2065472/2
Service Bulletin Details
Public Details for: 2065472/2
V8 kovomo - new continental gt/gtc and new flying spur - valve spring replacement (sc21/41). Technical background: the intake valve springs (16) and outlet valve springs (16) located within the cylinder heads of bank 1 and 2 require repla
Field campaign Topic Market area Brand Transaction No. Campaign number Note Type US code V8 Kovomo - New Continental GT/GTC and New Flying Spur - Valve spring replacement (SC21/41) Bentley: worldwide (2WBE) Bentley 2065472/2 EC24 Vehicle data New Continental GT/GTC and New Flying Spur Sales types Type 3S32CB 3S32CB 3S42CB 3S42CB ZG22CB ZG22CB MY 2021 2022 2021 2022 2021 2022 Brand Designation Engine code E * E * E * E * E * E * Gearbox code * * * * * * Final drive code * * * * * * Chas is numbers Manufacturer Filler Type Filler MY Factory From To Prod from Prod to SCB * * * * C 090579 093477 Documents Document name master.xml enginehydraulicliftingtable.pdf install1-18.pdf removal1-18.pdf sc2141vinlist.pdf EC24 V8 Kovomo - New Continental GT/GTC and New Flying Spur - Valve spring replacement (SC21/41) Notes Transaction No.: 2065472/2 Repair instructions Technical background The intake valve springs (16) and outlet valve springs (16) located within the cylinder heads of Bank 1 and 2 require replacing The replacement of all valve springs is required due to an issue which was discovered during a routine quality inspection Remedy The replacement of all intake valve springs and all outlet valve springs (Bank 1 and Bank 2) is required IMPORTANT: The removal and installation instructions are attached to this document, the operative MUST ensure the instructions are followed in numerical order as detailed within the work section NOTE: There is also a separate attachment with instructions regarding the hydraulic lifting table which must be followed NOTE: The Work section also contains task applicable instructions which MUST also be referred to and conducted. The instructions can change without warning, the operative must always ensure the latest version of this document and the attached instructions are referred to (Use the applicable VIN in Elsa pro to ensure latest version is always referred to) TIP: The removal and installation procedures have been specifically devised, all procedures MUST be strictly adhered to Customer notification The procedure must be carried out in conjunction with the PDI process Warranty accounting instructions Replacement of the intake and outlet valve springs Warranty type 790 Damage service number EC24 Damage code 0066 Criteria 01 Labour Labour Operation Code 15 65 56 20 (Use 99 index until 17/02/22) Time 2190 TU Alignment of applicable driver assist systems (Depending on vehicle specification) NOTE: The codes for each vehicle type are the same, however some of the times may be different please note that Saga will auto-populate the times when the claim is submitted • Vehicle front + rear measured wheel alignment checked - 44 95 03 00 • Rear wheel camber adjust - 44 94 15 50 • Rear wheel track adjust - 44 93 15 50 • Front wheel camber adjust - 44 89 15 50 • Front wheel track adjust - 44 88 15 50 • (ACC) - Radar sensor checked + adjusted - 91 63 05 51 • Overhead view camera adjusted - 90 83 15 00 • Driver assist camera adjusted - 96 38 15 50 • Control unit for (Lane change assist) adjusted - 96 35 15 00 • Night vision system calibration - 90 80 15 50 • Headlamps to adjust - 94 15 16 00 • ODIS Time - 01 50 00 00 (Time as per ODIS log) Genuine parts Part number Description Quantity 06E109623AD Intake valve springs 16 0P2109623 Outlet valve springs 16 3SA198115 Parts set 1 0P2103484 Seal 1 0P2103517 Seal 1 G052565A1 Silicone paste As required N10458202 Hexagon bolt M6x22 4 WHT007821 O-ring 31x2 2 WHT008638 O-Ring 17.5x1.5 8 04E998907A Repair kit for valve unit 8 D176501A1 Loctite 5970- BM (Source locally) As required 04E906145 Seal ring 4 06M145113 Seal 1 034115427B O-Ring 12x2 1 0P2103650E Gasket for cover Cylinders 1-4 1 0P2103649E Gasket for cover Cylinders 5-8 1 0P2103113A Cover 3 06M109235 Seal 4 06M109493D Plate 4 0P2129056 Seal 2 WHT008730 O-Ring 12x3 2 WHT008729 O-Ring 14x3 2 N90344501 O-Ring 45x3 2 N90521604 O-Ring 55x3 2 99970751741 O-Ring 22x3 2 N90365304 O-Ring 20x3 1 N90925001 O-Ring 17x3 3 971253115B Turbo to pre catalytic seal 2 8W0253725D Clamp for turbochargers 2 5Q0253115B Downpipe to pre catalytic seal 2 982251616 Band clamp 2 Refer to ETKA and Rep.Gr 00 (Power transmission fluids and capacities) Differential oil (front and centre) As required Refer to ETKA and Rep.Gr 00 (Power transmission fluids and capacities) Transmission fluid As required Refer to ETKA and Rep.Gr 00 (Engine fluids and capacities) Engine coolant As required 00004320935 Microgleit DF977S (Source locally) As required Loctite 7515 primer Loctite 7515 primer (Source locally) As required Parts supply All parts listed within this document are currently restricted and will follow a specific process to minimise disruption for Retailers and ensure delivery is received in complete vehicle sets. Please do not raise any unnecessary part orders or service calls. Parts despatch control The parts will be controlled centrally and automatically allocated and distributed therefore in this case there is no requirement for retailers to place orders. Repair instructions Notes Technical background The intake valve springs (16) and outlet valve springs (16) located within the cylinder heads of Bank 1 and 2 require replacing The replacement of all valve springs is required due to an issue which was discovered during a routine quality inspection Check If the vehicle is not already listed as repaired in the “Repair history” (in Elsa Pro) refer to the Identification section to check the presence of the yellow paint completion mark (Figure 5) Should neither be evident (“Repair history” or applicable paint mark) carry out the required work in accordance with these instructions Genuine parts Part number Description Quantity 06E109623AD Intake valve springs 16 0P2109623 Outlet valve springs 16 3SA198115 Parts set 1 0P2103484 Seal 1 0P2103517 Seal 1 G052565A1 Silicone paste As required N10458202 Hexagon bolt M6x22 4 WHT007821 O-ring 31x2 2 WHT008638 O-Ring 17.5x1.5 8 04E998907A Repair kit for valve unit 8 D176501A1 Loctite 5970- BM (Source locally) As required 04E906145 Seal ring 4 06M145113 Seal 1 034115427B O-Ring 12x2 1 0P2103650E Gasket for cover Cylinders 1-4 1 0P2103649E Gasket for cover Cylinders 5-8 1 0P2103113A Cover 3 06M109235 Seal 4 06M109493D Plate 4 0P2129056 Seal 2 WHT008730 O-Ring 12x3 2 WHT008729 O-Ring 14x3 2 N90344501 O-Ring 45x3 2 N90521604 O-Ring 55x3 2 99970751741 O-Ring 22x3 2 N90365304 O-Ring 20x3 1 N90925001 O-Ring 17x3 3 971253115B Turbo to pre catalytic seal 2 8W0253725D Clamp for turbochargers 2 5Q0253115B Downpipe to pre catalytic seal 2 982251616 Band clamp 2 Refer to ETKA and Rep.Gr 00 (Power transmission fluids and Differential oil (front and centre) capacities) As required Refer to ETKA and Rep.Gr 00 (Power transmission fluids and Transmission fluid capacities) As required Refer to ETKA and Rep.Gr 00 (Engine fluids and capacities) Engine coolant As required 00004320935 Microgleit DF977S (Source locally) As required Loctite 7515 primer Loctite 7515 primer (Source locally) As required Tools Refer to the attached instructions Work 1) To gain access/to replace all of the Intake and Outlet valve springs - Refer to the attached instructions ensuring each process is conducted in numerical order (1 through to 18) as follows: Removal 1 - Remove engine 2 - Remove exhaust downpipes, heatshields and catalytic converters 3 - Remove rear high-pressure fuel line 4 - Remove upper chain housing covers 5 - Remove oil mist separators 6 - Remove ignition coils 7 - Remove high pressure fuel lines, banks 1 and 2 8 - Remove high pressure fuel pumps 9 - Remove fuel rails 10 - Remove CDA solenoids 11 - Remove fuel injectors 12 - Remove mechanical vacuum pump 13 - Remove pressure pipes 14 - Remove camshaft actuators 15 - Remove cylinder head cover 16 - Remove valve lifters (hydraulic tappets) 17 Remove spark plugs 18 - Remove valve springs NOTE: It is imperative the attached instructions are followed in numerical order as each task has been individually generated to allow the operative to conduct the rework with minimal disruption VERY IMPORTANT: The operative MUST ensure the valve springs are fitted in the correct location as the part numbers of the Intake valves and Outlet valves are different. TIP: To ensure consistency/accuracy during the replacement of the valve spring process and to ensure the springs are fitted in the correct location, it is highly recommended the same operative is used for the duration of this process • 06E 109 623AD - Intake valve springs - Figure 1 (Located on the outside edge of each bank) HINT: Referring to Figure 1 - The valve spring is shown in the orientation as it should be fitted IMPORTANT: The 3 white lines shown/circled on the upper face of the spring must be facing upwards when fitted Figure 1 • 0P2 109 623 - Outlet valve springs - Figure 2 (Located on the inside of each bank) HINT: Referring to Figure 2 - The valve spring is shown in the orientation as it should be fitted IMPORTANT: The 4 blue lines shown/circled on the upper face of the spring must be facing upwards when fitted Figure 2 NOTE: Once the engine is removed there is not a requirement to separate the transmission from the engine, the replacement of the valve springs should be conducted with the engine and transmission sitting on the hydraulic lifting table CAUTION: Ensure the engine and transmission is suitably secured to the hydraulic lifting table TIP: When removing the original parts it is best practice to keep the new parts completely separate to eliminate cross contamination between the old and new parts HINT: Ensure all parts which are not required to be replaced as part of this process are inspected prior to refitting and replaced if required VERY IMPORTANT: When replacing the valve springs (once the collets and valve spring cap is removed from each valve) it is imperative that constant air pressure is supplied to the affected cylinder whilst the replacement of the valve springs is being conducted, in the event the air supply is lost or is not maintained during this operation, the valve could drop directly into the cylinder resulting in the requirement to remove the cylinder head to retrieve the valve 2) To complete the installation of the valve springs - Refer to the attached installation instructions in numerical order VERY IMPORTANT: The operative MUST ensure the valve springs are fitted in the correct location as the part numbers of the Intake valves and Outlet valves are different. TIP: To ensure consistency/accuracy during the replacement of the valve spring process and to ensure the springs are fitted in the correct location, it is highly recommended the same operative is used for the duration of this process INSTALLATION 1 - Install valve springs 2 - Install spark plugs 3 - Install valve lifters (hydraulic tappets) 4 - Install cylinder head covers 5 - Install camshaft actuators (includes setting timing) 6 Install