Audi Workshop Service and Repair Manuals

Removing and installing subframe

Special tools and workshop equipment required

t	Support bracket -10 - 222 A-

t	Rack -10 - 222 A /1-

t	Mandrels -3393-

t	Torque wrench -V.A.G 1331-

t	Torque wrench -V.A.G 1332-

t	Engine and gearbox jack -V.A.G 1383 A-

Removing –  Take up weight of engine assembly with support bracket. –  Remove wheel trim; on light-alloy wheels, pull off trim cap (use puller in vehicle tool kit). –  Remove wheels. –  Secure brake disc with one wheel bolt. –  Remove noise insulation → Rep. Gr.50. → Rep. Gr.50 Cabriolet models only –  Remove front diagonal strut → Chapter.

All vehicles (continued): –  Before loosening subframe, use special tool -3393- to check that holes -1- and -2- are aligned. If this is not the case, wheel alignment must be checked and if necessary adjusted after installing subframe.

–  If necessary, remove nuts -arrows- at gearbox mountings.

–  Remove nut -1-. –  On vehicles with headlight range control, detach coupling rod of vehicle level sender from track control link → Chapter.

–  Unscrew bolt -5- for ABS speed sensor. –  Detach ABS speed sensor wiring from bracket on wheel bearing housing.

Vehicles with HP-2 brake caliper –  Unscrew hexagon bolt -2- and detach brake pipe bracket. –  Remove bolts -1- for brake caliper and take off brake caliper. –  Re-attach brake pipe bracket. Re-install and tighten hexagon bolt -2-. –  Secure the brake caliper to the body so that the weight of the brake caliper does not bend or damage the brake line. All vehicles (continued): –  Detach brake caliper and secure to body so that weight of brake caliper does not stretch or damage brake hose or brake pipe. To avoid damage to joints of upper links, support wheel bearing housing (e.g. using engine and gearbox jack -V.A.G 1383 A-) to prevent the suspension from extending too far.

–  Remove bolt -1-. –  Remove bolt -4-. –  Remove bolt -3-. –  Loosen bolt connections between guide links and subframe. –  If necessary, remove tunnel cross-member → Chapter –  Position engine and gearbox jack -V.A.G 1383 A- with suitable wooden block under subframe and press subframe upwards lightly.

–  Remove hexagon bolts -1-. –  Remove hexagon bolts -2- and lower subframe at the rear. –  Pull out hexagon bolts for guide links. –  Pull guide links out of subframe.   Note To prevent the outboard joints on the track control links and guide links from being bent too far, secure the links to the car body with a piece of wire or similar.

–  Detach hydraulic pipe -arrow- from bracket.

–  Remove bolt -3-. –  Slacken off hexagon bolts -2- until subframe can be taken out.

Installing –  Fit subframe and install hexagon bolts -5- and -6-. –  Fit hexagon bolt for suspension strut at track control link. –  Insert track control links and guide links in subframe. Before tightening the mountings, the position of the subframe relative to the body must be fixed using special tools 3393.

–  Hole -1-, hole -2- in subframe and hole -3- in aluminium bracket must align on both sides.   Note t  This locating method avoids the need for a subsequent wheel alignment check, provided that: t  Only the subframe has been removed and installed. t  Holes -1- and -2- were in alignment prior to repair work.

–  Start hexagon bolts -1- and -2-. –  Apply corrosion protection to holes in body where special tools 3393 are inserted.

–  Screw on nut -1-.

–  Screw on nuts for gearbox mounting -arrows- if necessary.

–  Clip cable -arrow- onto bracket. Tightening sequence   Note t  Thread in body can be repaired using wire thread insert according to DIN 8140 (Helicoil). The thread insert must be of the same length as the thread in the body. t  Bonded rubber bushes can only be turned to a limited extent. The mountings of the suspension links must therefore only be tightened when the suspension is in the unladen position → Chapter.

–  Tighten hexagon bolts -2- and -5- → Item. –  Tighten hexagon bolts -1- → Item.

–  Tighten nuts on gearbox mounting -arrows-. → Manual gearbox; Rep. Gr. 34; Removing and installing gearbox → Automatic gearbox; Rep. Gr. 37; Removing and installing gearbox

–  Tighten bolt -2- → Item. –  Tighten nuts -1- for engine mounting. → Engine, mechanics; Rep. Gr. 10; Removing and installing engine

–  Tighten hexagon bolts -3- for track control links → Item. –  Tighten hexagon bolts for guide links → Item. –  Secure coupling rod to anti-roll bar -4- → Item. –  Secure suspension strut to track control link → Item. –  Install tunnel cross-member if fitted → Chapter.

–  Tighten bolt -5- for ABS speed sensor. → Brake system; Rep. Gr. 45 –  Secure brake caliper to wheel bearing housing → Brake system; Rep. Gr. 46. –  Fit and secure wheels → Wheels and tyres; Rep. Gr.44. Cabriolet models only –  Install front diagonal strut → Chapter. All vehicles (continued):   Note t  A wheel alignment check is not necessary if the position of the subframe relative to the body was fixed using special tools 3393 prior to removal and assembly (before tightening bolts). t  Wheel alignment must be checked if the position of the subframe was not fixed in this way. –  Check and adjust wheel alignment → Chapter. Wheel alignment must always be checked and adjusted if necessary using VW/Audi-approved equipment.