Section A - Heat Shield Installation

(1999-2005 automatic vehicles)

WARNING:
To prevent injury, allow exhaust to cool





- Lift vehicle on hoist

- Place screw jack or equivalent on tail housing of transmission to support transmission

NOTE:
Supporting transmission from the oil pan can cause damage and is not covered under this action





- Remove bolts -arrows- to remove cross member 1.8T only)





- Loosen exhaust clamp nuts and slide exhaust clamp(s) connecting down pipe to tail pipe toward rear of vehicle to allow down pipe to hang loosely





- Remove bolts -1- and -2- of sub-frame on both sides of the vehicle, discard bolts -1-.

NOTE:
Sub-frame bolts -1- are torque-to-yield bolts and should always be replaced when removed





- Slowly lower transmission with screw jack to allow approximately 50mm clearance between sub-frame and body





NOTE:
There are two different-looking versions of new passenger side heat shield (3B0 825 676). Either version can be used for this campaign.





- Remove nuts -arrows- securing heat shield on passenger side (all engines) and nuts -arrows- securing heat shield on driver side (2.8L & W8 only)

NOTE:
Picture shows heat shield for clarity DO NOT REMOVE EXISTING HEAT SHIELD FROM VEHICLE





NOTE:
It may be easier to remove heat shield nut between exhaust and body by using a long extension with a swivel 10mm socket to go between exhaust and transmission mount





(1.8T, 2.8L & W8)
- Carefully insert passenger side heat shield (3B0 825 676) between body and exhaust, then push front edge of heat shield between exhaust and body

(2.8L & W8 Only)
- Repeat this step for driver side heat shield (3B0 825 675)

NOTE: Be careful not to distort or damage heat shield

WARNING:
When installing heat shield, do not overly deform or damage new heat shield, including cuts, holes, or tears
Damage to new heat shield could potentially cause a fire. If during installation a heat shield is damaged, install a new and undamaged heat shield.
Damage to these parts will not be covered under this action.





- Bend center shield over to allow new shield to lay under it, bend center shield back into place

NOTE:
W8 vehicles will not need to have old heat shield overlapping new heat shield





- Ensure heat shield studs are properly aligned with new heat shield openings
- Reinstall heat shield nuts onto passenger side heat shield (all engines) and driver side heat shield (2.8L & W8 only)





- Raise transmission with the screw jack

NOTE:
Be careful not to crush old heat shield between sub-frame and body





- Install new sub-frame bolts (N 908 235 01) -1- and torque to 110 Nm + 1/4 turn
- Reinstall bolts -2- and torque to 30 Nm





- Slide exhaust clamp(s) forward to reconnect down pipe to tail pipe and torque to 40 Nm





- After the sub-frame and exhaust have been put back in place, ensure there is at least 20mm of clearance between new heat shield and exhaust pipe in locations 1,2,3 and A,B,C

NOTE:
If clearance is not at least 20mm, use flat end of a pry bar to adjust the heat shield for proper clearance





- Reinstall cross member and torque bolts to 30Nm (1.8T only)

NOTE:
There is an "L" and an "R" stamped on the cross member, make sure the "L" part of the cross member is on the driver side

Work is complete for Section A