2065472/5

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
2065472/5
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
63xinstall1-17.pdf
63xremoval1-3.pdf
63xremoval4-18.pdf
hydraulicliftingtable63x.pdf
sc2141vinlist.pdf
EC24
V8 Kovomo - New Continental GT/GTC and New Flying Spur - Valve spring replacement (SC21/41)
Notes
Transaction No.: 2065472/5
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
VERY IMPORTANT: Before continuing with the onward instructions the operative should confirm if the symptoms within TPI 2064776/are applicable
In the event the symptoms are applicable the operative MUST first conduct TPI 2064776/- to completion
The operative MUST then raise a new Technical DISS query or respond via the already open DISS query and await feedback from
Product Support before conducting any further work as further information will be requested back which may change the method of
repair
NOTE: The operative should raise a non-technical DISS query before commencing the rework operation within the Work section stating that
(SC21/41) is being conducted on the applicable VIN
Revision history
NOTE: All previous issues of this document should be disregarded. Only the latest document (VIN applicable within Elsa Pro) must
be used
Revision number
Type of change
2065472/3 (Archived) Updated to reference the V8 Misfire TPI 2064776/- a change was made to the hydraulic table instructions
2065472/4
See bullet points below
2065472/5
Changes made within the Warranty accounting instructions
•
The Genuine parts section has been updated advising 04E998907A or 06M998907 (Repair kit for valve unit) should be used
•
The Work section has been updated to include the search location of the valve spring replacement best practice videos (all cylinders) the
videos should be accessed via the eAcademy Technical catalogue
•
Instructions regarding the replacement of the valve springs (Valve springs - To remove and fit) can be found within the attached
documents, the operative MUST read through each attachment prior to starting the rework procedure
NOTE: The attached rework instructions have been amended from the last revision, the operative MUST read through each individual
attachment prior to starting the rework procedure
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
00 66
Criteria
01
Labour
Labour Operation Code 15 65 56 99
Time
2190 TU
Alignment of applicable driver assist systems (Depending on vehicle specification)
NOTE: Please also refer to the information within the Work section (step 3) for further clarification
•
Vehicle front + rear measured wheel alignment checked - 44 95 03 00 - 90 TU
•
Rear wheel camber adjust - 44 94 15 50 - 30 TU
•
Rear wheel track adjust - 44 93 15 50 - 30 TU
•
Front wheel camber adjust - 44 89 15 50 - 40 TU
•
Front wheel track adjust - 44 88 15 50 - 20 TU
•
(ACC) - Radar sensor checked + adjusted - 91 63 05 51 - 30 TU
•
Overhead view camera adjusted - 90 83 15 00 - 40 TU
•
Driver assist camera adjusted - 96 38 15 50 - 120 TU
•
Control unit for (Lane change assist) adjusted - 96 35 15 00 - 50 TU
•
Night vision system calibration - 90 80 15 50 - 40 TU
•
Headlamps to adjust - 94 15 16 00 (as per Labour operations)
•
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 or 06M998907
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
00004320993
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
VERY IMPORTANT: Before continuing with the onward instructions the operative should confirm if the symptoms within TPI 2064776/are applicable
In the event the symptoms are applicable the operative MUST first conduct TPI 2064776/- to completion
The operative MUST then raise a new Technical DISS query or respond via the already open DISS query and await feedback from
Product Support before conducting any further work as further information will be requested back which may change the method of
repair
NOTE: The operative should raise a non-technical DISS query before commencing the rework operation within the Work section stating that
(SC21/41) is being conducted on the applicable VIN
Revision history
NOTE: All previous issues of this document should be disregarded. Only the latest document (VIN applicable within Elsa Pro)
must be used
Revision number
Type of change
2065472/3 (Archived) Updated to reference the V8 Misfire TPI 2064776/- a change was made to the hydraulic table instructions
2065472/4
See bullet points below
2065472/5
Changes made within the Warranty accounting instructions
•
The Genuine parts section has been updated advising 04E998907A or 06M998907 (Repair kit for valve unit) should be used
•
The Work section has been updated to include the search location of the valve spring replacement best practice videos (all cylinders) the
videos should be accessed via the eAcademy Technical catalogue
•
Instructions regarding the replacement of the valve springs (Valve springs - To remove and fit) can be found within the attached