pressure pipes 7 - Install mechanical vacuum pump 8 - Install fuel injectors 9 - Install cylinder deactivation solenoids 10 - Install fuel rails 11 - Install high pressure fuel pumps 12 - Install high pressure fuel lines, banks 1 and 2 13 - Install ignition coils 14 - Install oil mist separators 15 - Install upper chain housing covers 16 - Install rear high-pressure fuel line 17 - Install catalytic converters, exhaust downpipes and heatshields 18 Install engine 3) Carry out wheel alignment and ensure the driver assist system calibrations are performed (Depending on vehicle specification) as follows • Vehicle front + rear measured wheel alignment checked • Rear wheel camber adjust • Rear wheel track adjust • Front wheel camber adjust • Front wheel track adjust • (ACC) - Radar sensor checked + adjusted • Overhead view camera adjusted • Driver assist camera adjusted • Control unit for (Lane change assist) adjusted • Night vision system calibration • Headlamps to adjust 4) Raise a non-technical DISS query attaching the following: • Before and after screen shots of the wheel alignment results • Screen shots confirming the applicable drive assist systems have been successfully adjusted/calibrated Warranty payments will not be approved without the submission of the requested results via the open DISS query 5) Conduct the PDI road test - On return confirm that no DTC’s are evident 6) Check and confirm that no DTC’s are stored or there are no engine operation issues evident - Save an online log to confirm that no DTC’s were evident at this stage of the procedure • Referring to Figure 3 • Select Guided functions from 01 – Engine Control Module 1 • Select Generate readiness code • Select Execute Figure 3 Please be aware that not all readiness bytes may be at zero, however this is not a requirement as the remaining bytes will set during normal customer driving cycle routines 7) Confirm no oil/fluid leaks are evident 8) Place a yellow paint completion mark as shown within the Identification section (Figure 4) Identification Yellow paint completion mark on the right hand side of the engine partition brace (Figure 4) Figure 4 Repair instructions Notes New Continental GT V8 Kovomo SCBCZ13S5MC090579 SCBCX13S9NC092553 SCBCZ13S2MC090586 SCBCG2ZG8NC092567 SCBCZ13S1MC090594 SCBCZ13S2NC092596 SCBCG2ZG1NC090885 SCBCG13S0NC092599 SCBCG2ZG7NC090986 SCBCG2ZG6NC092602 SCBCF13S1NC091108 SCBCG13S8NC092608 SCBCF13S4NC091166 SCBCF13SXNC092614 SCBCF13S7NC091193 SCBCZ13S6NC092617 SCBCF13S9NC091213 SCBCX13S3NC092628 SCBCF13S7NC091274 SCBCG13S6NC092641 SCBCG2ZG2NC091303 SCBCF13SXNC092645 SCBCG2ZG4NC091304 SCBCG2ZG6NC092650 SCBCZ13S2NC091321 SCBCG2ZGXNC092652 SCBCZ13S0NC091365 SCBCG2ZG0NC092658 SCBCG2ZG5NC091456 SCBCG2ZG2NC092662 SCBCF13S5NC091502 SCBCG2ZG1NC092670 SCBCG2ZG0NC091509 SCBCG13S8NC092690 SCBCG13S2NC091597 SCBCF1ZG1NC092701 SCBCX13S4NC091598 SCBCX13S7NC092714 SCBCX13S0NC091601 SCBCG2ZG8NC092729 SCBCJ13S9NC091727 SCBCG2ZG9NC092738 SCBCX13S1NC091753 SCBCG2ZGXNC092747 SCBCZ13S8NC091761 SCBCZ13S1NC092752 SCBCZ13S2NC091769 SCBCG2ZGXNC092764 SCBCZ13S6NC091788 SCBCG2ZG5NC092767 SCBCG2ZG8NC091791 SCBCG2ZG5NC092770 SCBCG13S6NC091909 SCBCG2ZG8NC092777 SCBCX13S8NC091913 SCBCG2ZG3NC092783 SCBCG13S3NC091950 SCBCG13S0NC092795 SCBCG2ZG7NC092222 SCBCG2ZG4NC092808 SCBCG13S0NC092229 SCBCF13S7NC092814 SCBCG2ZG0NC092238 SCBCG2ZG1NC092829 SCBCF13S7NC092263 SCBCZ13S9NC092837 SCBCG2ZG5NC092316 SCBCG13S7NC092843 SCBCG2ZG0NC092322 SCBCZ13S5NC092849 SCBCX13S1NC092336 SCBCZ13S6NC092861 SCBCF13S7NC092389 SCBCZ13S0NC092872 SCBCG2ZG5NC092395 SCBCG13S7NC092907 SCBCG2ZG2NC092399 SCBCF13S3NC092910 SCBCG2ZG7NC092429 SCBCF1ZG0NC092916 SCBCF13S0NC092430 SCBCJ13S1NC092919 SCBCZ13S3NC092462 SCBCF1ZG9NC092929 SCBCF13S9NC092474 SCBCF13S3NC092941 SCBCG2ZG7NC092480 SCBCG13S2NC092944 SCBCJ13SXNC092482 SCBCG2ZG9NC092951 SCBCG2ZG8NC092486 SCBCG2ZG4NC092954 SCBCG13S2NC092488 SCBCG2ZG1NC092961 SCBCX13S2NC092510 SCBCG2ZG5NC092963 SCBCZ13S7NC092514 SCBCX13SXNC092965 SCBCJ13S3NC092520 SCBCG2ZG4NC092971 SCBCZ13SXNC092524 SCBCF13S5NC092973 SCBCG2ZG5NC092526 SCBCG2ZG1NC092975 SCBCZ13S5NC092530 SCBCX13S5NC092985 SCBCG2ZG4NC092534 SCBCX13S0NC092988 SCBCX13S2NC092538 SCBCG2ZG8NC092990 SCBCG2ZG0NC092546 SCBCX13S8NC092995 SCBCX13S3NC092998 SCBCX13S7NC093006 SCBCG2ZG9NC093016 SCBCG2ZG2NC093018 SCBCX13S5NC093019 SCBCX13S5NC093022 SCBCG2ZG9NC093033 SCBCJ13S7NC093041 SCBCG2ZG1NC093043 SCBCF1ZG6NC093052 SCBCG2ZG3NC093058 SCBCF1ZG7NC093061 SCBCG2ZG4NC093070 SCBCJ13S9NC093073 SCBCF1ZG4NC093096 SCBCG2ZG6NC093099 SCBCG2ZG5NC093109 SCBCG2ZG4NC093117 SCBCX13S1NC093129 SCBCF1ZG2NC093131 SCBCX13S0NC093137 SCBCG2ZG0NC093146 SCBCF1ZG3NC093154 SCBCG2ZG7NC093158 SCBCF13SXNC093164 SCBCZ13S6NC093167 SCBCG2ZG8NC093170 SCBCG2ZG4NC093182 SCBCG2ZG1NC093186 SCBCG2ZG7NC093192 SCBCX13S9NC093198 SCBCF1ZG6NC093228 SCBCG2ZG7NC093242 SCBCG2ZG7NC093256 SCBCG2ZG9NC093260 SCBCG2ZG6NC093264 SCBCF13S9NC093267 SCBCX13S1NC093275 SCBCG2ZG4NC093375 SCBCF1ZGXNC093443 SCBCG2ZG6NC093457 SCBCF1ZG1NC093461 New Continental GTC V8 SCBDG4ZG2NC090815 SCBDG4ZG5NC091098 SCBDF33S1NC091142 SCBDX33S5NC091223 SCBDX33S2NC091230 SCBDF33S7NC091310 SCBDG4ZG6NC091319 SCBDX33S2NC091440 SCBDG4ZG3NC091522 SCBDG4ZG0NC091588 SCBDX33S1NC091770 SCBDX33S4NC091794 SCBDG4ZG9NC091945 SCBDG4ZG3NC092220 SCBDG4ZG7NC092236 SCBDG4ZG8NC092245 SCBDG4ZG9NC092254 SCBDG4ZG6NC092308 SCBDX33SXNC092335 SCBDG4ZG5NC092350 SCBDG4ZG3NC092363 SCBDX33S9NC092391 SCBDX33SXNC092397 SCBDG4ZG8NC092410 SCBDG4ZG6NC092423 SCBDG4ZG5NC092431 SCBDX33S7NC092454 SCBDG4ZG1NC092460 SCBDZ33S5NC092463 SCBDG4ZG8NC092472 SCBDG4ZG9NC092481 SCBDG4ZG4NC092484 SCBDX33S0NC092487 SCBDG4ZG5NC092493 SCBDG4ZG0NC092496 SCBDG4ZG6NC092521 SCBDX33S8NC092527 SCBDF33SXNC092600 SCBDF33S0NC092606 SCBDG4ZG9NC092609 SCBDG4ZG8NC092620 SCBDG4ZG1NC092636 SCBDX33S8NC092639 SCBDG4ZG8NC092651 SCBDG4ZG3NC092654 SCBDG4ZG9NC092660 SCBDG4ZG5NC092672 SCBDG4ZG0NC092675 SCBDX33S5NC092677 SCBDX33S1NC092692 SCBDG4ZG1NC092703 SCBDG4ZG2NC092709 SCBDJ33S3NC092730 SCBDG4ZG5NC092736 SCBDG4ZG0NC092739 SCBDG4ZGXNC092750 Kovomo SCBDX33S6NC092753 SCBDZ33S1NC092766 SCBDG4ZG9NC092769 SCBDG4ZG6NC092776 SCBDX33S2NC092779 SCBDX33S1NC092787 SCBDX33SXNC092822 SCBDG4ZG8NC092827 SCBDG4ZGXNC092845 SCBDX33S6NC092851 SCBDG4ZG1NC092863 SCBDG4ZG2NC092869 SCBDG4ZG4NC092873 SCBDG4ZG5NC092901 SCBDX33S3NC092905 SCBDF33S5NC092908 SCBDZ33S6NC092911 SCBDG4ZG3NC092914 SCBDX33S5NC092923 SCBDZ33SXNC092930 SCBDZ33S1NC092945 SCBDG4ZG4NC092968 SCBDZ33S4NC092972 SCBDG4ZG8NC093024 SCBDG4ZG6NC093037 SCBDG4ZG3NC093044 SCBDX33S1NC093051 SCBDG4ZG5NC093059 SCBDX33S6NC093062 SCBDG4ZG6NC093071 SCBDG4ZG1NC093074 SCBDX33S8NC093077 SCBDG4ZG7NC093080 SCBDG4ZG2NC093083 SCBDG4ZG7NC093094 SCBDX33S1NC093101 SCBDX33S2NC093107 SCBDG4ZG0NC093115 SCBDG4ZG8NC093119 SCBDG4ZGXNC093123 SCBDG4ZG7NC093127 SCBDF3ZGXNC093135 SCBDG4ZG1NC093141 SCBDX33S3NC093150 SCBDJ33S2NC093156 SCBDG4ZG5NC093160 SCBDG4ZG0NC093194 SCBDG4ZG3NC093240 SCBDG4ZGXNC093266 SCBDZ33S2NC093294 SCBDG4ZG6NC093331 SCBDG4ZGXNC093350 SCBDF33S2NC093451 SCBDG4ZG2NC093455 SCBDG4ZGXNC093476 New Flying Spur V8 Kovomo SCBBG53S0NC090726 SCBBG6ZG1NC092221 SCBBG53S2NC090730 SCBBZ53S7NC092225 SCBBZ53S4NC090738 SCBBX53S0NC092234 SCBBG53S0NC090774 SCBBZ53S6NC092247 SCBBG53S2NC090792 SCBBG6ZG4NC092262 SCBBG53S5NC090804 SCBBZ53S8NC092315 SCBBG53S0NC090824 SCBBZ53S0NC092325 SCBBZ53S1NC090874 SCBBG53S7NC092330 SCBBG53S1NC090878 SCBBZ53S7NC092337 SCBBG53S6NC090892 SCBBG53S0NC092346 SCBBG53S5NC090902 SCBBG53S6NC092349 SCBBG53S5NC090947 SCBBG53S4NC092351 SCBBG53S3NC090977 SCBBZ53S7NC092354 SCBBG53S6NC090987 SCBBG6ZG2NC092373 SCBBZ53S2NC090995 SCBBZ53S8NC092377 SCBBG53S5NC091001 SCBBZ53S3NC092383 SCBBG53S9NC091017 SCBBX53SXNC092385 SCBBG53SXNC091026 SCBBZ53S2NC092388 SCBBX53S3NC091126 SCBBG6ZG2NC092390 SCBBG53S9NC091146 SCBBG53S7NC092392 SCBBG53S8NC091199 SCBBZ53S5NC092398 SCBBG53S9NC091227 SCBBG6ZG5NC092402 SCBBG53S6NC091234 SCBBZ53S7NC092404 SCBBG53S1NC091240 SCBBG53S6NC092416 SCBBG53S7NC091243 SCBBG53S9NC092426 SCBBG53S9NC091261 SCBBG6ZG1NC092428 SCBBG53S0NC091262 SCBBG6ZG7NC092434 SCBBG53S6NC091279 SCBBG6ZG2NC092440 SCBBG53S4NC091300 SCBBG6ZG4NC092455 SCBBZ53S7NC091317 SCBBG6ZGXNC092461 SCBBG53S0NC091326 SCBBZ53S3NC092464 SCBBG53S7NC091341 SCBBG53S1NC092467 SCBBG53S2NC091344 SCBBX53S7NC092473 SCBBG53S3NC091353 SCBBG6ZG7NC092479 SCBBX53S8NC091400 SCBBX53SXNC092483 SCBBX53S1NC091402 SCBBG6ZGXNC092492 SCBBG53S6NC091413 SCBBG6ZG5NC092495 SCBBG53S1NC091416 SCBBZ53S5NC092501 SCBBG53S0NC091438 SCBBX53S1NC092503 SCBBG53S0NC091441 SCBBG6ZG4NC092505 SCBBG53SXNC091463 SCBBZ53SXNC092509 SCBBX53S3NC091580 SCBBZ53S1NC092513 SCBBG53S2NC091599 SCBBZ53S2NC092519 SCBBG6ZGXNC091729 SCBBZ53S8NC092525 SCBBG53SXNC091737 SCBBG53S6NC092531 SCBBX53S6NC091752 SCBBX53S3NC092535 SCBBG6ZG6NC091789 SCBBG6ZGXNC092539 SCBBZ53S4NC091792 SCBBG6ZG5NC092545 SCBBG6ZG9NC091799 SCBBX53S1NC092548 SCBBZ53S5NC091803 SCBBZ53S7NC092550 SCBBG53S9NC091809 SCBBZ53S0NC092552 SCBBG53S4NC091815 SCBBG53S7NC092554 SCBBG53S0NC091908 SCBBZ53S8NC092556 SCBBG53S6NC091914 SCBBZ53S1NC092558 SCBBZ53S3NC091928 SCBBZ53SXNC092560 SCBBG6ZG0NC092209 SCBBZ53S3NC092562 SCBBZ53S4NC092568 SCBBG53S9NC092572 SCBBX53S4NC092575 SCBBG53SXNC092578 SCBBZ53S3NC092593 SCBBZ53S2NC092598 SCBBG53S2NC092607 SCBBZ53SXNC092610 SCBBZ53S0NC092616 SCBBG53S1NC092646 SCBBG6ZGXNC092668 SCBBX53SXNC092676 SCBBZ53S2NC092682 SCBBX53S6NC092691 SCBBG53S7NC092702 SCBBX53S2NC092705 SCBBG53S8NC092708 SCBBZ53S3NC092710 SCBBX53S1NC092713 SCBBZ53SXNC092719 SCBBX53S2NC092722 SCBBG6ZG2NC092728 SCBBZ53S7NC092743 SCBBX53S9NC092751 SCBBX53S4NC092754 SCBBZ53S6NC092765 SCBBZ53S1NC092768 SCBBZ53S5NC092773 SCBBZ53SXNC092784 SCBBZ53SXNC092817 SCBBG53S6NC092819 SCBBG6ZG0NC092825 SCBBZ53S2NC092830 SCBBG53SXNC092838 SCBB153SXNC092842 SCBBZ53S2NC092844 SCBB15ZG3NC092846 SCBBG53S2NC092848 SCBBX53S0NC092850 SCBBG6ZG3NC092852 SCBBZ53S9NC092856 SCBBZ53S2NC092858 SCBBG53S3NC092860 SCBBG6ZG7NC092871 SCBBG6ZG2NC092874 SCBBG6ZG1NC092882 SCBBZ53S3NC092884 SCBBZ53S9NC092890 SCBBZ53S2NC092892 SCBBG6ZGXNC092895 SCBBZ53S3NC092898 SCBB15ZG5NC092900 SCBBZ53S3NC092903 SCBBG6ZG0NC092906 SCBBG6ZG1NC092915 SCBBZ53S5NC092918 SCBBG6ZG7NC092921 SCBBZ53S0NC092924 SCBB15ZG1NC092926 SCBB15ZG5NC092928 SCBBG6ZGXNC092931 SCBBZ53S9NC092937 SCBBZ53S9NC092940 SCBBZ53SXNC092946 SCBBZ53S1NC092950 SCBB15ZG2NC092952 SCBBZ53S0NC092955 SCBBZ53S4NC092960 SCBBG6ZG7NC092966 SCBBG53S0NC092976 SCBBG6ZG1NC092980 SCBBG6ZG1NC092994 SCBB15ZG2NC093003 SCBBZ53S2NC093007 SCBBG6ZG8NC093009 SCBBG6ZGXNC093013 SCBBG6ZG3NC093015 SCBB153S1NC093023 SCBBZ53SXNC093028 SCBBZ53S1NC093032 SCBBZ53SXNC093045 SCBBG6ZG5NC093050 SCBBG6ZG0NC093053 SCBBZ53S2NC093055 SCBBX53S9NC093057 SCBBG6ZG3NC093063 SCBBG6ZG9NC093066 SCBBG6ZG4NC093069 SCBBZ53S2NC093072 SCBBG6ZGXNC093075 SCBBZ53S3NC093078 SCBBZ53S9NC093084 SCBBX53S7NC093087 SCBBG53S0NC093089 SCBBZ53S6NC093091 SCBBZ53SXNC093093 SCBBZ53S3NC093095 SCBBX53S1NC093098 SCBBZ53S3NC093100 SCBBZ53S0NC093104 SCBB15ZG1NC093106 SCBBX53S0NC093108 SCBBG6ZG5NC093114 SCBBZ53S7NC093116 SCBBG6ZG0NC093120 SCBB15ZG7NC093126 SCBBG6ZG5NC093128 SCBBZ53S1NC093130 SCBBZ53S2NC093136 SCBBZ53S4NC093140 SCBBX53S6NC093145 SCBBZ53S0NC093149 SCBBX53S1NC093151 SCBBZ53S2NC093153 SCBBZ53SXNC093157 SCBBZ53S5NC093163 SCBBG6ZG0NC093165 SCBBZ53S4NC093168 SCBBZ53S4NC093171 SCBBZ53S1NC093175 SCBBG53S1NC093179 