Removing and installing Haldex coupling pump, to model year 2010 — VW

Removing and installing Haldex coupling pump, to model year 2010
Special tools and workshop equipment required
Drip tray for workshop hoist
VAS 6208
Torque wrench
V.A.G 1783
Puller
T10055
Removing
Switch off ignition.
Place
drip tray for workshop hoist
VAS 6208
under Haldex coupling.
If fitted, lever stone deflector
2
off
Haldex coupling pump
V181
1
.
Unscrew drain plug
arrow
and drain off all of
high-performance oil for Haldex coupling
.
Note
The final drive and the Haldex coupling have separate
»oil circuits«
. To drain
high-performance oil for Haldex coupling
, only remove drain plug
arrow
.
Screw in new drain plug
arrow
with new seal and tighten.
Remove rear final drive
Chapter
.
Lay rear final drive on a flat surface and support with wood blocks.
Pull connector
arrow
for pump off control unit.
Remove bolts
arrows
.
Pull Haldex coupling
1
out of rear final drive.
Remove oil seal
arrow
.
Pull wiring harness
1
out of bracket
2
.
Unscrew bolts
arrows
and remove cover
3
.
Note
Figure shows only 2 of the bolts.
Place
drip tray for workshop hoist
VAS 6208
under rear final drive.
Unscrew bolts
arrows
from pump.
Withdraw pump in
direction of arrow
using
puller
T10055
.
A
Wooden block
Installing
Install in reverse order of removal, observing the following:
Renew seal
arrow
.
Renew O-rings
1
and
2
.
Note different diameters:
Diesel engine
Inner diameter O-ring
1
= 29.6 x 2.4 mm
Inner diameter O-ring
2
= 32.0 x 2.0 mm
Petrol engine
Inner diameter O-ring
1
= 29.6 x 2.4 mm
Inner diameter O-ring
2
= 32.0 x 2.5 mm
Thinly coat O-rings
1
and
2
with
high-performance oil
for Haldex coupling.
Press in pump as far as stop.
Tighten bolts to specified torque.
Install rear final drive
Chapter
.
Top up oil in Haldex coupling
Chapter
.
Slide stone deflector
2
onto
Haldex coupling pump
V181
1
.
If no stone deflector
1
is fitted, install a stone deflector
Electronic Parts Catalogue
.
.
Specified torques
Chapter
“
Assembly overview - Haldex coupling
”
Chapter
“
Assembly overview - two section propshaft
”
Chapter
“
Assembly overview - three section propshaft
”
Drive shafts; Assembly overview - drive shafts
Rep. gr.
42
Drive shaft; Assembly overview - drive shaft
Subframe; Assembly overview - gearbox carrier for final drive
Rep. gr.
42
Subframe; Assembly overview - subframe
Component
Specified torque
Drain plug
38 Nm
Wiring harness cover to Haldex coupling
1 Nm