Lock Carrier, Removing And Installing

• To complete the procedure, a second technician is required to be at the following position found here. Refer to LOCK CARRIER, REMOVING AND INSTALLING => Have a second technician hold the lock carrier -2- and remove the bolts -1, 3 and 4-. .

Special tools and workshop equipment required 

• Engine Bung Set:VAS6122 
• Coolant Collecting System:VAS5014  or Shop Crane - Drip Tray:VAS6208 

Removing 

-- Remove the bumper cover. Refer to BUMPER COVER, REMOVING AND INSTALLING .

-- Remove the headlamps. Refer to HEADLAMP, REMOVING AND INSTALLING .

-- Remove the charge air cooler. Refer to CHARGE AIR COOLER, REMOVING AND INSTALLING .

-- Place the :VAS5014  or :VAS6208  underneath.

-- Disconnect the radiator fan connector -arrow-.

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-- Lift the clamp -1- and remove the lower coolant hose from the radiator.

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-- Seal the hose couplings with clean plugs from the :VAS6122  .

-- Lift the clamps -1 and 2-, remove and free up the coolant connection from the radiator.

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-- Seal the hose couplings with clean plugs from the :VAS6122  .

-- Disconnect the connectors on the lock carrier and free up the wiring harness.

-- Disconnect the washer fluid hose for the headlamp washer system and free it up.

-- Remove the bolts -arrows-, remove the air duct -1-, and unclip the air duct -2-.

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-- Release the catches -arrows- and remove the upper air duct -1-.

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Equipment versions with TDI engine:

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-- Disconnect the connector -1-.

-- Remove the bolts -arrows- and remove the NOx Sensor Control Module -J583- , free it up and place it on the engine.

Continuation:

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-- Disconnect the connector -2- for the High Pressure Sensor -G65-.

-- Release the left and right catches -arrows-, disengage the condenser -1- from the radiator and tie up to the side.

-- Free up the latch release cable on the lock carrier.

-- Remove the latch and move with connected release cables to the side. Refer to LATCH, REMOVING AND INSTALLING .

-- Release the catch -arrows-, disengage the release cable bracket housing -1- on the lock carrier, and move with connected release cables to the side.

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-- Disengage the mounting bracket with the operating lever release cable hook on the lock carrier and move to the side. Refer to MOUNTING BRACKET WITH HOOK RELEASE LEVER RELEASE CABLE, REMOVING AND INSTALLING .

-- Have a second technician hold the lock carrier -2- and remove the bolts -1, 3 and 4-. 

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-- Remove the lock carrier forward with a second technician.

-- The following components must also be removed if the lock carrier is being replaced:

• Radiator with fan shroud. Refer to RADIATOR, REMOVING AND INSTALLING .
• Connecting Brace. Refer to CONNECTING BRACE, REMOVING AND INSTALLING .
• Impact Member. Refer to IMPACT MEMBER, REMOVING AND INSTALLING .

Installing 

Install in reverse order of removal and note the following:

-- Fill the coolant. Refer to COOLANT, DRAINING AND FILLING .

Tightening Specifications

• Refer to OVERVIEW - LOCK CARRIER