SCBBZ53S7NC093181 SCBBG6ZG2NC093183 SCBBZ53S8NC093187 SCBBZ53S1NC093189 SCBBZ53SXNC093191 SCBBG6ZG9NC093195 SCBB153SXNC093201 SCBB15ZG3NC093219 SCBBZ53S1NC093239 SCBBG6ZG1NC093241 SCBBG6ZG5NC093243 SCBB15ZG1NC093249 SCBBX53S5NC093251 SCBBG6ZG8NC093253 SCBBZ53SXNC093255 SCBBG6ZG5NC093257 SCBBX53SXNC093259 SCBBG6ZG7NC093261 SCBBZ53S2NC093265 SCBBX53S2NC093272 SCBBX53SXNC093276 SCBBZ53S2NC093301 SCBBZ53S0NC093314 SCBBG6ZG0NC093330 SCBBX53S7NC093333 SCBB15ZG2NC093440 SCBBZ53S6NC093446 SCBBG53S2NC093448 SCBBG6ZG0NC093456 SCBBZ53S4NC093462 SCBBG6ZG7NC093468 SCBB15ZG4NC093472 SCBBZ53S9NC093473 SCBBG6ZG4NC093475 SCBBG6ZG8NC093477 Engine and automatic transmission hydraulic lifting table - to prepare General Information The information in this procedure is for setting up the Hydraulic lifting table -VAS 6131for engine and transmission removal from the vehicle ONLY. WARNIN G For safety reasons refer to the operating manual supplied with the table BEFORE using the hydraulic lifting table. This document shows the procedures for setting up the Hydraulic lifting table -VAS 6131-. This document does not cover the steps required to prepare the car prior to raising the engine and automatic transmission support pillars into place, refer to the relevant engine and automatic transmission remove and fit procedure before setting up the pillars. Engine and automatic transmission hydraulic lifting table - To set up Check that the lifting table bed is level by using the spirit level – arrow- at the front of the table. Adjust as necessary using the control box. Allow the table bed to float, release – the locking levers -arrow- on the side of the bed. The Hydraulic lifting table -VAS 6131requires a 3 phase electricity supply and armoured lead, to be sourced from a local qualified supplier. Check the hydraulic oil level, the – tank is situated at the front of the table under the blue housing. WARNING The following procedure should only be carried out by qualified personnel: Briefly test the table, refer to the "Engine and automatic – transmission hydraulic lifting table controls" section below. Using the controls, lift the table. If the table rises then the operating – voltage has the correct rotating field. If the table fails to operate or the motor turns in the wrong direction, disconnect from the electricity – supply from the wall socket, open the socket, swap connections L1 and L2. This reverses the direction of the motor. Engine and automatic transmission hydraulic lifting table controls The table controls are as follows: Vertical lift = Hold button -1- and press button -4-. Fast vertical lift = Hold button -2 and press button -4-. Vertical descent = Hold button -1 and press button -3-. Fast vertical descent = Hold button -2- and press button -3-. Lift the rear end (handle end) of the table = Press button -5-. Lift the front of the table = Press button -6-. Lift the left hand side of the table = Press button -7-. Lift the right hand side of the table = Press button -8-. Engine, automatic transmission and front sub frame support pillars - To set up Continental GT/GTC 4.0L V8 Special tools and workshop equipment required Hydraulic lifting table VAS 6131- Support set -VAS 6131/10- Support set -VAS 6131/13- Engine support pin -WT 10368- (2 off to support transmission) Caution When raised, the engine and automatic support pillars are located in close proximity to hoses and pipework. Ensure that all pillars are fully located in their locating points prior to supporting the sub frame, engine and automatic transmission. Failure to do so may result in damage to the underside of the car. Note It is recommended that all procedures are carried out with the help of an assistant to ensure that ALL pillars are fully located in their locating points prior to supporting the sub frame, engine and automatic transmission. Attach the tool elements to the Hydraulic lifting table -VAS 6131- as shown: A2 - Engine/subframe - Front left Plate -VAS 6131/10-1Support -VAS 6131/10-3Threaded support -VAS 6131/10-5Support pin -VAS 6131/10-13H2 - Engine/subframe - Front right Plate -VAS 6131/10-1Support -VAS 6131/10-3Threaded support -VAS 6131/10-5Support pin -VAS 6131/10-13A5 - Engine/subframe - Rear left Plate -VAS 6131/10-1Support -VAS 6131/10-3Threaded support -VAS 6131/10-5Support pin -VAS 6131/11-1H5 - Engine/subframe - Rear right Plate -VAS 6131/10-1Support -VAS 6131/10-3Threaded support -VAS 6131/10-5Support pin -VAS 6131/11-1B13 - Transmission - Rear left Plate -VAS 6131/10-1Support -VAS 6131/10-4Threaded support -VAS 6131/10-5Support pin -VAS 6131/10–8G13 - Transmission - Rear right Plate -VAS 6131/10-1Support -VAS 6131/10-4Threaded support -VAS 6131/10-5Support pin -VAS 6131/10–8F16 - Transmission body mount - Rear centre right Plate -VAS 6131/10-1Support -VAS 6131/10-2Threaded support -VAS 6131/10-5Pad -VAS 6131/13-02C16 - Transmission body mount - Rear centre Left Plate -VAS 6131/10-1Support -VAS 6131/10-2Threaded support -VAS 6131/10-5Pad -VAS 6131/13-02– Positioning the support pillars Raise the Hydraulic lifting table VAS 6131- until all supports – positioned in close proximity to the points as shown below: Engine/subframe - Front right - Position – H2 Into the front right support boss. Engine/subframe - Front left - Position – A2 Into the front left support boss. Engine/subframe - Rear left - Positions H5 As viewed from the front of the vehicle. Into the rear right support boss. Engine/subframe - Rear Right - Position – A5 Into the rear left support boss. As viewed from the front of the vehicle. – Note RH side shown, LH side symmetrically opposite. Transmission - Rear right - Position G13 Over the head of the transmission crossmember retaining screw (support pin is hollow) – Transmission - Rear left - Position B13 Over the head of the transmission crossmember retaining screw (support pin is hollow) – – Transmission body mount- Rear Centre right - Position F16 Rubber pad supporting the transmission mount – Transmission body mount- Centre Rear left - Position C16 Rubber pad supporting the transmission mount Note LH side shown, RH side symmetrically opposite. Wind all supports upwards until they are located but not – fully supporting the sub frame, engine and automatic transmission assembly. Slowly raise the table to support the engine, sub frame – and automatic transmission. After conformation that the engine, sub frame and automatic transmission are correctly supported, refer back to the step Lowering the engine and automatic transmission – assembly in section "Engine and automatic transmission To remove and fit". → Rep.-Gr.10 1. Install valve springs: Special tools and workshop equipment required Guide plate -VAS 5161A/38Removal and installation device for valve keys -VAS 5161A- Valve stem seal puller -3364- Press-on tool -3365- Note In the Guide plate -VAS 5161A/38- -1- there are four bore holes -a, b, c, d- for mounting on the cylinder head. Depending on the installation situation, observe the use of the bores and secure the Guide plate -VAS 5161A/38- with the supplied screws, M5x40 -2-. -E- Intake side -A- Outlet side Installation – Insert NEW valve springs and valve-spring plates in their original position. Observe installation positions. – Install valve keys. – Insert assembly cartridge -VAS 5161/8A- -4- into the Guide plate -VAS 5161A/38-. Press pressure fork -VAS 5161/2- -1- down, pull knurled – screw -arrow- on the assembly cartridge -VAS 5161/8A- 4- upwards by turning it back and forth, thereby inserting the valve collets. – Relieve pressure on the pressure fork -VAS 5161/2- -1whilst pulling on the knurled screw. – Repeat the procedure on each valve. When all valves are secured again, disconnect the – compressed air connection and unscrew hose adapter VAS 5161A/35-. – Do the same on the other cylinders. 2.Install spark plugs: Special tools and workshop equipment required Spark plug socket (14 mm) commercially available. Installation Installation is the reverse of removal procedure, noting the following: – Torque tighten each spark plug to 23 Nm. WARNING Always fit a complete set of spark plugs of the same specification. 3. Install valve lifters (hydraulic tappets): Installation – Fit hydraulic tappet -2- on valve lever -3-. – Position hydraulic tappet -2- and safety clip -1- on valve lever -3-. Insert hydraulic tappet -2- and hook safety clip -1- into – valve lever -3-. Check that the safety clip -1- is fitted correctly. – Fit hydraulic tappet -1- and valve lever -2-. – – – – Lightly lubricate the hydraulic tappet -1- and valve lever 2-with engine oil (0W-40). Insert hydraulic tappet -1- with the valve lever -2- into the cylinder head together. Position the pressure face of the valve lever -2- on the valve pressure face. After you have installed all hydraulic tappets and valve levers, check that they are fitted correctly. In particular, check that the safety clip is fitted correctly – and that the pressure faces of the valve lever and valve are positioned correctly. 4. Install cylinder head covers: The following procedure covers both bank 1 and bank 2 camshaft covers. Note Cylinder heads are labelled Bank 1 (RHS) and Bank 2 (LHS) as viewed from the driver’s seat. Special tools and workshop equipment required Camshaft clamp kit -T40331- Locating pins -T40116- Installation Installation is the reverse of removal, noting the following. Note The Camshaft clamp -T40331- must be fitted before removal and installation. → Rep.-Gr.15 Note Fitting and sealing components using liquid sealant. Clean sealing faces to remove all traces of residual sealant. Sealing faces must be free of grease and oil. Clean sealing faces with primer Loctite -7515-. Use liquid sealant Loctite -5970-BM-. Note Before fitting the cylinder head cover, check that the rocker arms are aligned correctly. – Apply liquid sealant Loctite -5970-BM- -1- on the cylinder head. Note Install the cylinder head cover within five minutes of applying the liquid sealant. – Fit and align cylinder head cover -1- on the cylinder head using Locating pins -T40116- -2-. – Fit cylinder head cover. Note Top image – Bank 1 (RHS) Bottom image – Bank 2 (LHS) – Fit screws on the cylinder head cover uniformly and tighten according to the specified tightening sequence. Torque tightening: 9 Nm – Locating pins -T40116- must now be pulled off. – Close off bearing tunnels with rubber caps. Exception: Left intake side with brake booster vacuum pump. 5. Install camshaft actuators (includes setting timing): The camshaft actuators are located at the rear of cylinder banks 1 and 2, behind the upper chain housing covers. WARNING Before commencing work on and around the engine, ensure that it has cooled sufficiently, failure to do so may cause injury to personnel. Avoid prolonged and repeated contact with oils and fluids etc. Always protect the skin with impervious gloves. Always wear suitable eye protection. Caution Suitably blank open ports to prevent the ingress of dirt, moisture and foreign objects into the engine. Failure to do so may cause irreparable damage to the engine. Special tools and workshop equipment required Counter hold tool -T90001- (not illustrated) Ring wrench insert, a/f 41 -VAS 261 