Subframe, Removing and Installing

Special tools, testers and auxiliary items required

Fig 1: Identifying Special Tools - Subframe, Removing And Installing

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Torque wrench V.A.G 1331
Torque wrench V.A.G 1332
Engine/transmission jack V.A.G 1383 A with universal transmission support V.A.G 1359/2
Tensioning strap T10038 , quantity: 2

8 mm drift , (commercially available), quantity: 2

Removing

Place vehicle on a hoist → Positioning Vehicle on Hoist and Wheels .

Fig 2: Positioning Engine Support Bridge And Support Engine

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Position engine support bridge and support the engine. Engine code BFM → 10 - ENGINE - ASSEMBLY , BSB → 10 - ENGINE - ASSEMBLY , BSM and BVJ → 10 - ENGINE - ASSEMBLY .
Remove wheel covers, remove cover cap on light-alloy wheels (removal hook in vehicle tool kit).
Remove wheels.
Secure brake discs with a wheel bolt.

Clean air connection area.

Fig 3: Residual Pressure Valve & Connecting Piece

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Remove connector pieces - 1 - on residual pressure retaining valves - 2 - on both sides. Air escapes then.

NOTE:

Generally, residual pressure valve - 2 - must not be loosened or removed.

Seal both connections. Ensure no dust particles enter connections.

Fig 4: Identifying Exhaust Pipe Fasteners

Courtesy of VOLKSWAGEN UNITED STATES, INC.

On vehicles with an auxiliary heater, remove the bolts - arrows - connecting the exhaust pipe to the noise insulation.

Fig 5: Front Sound Insulation Fasteners

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Loosen quick-release fasteners - 1 - through - 4 - and remove the noise insulation.

Fig 6: Bracket For Noise Insulation

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Remove noise insulation crossbrace on subframe - arrows -.

Fig 7: Level Control System Sensor, Left/Right Coupling & Control Arm

Courtesy of VOLKSWAGEN UNITED STATES, INC.

On both sides, remove level control system sensor coupling rod - 1 - from control arm.
Disconnect connector from left and right level control system sensors.
Remove left and right coupling - 2 - → Coupling, Removing and Installing .
Remove nuts on subframe from both control arms and control arms.

NOTE:

To prevent the joints on the upper control arm from being damaged, support wheel bearing housing.

Fig 8: Raising Both Wheel Bearing Housings

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Raise both wheel bearing housings approximately 50 mm and secure. Guide tensioning strap T10038 through hole in the body to do this.
Mark position of the subframe to the body with a felt tip pen.

Fig 9: Placing Engine/Transmission Jack V.A.G 1383 A With Wooden Block Under Subframe

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Place Engine/transmission jack V.A.G 1383 A with wooden block under subframe and press lightly against.
Remove engine mount bolts - 1 -.
Remove bolts - 2 - and - 3 - and engine carrier - 4 - with stabilizer bar.
Remove bolts - 5 - and - 6 -.

Fig 10: Identifying Transmission Mounting/Support Nut

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Loosen nut - arrow - for front transmission mount.

Fig 11: Front Transmission Mount Left/Right Bolts

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Remove left and right bolts - A arrows - for front transmission mount.

NOTE:

There are spacers - arrow B - between the subframe and the front transmission mount so the two components can be assembled without tension. The gap dimension between the transmission mount and subframe must be established again when installing.

Fig 12: Placing Engine/Transmission Jack V.A.G 1383 A Under Subframe

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Place engine/transmission jack V.A.G 1383 A under subframe and press against it lightly.

A second technician is needed for additional work.

Lower rear of subframe approximately 80 mm (the subframe mount must be located under the longitudinal member).
Remove spacers between subframe and front transmission mount.
Remove bolt from left guide link.
Turn steering all the way to the right.

Press subframe as far to the right as possible and pull left guide link out of the subframe.

NOTE:

To prevent damage to the guide link joints, do not put weight on the guide link once it has been removed.

The right guide link is removed from the subframe the same way as the left one is.
Remove bolts from right and left control arms.
Slide subframe as far to the right or left as possible and tilt the left or right control arm out.
Lower subframe.

Installing

Installation is in reverse order of removal. Observe the following when doing so:

First tighten bolts/nuts on components with bonded rubber bushings by hand. Raise wheel bearing housing to tighten bolts/nuts → Wheel Bearing Housing, Raising to Control Position .
Guide control arms and guide links into subframe.
Position subframe on the body at the location marked.

