows - if necessary.
- Clip cable - arrow - into console.
Tightening sequence
Note:
^ Threads in body can be repaired according to DIN 8140 using wire thread inserts (Heli-Coil). Thread insert must be same length as thread in body.
^ Bonded rubber bushings have a limited torsional range. Only tighten threaded connections at control arms if vehicle is in curb weight position
- Tighten hex bolts - 2 - and - 5 -
- Tighten hex bolts - 1 -.
- Tighten transmission mount nuts - arrows -.
- Tighten bolt - 2 -,
- Tighten engine mount nuts - 1 -.
- Tighten control arm hex head screws - 3 -
- Tighten guide link hex bolts,
- Tighten connecting link to stabilizer bar - 4 -,
- Suspension strut to link,
- Install tunnel crossmember.
- Tighten ABS speed sensor screw - 5 -.
- Tighten brake caliper to wheel bearing housing
- Mount wheel and tighten. This information is contained in AESIS; Library; Additional Information; Wheels and Tire Guide
Convertible only
- Install front diagonal brace.
Continued for all vehicles
Note:
^ If the subframe has been located to the body with Testing Mandrel 3393 before subframe removal and installation (before tightening bolts), vehicle alignment does not have to be done.
^ If the subframe was not located, vehicle alignment must be done.
- Perform vehicle alignment.
Alignment must take place on a VW/Audi recommended alignment stand.