001- (not illustrated) Camshaft clamp -T40331- Socket E24 -T90000- (not illustrated) Locking pin -T03006- Hook wrench -VAS 261 005- (not illustrated) Counterhold tool -T90002- (not illustrated) Vehicle tester Component overview Camshaft control 1 - Actuator for camshaft controller 2 - Screws, M6 x 16 Tightening torque: 9 Nm 3 - Central screw for camshaft controller Replace O-ring Initial tightening: 27 Nm Final tightening: 30 Nm +35º 4 - Actuator for outlet camshaft 5 - Actuator for intake camshaft 6 - Installation marking 7 - Valve lift adjustment 8 - Screw, M5 x 20 Tightening torque: 5 Nm Tightening sequence for central screw for camshaft controller (item -3-) Result: Cylinder bank: Camshaft: 1. Bank 2 Outlet 2. Bank 2 Intake 3. Bank 1 Intake 4. Bank 1 Outlet Installing camshaft actuators – setting the timing Note No TDC markings on cylinder head cover. ● In the event that there are no TDC markings on the cylinder head covers, raise a DISS query with Aftersales technical support. Note Camshaft actuator must not be disassembled! Friction plate in camshaft actuator – – – The camshaft actuator must never be disassembled. To replace the friction plate -1-, lever it out carefully using a small slotted screwdriver -2-. Check whether the crankshaft, the camshafts and the chain tensioners are fixed. Fit new friction plates between the camshaft actuators and camshaft stub. Allocate actuators to the camshafts. The actuator with the black surface is for the outlet side. Distinguishing features of actuators -1- Actuator for intake camshaft -2- Actuator for exhaust camshaft -3- TDC markings Position the actuators on the camshafts and fit timing – chain. Make sure that the markings on the actuators -1match the cylinder head covers -2-. Note If there are no markings -2- on the cylinder head cover, raise a DISS query with Aftersales technical support. – Replace O-rings -1- on the central valves -2-. – Lever out old O-ring -1- using a plastic wedge and dispose of it. – Coat groove on central valve and new O-ring with oil. Carefully slide O-ring over the thread and shoulder -3– of the central valve and press it on using a plastic wedge. – Do not use sharp-edged tools, such as a screwdriver. Never mask the thread with tape. – Remove lock on the chain tensioner -3-. WARNING If the tensioner pin is removed without chain guide lever in place, the piston & spring may fly out! (depending on version fitted). – Screw in central valves. – Pre-tension the timing chain and pre-tighten central valves. Caution Observe specified tightening sequence! 1. Outlet, cylinder bank 2 2. Intake, cylinder bank 2 3. Intake, cylinder bank 1 4. Outlet, cylinder bank 1 Use Hook wrench -VAS 261 005- -1- to pre-tension the – actuators anti-clockwise and use Socket E24 -T90000- 2- and a torque wrench -3- to pre-tighten the central valves. Initial tightening: 27 Nm. – Remove all staking tools. – Camshaft clamp -T40331- and adapter can now be removed. – The tool securing the crankshaft at the front of the engine can now be removed. – Secure central valves. Counterhold tool -T90001- -1- and Counterhold tool – T90002- -2- must be fitted on the actuators. To do this, turn the engine clockwise until the tool engages. – Tighten central valves using Socket E24 -T90000- -3-. Final tightening: 30 Nm. Final tightening: + 35°. Subsequent work – Fit change-over valve for water pump -3- and holder. Vacuum System for reference: -1- Brake booster vacuum pump -2- Vacuum line -3- Electric change-over valve for water pump -4- Control valve for boost pressure control, cylinders 1 to 4 -5- Control valve for boost pressure control, cylinders 5 to 8 -6- Brake booster connection -7- Vacuum unit connection – – Secure tank ventilation sensor (USA) or dummy (cylinders 1-4) -1-. Position tank ventilation sensor (USA) or dummy -1together with vent line -5- on holder -4-. – Screw in and tighten fastening screw -2-. – Plug in electric plug connection -3-. – For bank 2 only, fit the dipstick. 6. Install pressure pipes: Special tools and workshop equipment required Hose clip pliers -ASE 451 492 00 000-. Installation Installation is the reverse of removal procedure, noting the following. – RENEW any "O-rings". – Refit all previously removed components. Torque tighten all fixings as per removal. – → Rep.-Gr.00 7. Install mechanical vacuum pump: Installation Installation is the reverse of removal procedure, noting the following. – Ensure the mating faces between the vacuum pump and cylinder head are clean and free of dirt and residual oil. – RENEW the "O-ring" -1- for the vacuum pump. – Using NEW fixings -3-, secure the vacuum pump. Torque tighten in the sequence shown: Stage 1 — Hand tighten Stage 2 — 5 Nm Stage 3 – 9 Nm Drive gear – Ensure that the drive gear in the camshaft -arrowedaligns with the slot in the vacuum pump -arrowed-. Camshaft keyway Drive gear in vacuum pump – Ensure all wiring and hoses are clipped in their original positions. Torque tighten all remaining fixings. – → Rep.-Gr.00 8. Install fuel injectors: Special tools and workshop equipment required Tool set for TSI engines -T10133- Dismantling the injector – Pull the O-ring -3- and spacer ring -2- off from the injector -1- and DISCARD. – Unclip the sealing element -5- and DISCARD. Carefully remove the old combustion chamber sealing – ring -6- and DISCARD. To do so, very carefully cut the sealing ring with a knife or prise off with a suitable nonmetallic tool. Note Take care not to damage the sealing groove on the injector. The injector must be renewed if the groove is damaged. Installation Installation is the reverse of removal procedure, noting the following. Note Renew sealing element -5-, combustion chamber ring -6-, seal and O-ring-3- and backing ring -2-. Renew spacer ring if damaged. Lubricate O-rings of injectors lightly with clean engine oil. – Clean the bore in cylinder head with Nylon cylinder brush -T10133/4-. – Fit Assembly cone -T10133/5- with a NEW combustion chamber sealing ring -1- onto the injector -2-. Using the Assembly sleeve -T10133/6- push the – combustion chamber sealing ring onto Assembly cone T10133/5- as far as it will go. Turn around Assembly sleeve -T10133/6- and slide the – combustion chamber sealing ring into the groove of the injector. Note The combustion chamber sealing ring is widened when it is pushed onto the injector. After pushing it on, it therefore has to be compressed again. This is done in four stages, as described below. Push Calibration sleeve -T10133/7- onto the injector as far as it will go and simultaneously turn it 180°. Pull Calibration sleeve -T10133/7- off again by turning in the opposite direction. Push Calibration sleeve -T10133/8- onto the injector as far as it will go and simultaneously turn it 180°. Pull Calibration sleeve -T10133/8- off again by turning in the opposite direction. – Fit the parts from the injector repair kit onto the injector 1-: To ease injector installation into the fuel rail, lubricate – new O-ring lightly with clean engine oil before installing it. Note The combustion chamber ring seal -6- must NOT be lubricated. Caution Use Press tool -T10133/9-, push the injector into the cylinder head as far as it will go. DO NOT push the injector in by force. – Replace all previously discarded parts. – Replace low pressure injector O rings and the fuel supply pipes and clamps. 9. Install cylinder deactivation solenoids: Installation Installation is the reverse of removal procedure, noting the following. – – RENEW the "O-rings" on the cylinder deactivation solenoids. Before refitting the solenoids, apply a small amount of CLEAN engine oil to the "O-ring". Torque tighten all fixings as per removal. – → Rep.-Gr.00 10. Install fuel rails: The installation of the fuel rails is symmetrically the same on both banks of the engine unless stated otherwise. Installation Installation is the reverse of removal procedure, noting the following. – Torque tighten the fixings in the sequence shown. Stage 1 — Hand tight. Stage 2 — 7 Nm. Stage 3 — 10 Nm. 11.Install high pressure fuel pumps: The installation of the high pressure fuel pump is the same for both sides of the engine unless stated otherwise. Special tools and workshop equipment required Torque wrench -VAG 1331 - Tool insert AF 17 -VAG 1331/6- Consumables Microgleit DF977S lubricant (refer to electronic parts catalogue "ETKA") Installation Installation is the reverse of removal procedure, noting the following. Lightly lubricate roller tappet with engine oil (0W–40) and – insert it so that the lug -arrow A- slides into the guide notch. -arrow B-. Using a suitable "breaker" bar, rotate the engine in the – direction of normal engine rotation and at the same time press the roller tappet into the camshaft cover until it reaches its lowest point. – Fit the high pressure pump into the camshaft cover making sure that a NEW O-ring is fitted. Caution When installing the fixings -3- for the high pressure pump, first fit them by hand. When first installed, the high pressure pump will protrude from the camshaft cover, therefore the following tightening procedure MUST be adhered to. Stage 1 — Sequentially hand tighten the fixings -3- two turns at a time until the pump contacts the mating face to prevent damage to the internal spring in the high pressure pump. – Stage 2 — Torque tighten to 12 Nm. ALWAYS lubricate the fuel pipe threads with Microgleit DF977S lubricant prior to fitting. Torque tighten all remaining fixings. – → Rep.-Gr.00 – Upon completion check for leaks. 12. Install high-pressure fuel lines, banks 1 and 2: Special tools and workshop equipment required Torque wrench -VAG 1331 - Tool insert AF 17 -VAG 1331/6- Consumables Microgleit DF977S lubricant (refer to electronic parts catalogue "ETKA") Installation Installation is the reverse of removal procedure, noting the following. – Bank 1 – – Bank 2 ALWAYS lubricate the union threads -2- with Microgleit DF977S lubricant prior to fitting. The following procedure must be followed to ensure the high pressure fuel pipes are correctly tightened to eliminate the risk of fuel leaks. Fit the fixing for the fuel pipe clamp first onto the cylinder head BEFORE tightening the high pressure fuel pipes. Do – not tighten until the fuel pipes have been torque tightened. Note Hand tighten the high pressure fuel pipe unions before torque tightening. Ensure the pipes are stress free before tightening. Fit the fuel rail union first, then fit the high pressure fuel pump union. Using the Torque wrench -VAG 1331 - and Tool insert AF – 17 -VAG 1331/6- torque the high pressure fuel pipes -2- to the following torque. Stage 1 — Hand tighten. Stage 2 — 8 Nm. Stage 3 — + 50°. Caution During the torque tightening procedure, ensure the fuel pipe remains central inside the union. Failure to do so may cause damage to the brass fitment seal and cause a fuel leak. – Refit all previously removed components. Torque tighten all remaining fixings. – → Rep.-Gr.00 13.Install ignition coils: Consumables Silicone paste -G052565A1- (refer to ETKA) Installation Installation is the reverse of removal procedure, noting the following. – – – Apply Silicone paste -G052565A1- to the area shown arrow- prior to refitting the ignition coils. Push the ignition coils fully home to the abutment with the camshaft cover face. Ensure the correct electrical connector is fitted to each ignition coil. Torque tighten all remaining fixings. – → Rep.