Fig 13: Front Transmission Mount Left/Right Bolts

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Install spacers - arrow B - between subframe and front transmission mount → 37 - CONTROLS, HOUSING for 6 SPD. AUTOMATIC TRANSMISSION 09E ALL WHEEL DRIVE or 37 - AUTOMATIC TRANSMISSION - CONTROLS, HOUSING for 6 SPD. AUTOMATIC TRANSMISSION 09L ALL WHEEL DRIVE .
Install all the engine carrier and subframe bolts loosely by hand.

NOTE:

When installing the engine carrier, make sure the engine mount centering device is seated in the mounting holes on the engine carrier.

Fig 14: Drift, Subframe & Engine Carrier

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Align engine carrier and subframe to each other using an 8 mm drift - A -. The holes in the subframe - 1 - and engine carrier - 2 - must be aligned vertically.
Install subframe without tension → 37 - CONTROLS, HOUSING for 6 SPD. AUTOMATIC TRANSMISSION 09E ALL WHEEL DRIVE or 37 - AUTOMATIC TRANSMISSION - CONTROLS, HOUSING for 6 SPD. AUTOMATIC TRANSMISSION 09L ALL WHEEL DRIVE .

Fig 15: Identifying Transmission Mounting/Support Nut

Courtesy of VOLKSWAGEN UNITED STATES, INC.

To make it possible to align the subframe without tension, tighten nut for the left and right front engine mount - arrow - after the alignment → 37 - CONTROLS, HOUSING for 6 SPD. AUTOMATIC TRANSMISSION 09E ALL WHEEL DRIVE or 37 - AUTOMATIC TRANSMISSION - CONTROLS, HOUSING for 6 SPD. AUTOMATIC TRANSMISSION 09L ALL WHEEL DRIVE .
Install spacers → 37 - CONTROLS, HOUSING for 6 SPD. AUTOMATIC TRANSMISSION 09E ALL WHEEL DRIVE or 37 - AUTOMATIC TRANSMISSION - CONTROLS, HOUSING for 6 SPD. AUTOMATIC TRANSMISSION 09L ALL WHEEL DRIVE .
Only tighten subframe bolts to specification, do not tighten them further (only tighten the bolts after an alignment).

CAUTION: If vehicle will be driving on the streets, all bolts and nuts must be tightened properly!

Fig 16: Placing Engine/Transmission Jack V.A.G 1383 A With Wooden Block Under Subframe

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Place Engine/transmission jack V.A.G 1383 A with wooden block under subframe and press lightly against.
Tighten engine mount bolts - 1 -. Engine code BFM → 10 - ENGINE - ASSEMBLY , BSB → 10 - ENGINE - ASSEMBLY , BSM and BVJ → 10 - ENGINE - ASSEMBLY .
Position the engine carrier - 4 - with stabilizer bar and tighten bolts - 2 -. Engine code BFM → 10 - ENGINE - ASSEMBLY , BSB → 10 - ENGINE - ASSEMBLY , BSM and BVJ → 10 - ENGINE - ASSEMBLY .
Tighten bolts - 3 - and - 5 - in a diagonal sequence and only to specification. Bolt - 5 - , bolt - 3 -.

Tighten bolts - 6 -.
Insert and tighten bolts in the left and right control arms.
Insert and tighten the bolts in left and right guide links.

Fig 17: Bracket For Noise Insulation

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Install noise insulation crossbrace on the subframe - arrows -.

Fig 18: Level Control System Sensor, Left/Right Coupling & Control Arm

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Install vehicle level control system sensor coupling rod - 1 - on control arm.
Connect connector on left and right level control system sensors.
Install left and right couplings - 2 - and.
Remove bolt - 3 - from air spring damper on the control arm.

Fig 19: Residual Pressure Valve & Connecting Piece

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Connect connecting piece - 1 - at residual pressure valve - 2 -.
Install noise insulation.
Mount wheels and tighten → 44 - WHEELS, TIRES, VEHICLE ALIGNMENT .
Place vehicle on wheels → Positioning Vehicle on Hoist and Wheels .

Perform vehicle alignment → Wheel Alignment .
After vehicle alignment, tighten subframe mounting bolts to correct additional angle.
Re-adapt control position → Control Position, Programming .