-Gr.00 14. The following is applicable to both oil mist separators. Installation Installation is the reverse of removal procedure, noting the following. – RENEW the seal. – Refit all previously removed components. Torque tighten all remaining fixings. – → Rep.-Gr.00 15. Install upper chain housing covers: Installation Note Fitting and sealing components using liquid sealant. Clean sealing faces to remove all traces of residual sealant. Sealing faces must be free of grease and oil. Clean sealing faces with primer Loctite -7515-. Use liquid sealant Loctite -5970-BM-. – – Apply liquid sealant Loctite -5970-BM- -arrow- on the chain housing cover. Install the chain housing cover within 5 minutes of applying the liquid sealant. – Install chain housing cover -1-. – Fit chain housing cover -1- on cylinder head. – Fit and tighten screws -2- (9 Nm) uniformly. 16. Install rear high-pressure fuel line: Special tools and workshop equipment required Torque wrench -VAG 1331 - Tool insert AF 17 -VAG 1331/6- Consumables Microgleit DF977S lubricant (refer to electronic parts catalogue "ETKA") Installation Installation is the reverse of removal procedure, noting the following. – On both sides, lubricate the union threads -4- with Microgleit DF977S lubricant prior to fitting the link pipe. Note Hand tighten the high pressure fuel pipe unions before torque tightening. Ensure the pipes are stress free before tightening. Using Torque wrench -VAG 1331 - and Tool insert AF 17 – VAG 1331/6-, torque tighten the union fittings -4- to 8 Nm + 50°. Caution During the torque tightening procedure, ensure the fuel pipe remains central inside the union. Failure to do so may cause damage to the brass fitment seal and cause a fuel leak. – Fit NEW O-rings to the coolant pipes. Fit the catalyst support bracket -5- and secure with NEW fixings -4-, noting the information below: Note The fixings -1, 2 - for the catalyst support bracket (see previous graphic) are different lengths. Ensure the fixings are fitted in the correct location and torque tightened as shown below. Table 1 - Automatic transmission retaining bolt chart Position Material – Size Torque 1 Steel M12 x 110 20 Nm + 60° 2 Steel M12 x 75 20 Nm + 60° Notes Torque tighten all remaining fixings. → Rep.-Gr.00 17. Install catalytic converters, exhaust downpipes and heatshields: Installation Installation is the reverse of removal procedure, noting the following. – Fit the lower heatshields. – Fit a NEW sealing ring between the catalytic converter and the turbocharger. – Fit a NEW V-band clamp -1- and fixing -arrow-. – – Fit a NEW sealing ring between the catalytic converter and exhaust downpipe. Secure the exhaust downpipe -1- with a NEW V-band clamp and fixing -arrow-. Note Position the downpipes together loosely back on to the catalytic converter to correctly align the exhaust components. Once the exhaust components are correctly aligned THEN a final torque tighten can be applied. Torque tighten the fixings in the sequence shown to – ensure stress free alignment of the catalytic converter -2. Stage Fixing location Stage 1 Catalytic converter to turbocharger "V-band" clamp Torque figure 7 Nm Stage 2 Catalytic converter to downpipe "V-band" clamp -arrow- 15 Nm – Fit the upper heatshields. Torque tighten all remaining fixings. – → Rep.-Gr.00 18. Install engine: Special tools and workshop equipment required Hydraulic lifting table -VAS 6131- Engine bung set -VAS 6122 or ASE40451200000- Hose clip pliers -ASE45149200000-. Vehicle tester. Fuel connection cap (7.89 mm) (female) -WT 10259-. Fuel connection cap (9.89 mm) (female) -WT 10260-. Fuel connection cap (7.89 mm) (male) -WT 10250-. Fuel connection cap (9.89 mm) (male) -WT 10251-. Remote hose clip pliers -Such as VAS 6340- . Ball joint splitting tool -T40010A- Tensioning strap -T10038- Ball joint splitting tool -T10444- Installation Installation is the reverse of removal procedure, noting the following. Caution Check all relevant components and engine components are clear whilst raising the engine and automatic transmission assembly into the vehicle engine bay. – Align the front subframe with all previously marked lines 1- prior to tightening the mounting fixings. Note Insert all NEW fixings for the front subframe assembly and transmission assembly to secure them to the body before fully torque tightening the fixings. Secure the front subframe with a NEW fixing -1- and fully – torque tighten to (70) Nm +180°. Repeat on the other side. Secure the front subframe with a NEW fixing -2- and fully – torque tighten to (70) Nm +180°. Repeat on the other side. Disregard all other positions. Fit the shear plates, refer to "Front subframe shear plates – - To remove and fit". → Rep.-Gr.40 – Secure the rear section of the front subframe with NEW fixings -3- and fully torque tighten to (70) Nm +180°. Note The rearmost fixing will have been installed with the refitting of the shear plates. – Secure the transmission mounting to the body with NEW fixings -1- and fully torque tighten to (25) Nm + 90°. WARNING Ensure that ALL the subframe and transmission to body securing fixings are FULLY tightened to specification as described. Only then is it safe to remove the Hydraulic lifting table -VAS 6131-. DO NOT remove the Hydraulic lifting table -VAS 6131- until it is safe to do so. – ALWAYS fit NEW O-rings when connecting the "ATF" lines -1-. Secure the air spring damper to the lower trailing arm -1– with NEW fixings -2- but DO NOT yet torque tighten. Repeat on the opposite side. Fit the upper trailing arm -1- on the wheel bearing – housing, secure with a NEW fixing -2- and torque tighten to 85 Nm. Repeat on the opposite side. On both sides of the vehicle, raise the wheel bearing housing and torque tighten the fixings -2- to the specified – value. Refer to "Raising the wheel bearing housing - To tighten bolts". → Rep.-Gr.40 Only after torque tightening the lower lever fixings [-2 – above-] can the track rod end -1- be fitted. Secure the track rod -1- with a NEW fixing -2- and torque tighten to (85) Nm. On both sides of the vehicle, secure the caliper with NEW – fixings -1- and -2- and torque tighten both to 30 Nm, then plus a further 90°. – – On both sides of the vehicle install the fixings -2- (8 Nm) to secure the brake line -1- to the wheel bearing housing . Secure the steering rack universal joint -1- with a NEW fixing and torque tighten to (20) Nm +90°. Disregard the direction arrow. Ensure the anti-roll bar wiring and steering rack harness is – positioned correctly between the subframe -1- and the rear support -2-. Before refitting the under body earth strap, ensure the – earth connection and bodywork is free of dirt and corrosion. – – Torque tighten the fixing (20 Nm) "Counter hold stud" -2for the earth connection. Re-connect the four engine harness connections in the order of -D, C, B & A- on the engine control module -1-. Apply a light film of spline grease (available in "ETKA") to – the final drive splines -arrows- before refitting the propshaft. On the LH side of the engine, REPLACE the O-ring and – install the refrigerant pipe into the compressor, then secure with the fixing -arrow- (25 Nm). Refit the engine strut brace. Refer to "Engine cross brace – To remove and fit". → Rep.-Gr.50 – Install the NEW fixing -2- (50) Nm + 90° for the top engine mount bracket -3-. Disregard all other positions. Before refitting the engine bay earth strap, ensure the – earth connection and bodywork is free of dirt and corrosion. – Torque tighten the fixing -1- (20 Nm) for the engine earth strap. – Fit NEW O-rings before torque tightening the fixings -1to 20 Nm. Vacuum fill the cooling system. Refer to "Draining and – filling coolant" → Rep.-Gr.19 Charge the air conditioning system. Refer to – "Refrigeration system - To discharge and charge" → Rep.-Gr.87 Connect the battery. Refer to "Battery - To disconnect – and connect" → Rep.-Gr.27 Clear any diagnostic faults with the Vehicle tester. – → Rep.-Gr.97 Reset the vehicle geometry. Refer to" Vehicle geometry – Wheel alignment and ride heights" → Rep.-Gr.44 – Briefly run the engine and check for leakage of any fluids or exhaust gases. WARNING Use vehicle exhaust extraction equipment to extract the gases from the workshop. – Road test the vehicle, check for leaks and re check all fluid levels and top up as necessary. 1. Remove engine: Special tools and workshop equipment required Hydraulic lifting table -VAS 6131- Engine bung set -VAS 6122 or ASE40451200000- Hose clip pliers -ASE45149200000-. Vehicle tester. Fuel connection cap (7.89 mm) (female) -WT 10259-. Fuel connection cap (9.89 mm) (female) -WT 10260-. Fuel connection cap (7.89 mm) (male) -WT 10250-. Fuel connection cap (9.89 mm) (male) -WT 10251-. Remote hose clip pliers -Such as VAS 6340- . Ball joint splitting tool -T40010A- Tensioning strap -T10038- Ball joint splitting tool -T10444- Torque tightening values Unless otherwise shown, standard torque values apply. → Rep.-Gr.00 Single use items Within this procedure there are single use items which must be replaced and not reused. Ensure that new replacements are available prior to starting this procedure. WARNING Fuel is highly flammable and extreme care must be exercised whenever the system is opened (i.e. pipes or unions disconnected, fuel cap removed) or when the fuel system is drained. The following basic rules should apply:- Always ensure adequate ventilation. Disconnect the battery. Ensure that adequate firefighting equipment is available in the vicinity of the vehicle. Fuel system - Safety precautions. → Rep.-Gr.20 Fuel system - Rules for cleanliness. → Rep.-Gr.20 Before commencing work on and around the engine, ensure that it has cooled sufficiently, failure to do so may cause injury to personnel. Avoid prolonged and repeated contact with oils and fluids etc. Always protect the skin with impervious gloves. Always wear suitable eye protection. Caution Suitably blank or bung all disconnected electrical connectors, electrical connections, hoses and pipe work to prevent the ingress of dirt and moisture. Plastic connectors and fittings can become brittle with age. Do not use excessive force to remove hoses. Replace any damaged fittings as necessary. During removal, the orientation of fuel hoses must be noted. The same hose orientation is required for fit, i.e. flow direction, location markers and spring clamp positions. Do not over strain the connections. Note The following procedures regarding fitting and servicing of "quick connects" must be observed:Disconnecting:- Using a cloth or soft brush, wipe the external surface of the connector and male tube to remove loose dirt and road salt. Twist the connector about the tube or flush the joint with a mild penetrating oil such as WD40 or CRC spray to remove any stubborn contaminants. Using an airline, blow out any accumulated dirt and road salt from the retainer area of the connector. Squeeze the side of the connector and simultaneously pull the hose from the pipe fitting. Do not allow dirt or any foreign matter to contaminate the lines or allow the lines to drag on the floor. Connecting:- Using a clean cloth, wipe the tube end. Check the O-rings in the hose and the sealing surfaces on the pipe for damage. Apply a coating of clean engine oil over the entire male tube end surface, up to the bead. Push the "quick connector" fitting over the tube until the retainer seats, with an audible click. To ensure that a secure connection has been made and has locked in position, pull back on the "quick connector". Note Dispose of any collected oils, fuel or fluids in accordance with local environmental regulations. → Rep.-Gr.20 Note Some images show W12 variant for illustration purposes only, however they are applicable to all variants unless otherwise stated. Removal – Fit vehicle protection. Discharge the air conditioning system. Refer to – "Refrigeration system — to discharge and charge". → Rep.-Gr.87 Deactivate the 48v system where fitted. Refer to "48v – system — to activate and deactivate". → Rep.-Gr.27 Place the vehicle on a ramp and set to "Jack" mode. Refer – to "Raising and supporting the car". → Rep.-Gr.99 Disconnect the battery. Refer to "Battery — to disconnect – and connect". → Rep.-Gr.27 Remove the front undersheet. Refer to "Front undersheet – – To remove and fit". → Rep.-Gr.66 Remove the front and rear sections of the side undersheets on both sides, Refer to "Side undersheets – – To remove and fit". → Rep.-Gr.66 Remove the front wheel arch liners. Refer to "Front wheel – arch liners — to remove and fit". → Rep.-Gr.66 Remove the engine strut brace. Refer to "Engine cross – brace - To remove and fit". → Rep.-Gr.50 – Detach the fuel line rubber mount -1- from the carrier bracket at the point shown -arrow-. Remove and DISCARD the fixing -2- (50) Nm + – 90° and detach the top engine mount bracket -3. Note The other fixing would have previously been removed with the engine strut brace. – – On the RH side, disconnect the two electrical connections -1- and remove from the bracket -2-. Remove the two fixings -arrows- and detach the harness carrier bracket -2-. On both sides of the vehicle release the hose clips – -1- (5.5) Nm and remove the charge hoses -3from the pressure pipes. Disregard all other positions. Remove the horns. Refer to "Twin horns - To – remove and fit". → Rep.-Gr.96 On both sides, unclip the horn wiring harness from – the front support -arrows- and move away from engine. Remove the air intake hoses. Refer to "Air intake – ducts - To remove and fit". → Rep.-Gr.21 Remove the air intake duct from behind the – radiator. Refer to "Radiator air guide - To remove and fit". → Rep.-Gr.19 Remove the engine cooling fan. Refer to "Cooling – fan — To remove and fit". → Rep.-Gr.19 – On both sides, disconnect the electrical connection -1- to the boost pressure sensor. Disregard all other positions. On the lower LH side, release the quick connect – arrow- and detach the bottom radiator hose connection and drain into a suitable container. – Once the coolant system has fully drained, refit the hose connection and secure with the clip -arrow-. At floor level Using Hose clip pliers -ASE45149200000- , release – the "Springband" clamps -arrows- and disconnect the two hoses from the coolant pump. In order, disconnect the four engine harness – connections -A, B, C & D- from the engine control module -1-. Note Suitably mark each harness connector to the relevant control unit to aid installation. – Release the harness at the clipping point -A-. Remove the fixing -B- (9 Nm) to allow the – harnesses -1- to be manoeuvred through the inner wing aperture. On the LH side of the engine bay, remove the two – fixings -1- (20 Nm), disconnect the "HVAC" pipes and DISCARD the O-rings. On the LH side of the engine bay, disconnect the – vacuum line "quick connect" -1- to the brake booster. – – Release the harness edge clip -2- from the bracket. Unclip the wiring harnesses from their clipping points -3-. Release the harness clipping points -4- and fold – the harness over the top of the engine so that it is clear of the vehicle body. On the LH side of the engine bay, disconnect the – vacuum line "quick connect" -arrow- to the vacuum reservoir. On the RH side of the engine bay and using Hose clip pliers -ASE45149200000-, release the – "Springband" clamp -1- and disconnect the vacuum hose -2- to the expansion tank valve line. Disregard all other positions. – Disconnect the engine bay earth strap -1- (20) Nm. Image for illustration purposes only. On the RH side of the engine bay, press the – latch in -1- on the engine bay charging post and release the cover -2-. – Remove the fixing -2- (20 Nm) and detach the starter cable. Note Disregard items -1 & 3-. – Unclip the starter cable from the chassis -1-. On the RH side of the engine bay, disconnect – the fuel feed line "quick connect" -1- and detach the fuel line -2-. Using Hose clip pliers -ASE45149200000- , – release the "Springband" clamp -3- and disconnect the vent line -4-. On the LH side of the engine, remove the – fixing -arrow- (25 Nm), detach the refrigerant line from the compressor and DISCARD the Oring. On both sides (where "OPF" [Otto Particulate Filter] is fitted), disconnect the electrical – connection -1- from the exhaust pressure sensor and detach at the clipping point -arrow. Vehicle raised – On the LH side of the vehicle where "EAWS" is fitted: Remove the fixing -2- (5.5 Nm) securing the Release the harness retainer -3- securing the earth connection to the EAWS control module. harness -1- to the body. Disconnect the harness connections -2- and -5- only. Note The remaining connections -1, 3 and 4- can be left connected to the module. Continuation Under the LH side of the chassis, disconnect the – power steering power feed -1- and remove the fixing -2- (20 Nm) for the earth connection. Caution Counter holding the earth stud -2- is strongly advised when loosening and tightening. Front subframe front brace – Remove fixings -1- (55 Nm). – Remove fixings -2- (30 Nm). – Remove fixing -3- (6 Nm). – Remove fixings -4- (23 Nm). – Remove the front subframe front brace. Front subframe rear brace – Remove fixings -1- (30 Nm). – Remove fixings -2- (30 Nm). – Remove the front subframe rear brace. Remove and DISCARD the fixing (85 Nm) -2– and remove track rod end -1- from the wheel bearing housing using Ball joint splitting tool T40010A- . Remove and DISCARD the bolt -2- (20 Nm +90°) – for the steering rack universal joint -1-. Push the steering column universal joint backwards arrow- off the steering rack pinion. On both sides, disconnect the electrical – connection -arrow- from the exhaust temperature sensor. – – – Detach the harness edge clip -1- from the subframe. Detach the carrier -2- from the rear section of the subframe. Separate the carrier -2- from the top cover -3and release the harness connection. Note RH shown, LH symmetrically opposite. Disconnect the harness interconnect -1- and unclip – from the subframe -2- (located in the right hand wheel arch). Remove the shear plates, refer to "Front subframe – shear plates - To remove and fit". → Rep.-Gr.40 Using Remote hose clip pliers -Such as VAS 6340-, – release the "Springband" clamps -arrows- and detach the coolant hoses -1- and -2-. Note There will be some residual coolant in these hoses, use a suitable container to catch the residual and bung up the hoses to prevent further drips. On both sides, disconnect the harness connection – for the brake pad wear indicator -1- from the holder -2- -arrow A- and disconnect it -arrow B-. Note The pad wear indicator must be renewed if the retaining clip is lost or broken. On both sides of the vehicle remove the fixings – 2- (8 Nm) securing the brake line -1- to the wheel bearing housing. On both sides, remove and DISCARD the fixings – 1- and -2- securing the caliper to wheel bearing housing and remove the caliper. – Using Tensioning strap -T10038-, suspend the caliper from the vehicle body. Caution Do not allow the caliper to hang under its own weight as this could stress and damage the brake hose. – On both sides, disconnect the harness connector 2- for the wheel speed sensor. Note Disregard items -1- and -3- – On both sides, remove the fixings -arrows- and remove the brake disc from the vehicle. Image for illustration purposes only. WARNING Brake discs are heavy. Remove carefully. Do not allow grease or fluids to come into contact with the brake pad linings and discs, as the braking efficiency of the vehicle will become severely affected. On both sides, remove the fixings -2- and remove – the sensor harness and bracket -1- from the wheel bearing housing. – On both sides, remove and DISCARD the fixing -2on joint pin for upper trailing arm -1-. – On both sides, remove and DISCARD fixing -2- from lower trailing arm -1- and air spring damper. Remove the centre section of the exhaust system. – Refer to "Exhaust centre section - to remove and fit". → Rep.-Gr.26 Remove the propshaft. Refer to "Propshaft - To – remove and fit". → Rep.-Gr.39 On the front RH side, remove the automatic – transmission pipes -1- from the bottom of the radiator assembly. Note To detach the ATF lines release the "quick connect" unions -A- from the retaining latch -B-. Push the "quick connect" outwards -C- and detach the pipe. Note Please place a suitable container underneath the vehicle to catch any escaping fluid. Dispose of any waste fluids according to local environmental regulations. Suitably blank off any open connections to prevent ingress of dirt and moisture. On both sides of the vehicle, undo the worm drive – clamp -1- (5.5) Nm, then disconnect the boost hose 3- off the intercoolers and suitably bung both the pipe and the intercooler. Disregard all other positions. – Mark the position of the front subframe to the body in all accessible areas -1-. Preparing the engine lifting table Before the sub frame, engine and automatic transmission assembly can be removed from the vehicle, the Hydraulic lifting table -VAS 6131- MUST – be prepared with the appropriate special tools. Refer to "Engine and automatic transmission hydraulic lifting table - To prepare". → Rep.-Gr.10 Lowering the engine and automatic transmission assembly Position the engine and transmission table under the vehicle in the specified lifting locations. – In addition to marking the front subframes position, install the subframe locating pins in the instructed places. Refer to “Front subframe” – To fix position. → Rep.-Gr.10 Caution Due to the weight of the engine and transmission assembly, it is important that the vehicle is secured safely to prevent instability of the vehicle on the ramp with the assembly removed. – On both sides, remove and DISCARD the fixings 3- from the rear section of the front subframe. Note The rearmost fixing will have been removed during the removal of the shear plates. On both sides, remove and DISCARD the forward – fixing -1- securing the front subframe section to the body. On both sides, remove and DISCARD the single – fixing -2- securing the front subframe section to the body. Disregard position -1-. – Remove and DISCARD the fixings -1- that retain the transmission rear crossmember to the body. With the aid of an assistant, slowly lower the – engine and automatic transmission assembly completely out of the vehicle. Caution Check all relevant components are disconnected before lowering the engine and automatic transmission assembly, and that none of the engine components are fouling as it is lowered from the vehicle. 2. Remove exhaust downpipes, heatshields and catalytic converters: Special tools and workshop equipment required 14 mm spanner -3150- Tool set -T10395A- Tool set for lambda probes -3337- Removal – Remove the three fixings -A- (8 Nm) and the two fixings -B- (9 Nm) from the heatshields -1 & 2Depress the clips -arrows- in readiness for the – removal of the heatshields -1 & 2- away from the inner heatshields. Bank 2 – Remove the fixing (8 Nm) -arrow- from the heatshield -1-. Remove the fixings -A- (8 Nm) and -B- (8 Nm) and – depress the remaining clips -arrows- to allow the two halves -1- and -3- to separate away from one another. Note The fixing clip with the arrow marked -C- is obscured from view. Bank 1 Remove the fixings -A- (8 Nm) and -B- (8 Nm) and – depress the clips -arrows- to allow heatshields -2and -4- to separate from each other Note The fixing clip with the arrow marked -C- is obscured from view. – Remove fixings -1- (8 Nm) and -2- (8 Nm) securing the pressure line -3- to the engine. Continuation for both sides – Release the electrical connection carrier assembly -1from the subframe. Separate the electrical connection carrier assembly – (two halves) -1-, detach the temperature sensor electrical connection -2- and release the wiring harness. – Release the hose from the wiring at the clipping point -3-. Using Hose clip pliers -ASE 451 492 00 000-, release – the "Springband" clamp -4- and detach the pressure hose -5- from the "OPF" downpipe. – Remove the fixing -arrow- securing the heatshield -6-. – Release the wiring harness -1- at the clipping point -2on the subframe. Release the press-stud -arrow- and manoeuvre the – heatshield -3- from the "OPF" temperature sensor wiring harness -1-. Using Hose clip pliers -ASE 451 492 00 000-, release – the "Springband" clamp -arrow- and detach the hose -2- from the "OPF" stub pipe -3-. – Remove the fixing -1- (23 Nm) from the lower support bracket. Remove and DISCARD the fixing -arrow- and clamp – and detach the downpipe -1- from the catalytic converter -2-. – DISCARD the sealing ring. – Release the relevant lambda wiring harness plug -1from its retaining clip -arrow-. Note Bank 1 shown. It is not necessary to remove the lambda probe from the catalytic converter. – Unclip the lambda wiring harness from the clipping points. Remove and DISCARD the fixing -arrow- (comprising – of screw, spring, bush and washer) from the "V-band" clamp -1- between the catalytic converter -2- and turbocharger. – – – Undo and remove the two fixings -arrows- (23 Nm) and remove the catalytic converter. DISCARD the sealing ring between the catalytic converter and turbochargers. On both sides, remove the fixing (20 Nm) -arrow- from the side of the automatic transmission. Bank 2 shown, bank 1 fixing is different – Remove the four fixings -arrows- (9 Nm) from the heatshield -1-. Slide the captive nuts -A- upwards from the support – bracket to allow the heat shield assembly -1- to slide upwards and away from the engine. 3. Remove rear high-pressure fuel line: Special tools and workshop equipment required Torque wrench -VAG 1331 - Tool insert AF 17 -VAG 1331/6- Consumables Microgleit DF977S lubricant (refer to electronic parts catalogue "ETKA") Removal Using a suitable tool, unclip the top part of the harness – retainer -arrow- to allow the retainer to open up and the harness to be removed detached. – – Remove the fixing -1- (9 Nm), detach the P-clip -2- and move the starter cable -3- to one side. Remove and DISCARD the two fixings -4- and detach the catalyst support bracket -5-. – Remove the fixings -1 to 3- (9 Nm) securing the RH turbocharger coolant pipe. On the top RH side of the engine, remove the fixing – arrow- (9 Nm), detach the turbocharger coolant pipe -1and DISCARD the O-ring. Remove the two fixings -arrows- (9 Nm) securing the RH – turbocharger coolant pipe -1- and the "OPF" pipe -2(where fitted). – Remove the fixings -1- (9 Nm) and -2- (1.5 Nm) and detach the heatshield -3-. – Remove the fixings -arrows- (9 Nm) and detach the coolant pipe -1-. DISCARD the O-rings upon removal. Bank 1 – – – Release the lambda sensor cable -1- at the clipping point -arrow-. Disconnect the electrical connections -2- and release the harness from the clipping points. Remove the fixings -3- (8 Nm) and detach the fuel pump crash assembly -4-. Bank 2 – Remove the three fixings -1- (8 Nm) and detach the fuel pump crash assembly -2-. Continuation for both sides – – – On the RH side of the engine, disconnect the harness connector -1- from the pressure sensor -2-. Remove the fixing -arrow- (9 Nm) securing the pressure sender assembly. Undo the union nut -3- securing the high-pressure pipe to the fuel pump. – On the LH side of the engine, undo the union nut -4- (8 Nm + 50°). – Remove the fixing -5- (9 Nm) securing the P-clip. Note Disregard items -1, 2 & 3-. – Remove the fixings -arrows- (9 Nm) securing the P-clips and detach the fuel link pipe -1- from the engine. 4. Remove upper chain housing covers: Caution Dirt and contamination Risk of damage to units or components — Protect components from dirt and contamination. — Secure components to prevent them from falling down. — Clean or replace dirty components. Note The procedure for removing and installing is described for one side as an example. The procedure for the other side is practically identical. Removal – Unscrew fixings -2- (9 Nm). – Press off chain housing cover -1- at a suitable point and set it down on a clean surface. 5. Remove oil mist separators: Removal – Remove the turbocharger heatshields upper sections. Bank 1 – Disconnect the pipes -1- from the oil mist separator. – Loosen the captive fixings -2- (9 Nm) that retain the oil mist separator to the cylinder head cover. Note The foremost fixing may be obstructed by sound deadening, suitably peel back the material until the fixing is accessible. – Remove the oil separator and DISCARD the seal. Bank 2 – Disconnect the vent lines -2- from the oil mist separator. – Loosen the captive fixings -2.....7- (9 Nm) that retain the oil mist separator -1- to the cylinder head cover. Note Fixings -2, 4 and 6- may be obstructed by sound deadening, suitably peel back the material until the fixings are accessible. Oil filler cap shown not fitted for illustration purposes only. – Remove the oil separator -1- and DISCARD the seal. 6. Remove ignition coils: Consumables Silicone paste -G052565A1- (refer to ETKA) Removal Bank 1 – Remove the fixing -3- (55 Nm), the fixing -4- (20 Nm) and the engine mount bracket -2-. Note Disregard -1-. – – – Disconnect the lower quick connect -1- and detach the vent line. Remove the nuts -2- (9 Nm) for the cylinder head harness carrier. Disconnect ALL harness connectors from the following components; -1- Ignition coils -2- Cylinder deactivation solenoids -3- Fuel pressure sensor -4- Fuel injectors -5- Camshaft position sensor – Carefully move the harness to one side to allow access to the ignition coils. Caution Take care not to put too much tension on the harness. – Remove the studs -1- (9 Nm) for the ignition coils. – Carefully extract the ignition coil from the cylinder head. Note Number each ignition prior to removal to aid installation. Bank 2 – Disconnect the two electrical connections -2 & 3- and release from their clipping points. Note Disregard -1-, previously disconnected. Disconnect the lower ‘quick-connect’ (not shown) and remove the vent line. Disconnect the vacuum pipe ‘quick-connect’ from the intake manifold. – Disconnect ALL electrical harness connectors from the following components: -1- Ignition coils -2- Cylinder deactivation solenoids -3- Fuel pressure sensor -4- Fuel injectors – Remove the nuts -1- (9 Nm) and move the harness to one side to allow access to the ignition coils. Caution Take care not to put too much tension on the harness. – Remove the studs -2- (9 Nm) for the ignition coils. – Carefully extract the ignition coil from the cylinder head. Note Number each ignition prior to removal to aid installation. 7. Remove high-pressure fuel lines, banks 1 and 2: Special tools and workshop equipment required Torque wrench -VAG 1331 - Tool insert AF 17 -VAG 1331/6- Consumables Microgleit DF977S lubricant (refer to electronic parts catalogue "ETKA") Removal Bank 1 – Remove the fixing -1- (9 Nm) for the fuel line clamp. – Unscrew the union nuts -2- and remove the fuel line. Bank 2 – Remove the fixing (9 Nm) -1- for the fuel line clamp. – Unscrew the union nuts -2- and remove the fuel line. 8. Remove high-pressure fuel pumps: There are two high pressure fuel pumps fitted to the engine: The High-pressure pump -N290- is mounted on the rear top surface of the bank one camshaft cover. The High-pressure pump -N402- mounted on the rear top surface of the bank two camshaft cover. The removal of the high-pressure fuel pump is the same for both sides of the engine unless stated otherwise. Special tools and workshop equipment required Torque wrench -VAG 1331 - Tool insert AF 17 -VAG 1331/6- Consumables Microgleit DF977S lubricant (refer to electronic parts catalogue "ETKA") Removal – – Disconnect the harness connector -1- from the fuel pump. Disconnect the fuel pipe union -2- from the highpressure pump. – – Lift the sound insulation material up to gain access to the fuel pump fixings. Remove the fixings -3- and carefully withdraw the fuel pump from the camshaft cover. 9. Remove fuel rails: The removal of the fuel rail is symmetrically the same on both banks of the engine unless stated otherwise. Removal – – Lift the check valve assembly from the guide away from the valve cover -arrow-. Remove the sound proof material from the cylinder head -2-. – Remove the fixings -1.....10- in the sequence shown. – Detach the fuel rail from the cylinder head, ensuring that the fuel injectors remain seated in the cylinder head. 10. Remove cylinder deactivation solenoids: The cylinder deactivation solenoid system comprises of the following: Camshaft lobe sliding element - which is part of the camshaft assembly and operates on a splined section of the camshaft. CDA activation/ deactivation solenoids (actuators) (4 per engine bank). Removal – – – Remove the fixings -1- (5 Nm) for the relevant cylinder deactivation solenoid. Carefully remove the cylinder deactivation solenoid from the cylinder head. Repeat for all remaining cylinder deactivation solenoids, noting the locations to aid installation. 11. Remove fuel injectors: Special tools and workshop equipment required Tool set for TSI engines -T10133Removal – Apply Puller -T10133/2A- to the groove of the injector. – – Apply Puller -T10133/16A- over Puller -T10133/2A-, and extract the injector by turning the bolt -1-. Repeat for all injectors, taking note of the locations to aid installation. 12. Remove mechanical vacuum pump: The mechanical vacuum pump is located at the front LH side (bank 2) of the cylinder head -arrow-. Removal – Remove the fixing -1- retaining the engine harness -2-. – – – – – Detach the quick connect -3- from the pressure tube breather. Release the "Springband" clamp -arrow- and detach from the hose -4-. Release the pipe assembly -5- from the clipping points for improved access. From the top of the vacuum pump, disconnect the vacuum line -2- and the push-on hose -1-. Remove and DISCARD the three fixings -3- from the vacuum pump. – Carefully detach the vacuum pump from the engine. 13. Remove pressure pipes: Special tools and workshop equipment required Hose clip pliers -ASE 451 492 00 000-. Removal LH side (bank 2) only – Pull the breather stub -1- out from the pressure pipe. Continuation for both sides On the appropriate side, release the two captive fixings – 2- (9 Nm) and detach the pressure pipe -3- from the centre connecting hose -4-. An additional fixing may be fitted dependent on model year. Caution Blank off all open ports. – Remove and DISCARD the "O-rings" -arrows- from the breather stub -1- and the pressure pipe -2-. 14. Remove camshaft actuators: The camshaft actuators are located at the rear of cylinder banks 1 and 2, behind the upper chain housing covers. Special tools and workshop equipment required Counterhold tool -T90001- (not illustrated) Ring wrench insert, a/f 41 -VAS 261 001- (not illustrated) Camshaft clamp -T40331- Socket E24 -T90000- (not illustrated) Locking pin -T03006- Hook wrench -VAS 261 005- (not illustrated) Counterhold tool -T90002- (not illustrated) Vehicle tester Component overview Camshaft control 1 - Actuator for camshaft controller 2 - Screws, M6 x 16 Tightening torque: 9 Nm 3 - Central screw for camshaft controller Replace O-ring Initial tightening: 27 Nm Final tightening: 30 Nm +35º 4 - Actuator for outlet camshaft 5 - Actuator for intake camshaft 6 - Installation marking 7 - Valve lift adjustment 8 - Screw, M5 x 20 Tightening torque: 5 Nm Tightening sequence for central screw for camshaft controller (item -3-) Result: Cylinder bank: Camshaft: 1. Bank 2 Outlet 2. Bank 2 Intake 3. Bank 1 Intake 4. Bank 1 Outlet Preliminary work – For bank 2 only, remove the dipstick. Note Photos taken with a digital camera are helpful with complicated line routing (engine wire harness). – Loosen tank ventilation sensor (USA) or dummy (cylinders 1–4) -1-. – Unscrew and remove fastening screw -2-. – Release and disconnect electric plug connection -3-. – – Loosen tank ventilation sensor (USA) or dummy -1together with vent line -5- from holder -4-. Loosen change-over valve for water pump -3- and remove holder. Ref: Image Vacuum System for reference: -1- Brake booster vacuum pump -2- Vacuum line -3- Electric change-over valve for water pump -4- Control valve for boost pressure control, cylinders 1 to 4 -5- Control valve for boost pressure control, cylinders 5 to 8 -6- Brake booster connection -7- Vacuum unit connection Remove camshaft actuator Caution Timing not set correctly Risk of engine damage Rough running engine Loss of engine power — Do not use force when fitting the staking tool. — Make sure that the gap is equal on both sides. — When inserting the staking tools, do not use force to turn the camshafts against any resistance. — The engine must be exactly at top dead centre. — The opposite cylinder must be at ignition TDC. Caution Dirt and contamination Risk of damage to units or components — Protect components from dirt and contamination. — Clean or replace dirty components. Note Do not clean the camshaft controller in a parts washer. Only the outside can be cleaned using a clean, lint-free cloth. Note Never use the Camshaft clamps -T40331- as a counterhold tool for loosening and tightening the camshaft controllers. Note The Counterhold tool -T90001- can only be inserted at one position. The markings -1 and 2- must line up. – Turn engine clockwise to ignition TDC of cylinder 1. Check markings on crankshaft and actuators. – Secure camshafts. – – Carefully lever out stoppers on the cylinder head cover using a screwdriver. Screw adapter -1- into the camshaft housing and tighten to 9 Nm. Cylinder bank 1: T40331/2, Cylinder bank 2: T40331/3 Note It may be necessary for another person to carefully position the camshafts at the actuators using Counterhold tool T90001- and Ring wrench insert, a/f 41 -VAS 261 001-. Camshaft clamp -T40331- must be inserted. Cylinder bank 1: 1 - -T40331/1- – The letter "A" must be facing you 2 - -T40331/93 - -T40331/24 - -T40331/4- – Outlet camshaft 5 - -T40331/6- – Intake camshaft Cylinder bank 2: 1 - -T40331/1- – The letter "B" must be facing you 2 - -T40331/93 - -T40331/34 - -T40331/10- – Outlet camshaft 5 - -T40331/8- – Intake camshaft – Secure the crankshaft at the front of the engine using a suitable 6mm locking pin/drill bit. Caution It may be necessary to rotate the crankshaft to fit the tool securing the crankshaft. If the engine is turned over by hand using the crank damper bolt, it MUST be turned “clockwise” -arrowed- to avoid the possibility of loosening the bolt. – Loosen and unscrew central valves -1-. Counterhold tool -T90001- -2- with Ring wrench insert, – a/f 41 -VAS 261 001- -3- must be fitted on the actuators. Then loosen central valves -1- using Socket E24 -T90000-. – Fix chain tensioner in place. – – Press the chain tensioner piston back fully. To do this, actuate the tensioning rail by hand. Fix the chain tensioner -1- in place using Locking pin T03006- -3-. WARNING If the tensioner pin is removed without chain guide lever in place, the piston & spring may fly out! (depending on version fitted). – Unscrew central valves and remove actuators from camshafts and from the timing chain. Caution Secure the timing chain to prevent it from falling down. 15.Remove cylinder head cover: The following procedure covers both bank 1 and bank 2 camshaft covers. Removal Note The procedure for removing and installing is described for one side as an example. The procedure for the other side is practically identical, except where shown. Bank 1 – Remove the fixings -arrows- (20 Nm). – Remove the bracket-1-. Continuation for both sides – Remove cylinder head cover -1-. – – Unscrew screws -2- slowly and uniformly from the outside in. Remove cylinder head cover -1- (with camshaft clamp fitted) and set it down on a clean surface. 16. Remove valve lifters (hydraulic tappets): Removal – If you intend to re-use hydraulic tappets, safety clips and valve levers: Mark allocation of the components using a coloured marker. – Remove hydraulic tappet -1- and valve lever -2-. – Take hydraulic tappet -1- with valve lever -2- out of the cylinder head together. Note If you intend to re-use hydraulic tappets and valve levers, check that the components are not damaged. – Check component allocation and check that all components are fitted. – Remove hydraulic tappet -2- from valve lever -3-. – Open safety clip -1- carefully. – Remove safety clip -1- and hydraulic tappet -2-. 17. Remove spark plugs: Special tools and workshop equipment required Spark plug socket (14 mm) commercially available. Removal Note Ensure the area around the spark plugs is free from dirt and debris. – Using a suitable socket, remove the spark plugs. Note When spark plugs are removed, place a suitable clean cloth in the spark plug bore to prevent any dirt ingress. 18. Remove valve springs: The following procedure is carried out with the engine and automatic transmission removed from the vehicle but with the cylinder installed. Special tools and workshop equipment required Guide plate -VAS 5161A/38Removal and installation device for valve keys -VAS 5161A- Valve stem seal puller -3364- Press-on tool -3365- General information Note In the Guide plate -VAS 5161A/38- -1- there are four bore holes -a, b, c, d- for mounting on the cylinder head. Depending on the installation situation, observe the use of the bores and secure the Guide plate -VAS 5161A/38- with the supplied screws, M5x40 -2-. -E- Intake side -A- Outlet side For (Bank 1) - Using a suitable tool remove the “C-Clip” -1- that retains the “Waistgate actuator rod” to the turbocharger. - Remove the two fixings -arrows- and remove the waistgate Actuator. This will allow greater access. Before attempting to remove the valve keys (collets) firstly Ensure that all galleries in the area being worked are suitably Covered with lint free cloths, to ensure NO foreign bodies enter the engine . – Guide plate -VAS 5161A/38- -1- must now be secured on the cylinder head. Guide plate -VAS 5161A/38- -1- on the cylinder head must be aligned above the relevant combustion chamber. Observe markings "A – Outlet side / E – Intake side" while doing this. It is imperative that all the sealant is removed from the – mating faces of the cylinder heads before proceeding further. - Insert the two fixings -arrows-, then install two suitable M8 dowel bolts -2- finger tight ONLY. (The engine cross brace fixings are suitable for this instance) – Now tighten the fixings -arrows- to 9 Nm. (for the two rear cylinders, only one securing fixing –arrow- can be used) Fit punch -2- -VAS 5161/3A- -2- from tool set Removal and installation device for valve keys -VAS 5161A- on – the valve-spring plate and loosen any tight valve keys by tapping them with a plastic hammer. - – Disregard all other position Screw the sealing pin -VAS 5161/10- -2- from tool set “Removal and installation device for valve keys” -VAS 5161A- into the Guide plate -VAS 5161A/38-. Hand tight ONLY. – – Screw the hose adapter -VAS 5161A/35- -1- hand-tight into the respective spark plug thread. Connect compressed air to the hose adapter -VAS 5161A/35-1-. Note Minimum pressure: 6 bar – Remove the valve springs using “Removal and installation device for valve keys” -VAS 5161A-. Screw the retainer -VAS 5161/6- -2- with guided fork and – M8 threaded bolt -VAS 5161/5- -3- into the guide plate. – – Insert assembly cartridge -VAS 5161/8A- -4- into the bore over the valve spring to be removed. Engage pressure fork -VAS 5161/2- -1- in the retainer – VAS 5161/6- -2- and press assembly cartridge down. At the same time, turn the knurled screw -arrow- on – the assembly cartridge clockwise until the tips engage in the valve collets. Turn the knurled screw -arrow- back and forth to – press the valve collets apart and capture them in the assembly cartridge. The knurled screw slips in as far as it will go into the assembly cartridge. – Relieve tension on pressure fork -VAS 5161/2- -1- and remove assembly cartridge -VAS 5161/8A- -4-. – Remove valve keys from the assembly cartridge. Remove valve spring with valve-spring plate and mark – installation position. DISCARD spring. To remove the valve keys from the cartridge -VAS 5161/8A-If the valve keys were removed from the assembly cartridge, they must first be inserted into the insertion device –VAS 5161/18- -1- from the tool set “Removal and installation device for valve keys” -VAS 5161A-. -Insert the valve keys into the insertion device -VAS 5161/18- -1- . -The large diameter of the valve keys must be facing upwards. -Press the assembly cartridge -VAS 5161/8A- onto the valve keys from above and pick up the valve keys from the insertion device -VAS 5161/18- -1-.