documents, the operative MUST read through each attachment prior to starting the rework procedure
NOTE: The attached rework instructions have been amended from the last revision, the operative MUST read through each individual
attachment prior to starting the rework procedure
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 or 06M998907
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
00004320993
Loctite 7515 primer (Source locally)
As required
Tools
Refer to the attached instructions
Work
VERY IMPORANT: The operative must ensure all of the attached rework instructions are read and understood prior to
starting the rework
TIP: When replacing the valve springs the operative should refer to the valve spring replacement videos
Please see the information below to locate the Videos:
•
Log on to GRP: https://grp.volkswagenag.com/
•
Select “eAcademy”
•
Select “My Learning”, then “Browse a Catalogue”
•
Select “Technical”, then select page 7
Or
•
Select “My Learning”, then “Search”
•
Search “EA825” and the videos will be listed
•
Refer to Figure 1
Figure 1
1) To gain access/replace all of the Intake and Outlet valve springs - Refer to the attached rework instructions ensuring each process is
conducted in numerical order as follows:
IMPORTANT: Ensure the engine and transmission is suitably secured to the hydraulic lifting table and ensure the attached hydraulic
lifting table instructions are followed
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
Removal
1 - Engine
2 - Exhaust downpipes, heatshields and catalytic converters
3 - High-pressure fuel line
4 - Upper chain housing covers
5 - Oil mist separators
6 - Ignition coils
7 - High pressure fuel lines, banks 1 and 2
8 - High pressure fuel pumps
9 - Fuel rails
10 - CDA solenoids
11 - Fuel injectors
12 - Mechanical vacuum pump
13 - Pressure pipes
14 - Camshaft actuators
15 - Cylinder head cover
16 - Valve lifters (hydraulic tappets) 17
- Spark plugs
18 - Valve springs to remove and fit
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 2 (Located on the outside edge of each bank)
HINT: Referring to Figure 2 - 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 2
•
0P2 109 623 - Outlet valve springs - Figure 3 (Located on the inside of each bank)
HINT: Referring to Figure 3 - 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 3
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 as follows:
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 - Spark plugs
2 - Valve lifters (hydraulic tappets)
3 - Cylinder head covers
4 - Camshaft actuators (includes setting timing) 5 Pressure pipes
6 - Mechanical vacuum pump 7
- Fuel injectors
8 - CDA solenoids
9 - Fuel rails
10 - High pressure fuel pumps
11 - High pressure fuel lines, banks 1 and 2
12 - Ignition coils
13 - Oil mist separators
14 - Upper chain housing covers
15 - High-pressure fuel line
16 - Catalytic converters, exhaust downpipes and heatshields 17 Install engine
3) Carry out wheel alignment and ensure the driver assist system calibrations are performed as described in the onward instructions
(Depending on vehicle specification)
•
Check the alignment of the front + rear wheel alignment
NOTE: The requirement to adjust the front and rear wheel alignment should only carried out if alignment shown to be out of
specification
Please ensure a screenshot of the before and after measurements are attached to a new or existing non-technical DISS
query
•
Rear wheel camber adjust (see previous note)
•
Rear wheel track adjust (see previous note)
•
Front wheel camber adjust (see previous note)
•
Front wheel track adjust (see previous note)
•
(ACC) - Radar sensor checked + adjusted
NOTE: The following require recalibration/adjustment in the event the front and rear wheel alignment was found to be out of
specification and adjusted
•
Overhead view camera adjusted
•
Control unit for (Lane change assist) adjusted
•
Night vision system calibration
NOTE: The Driver assist camera recalibration/adjustment is MANDATORY and MUST BE conducted regardless - Refer to the applicable
Rep.Gr instructions
NOTE: The headlamps only require adjustment if headlamp/fender is removed/damaged
•
Headlamps to adjust
4) Respond on the previously opened 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 4
•
Select Guided functions from 01 – Engine Control Module 1
•
Select Generate readiness code
•
Select Execute
Figure 4
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 5)
Identification
Yellow paint completion mark on the right hand side of the engine partition brace (Figure 5)
Figure 5
Repair instructions Notes
New Continental GT V8 Kovomo
SCBCZ13S5MC090579
SCBCG2ZG0NC092546
SCBCZ13S2MC090586
SCBCX13S9NC092553
SCBCZ13S1MC090594
SCBCG2ZG8NC092567
SCBCG2ZG1NC090885
SCBCZ13S2NC092596
SCBCG2ZG7NC090986
SCBCG13S0NC092599
SCBCF13S1NC091108
SCBCG2ZG6NC092602
SCBCF13S4NC091166
SCBCG13S8NC092608
SCBCF13S7NC091193
SCBCF13SXNC092614
SCBCF13S9NC091213
SCBCZ13S6NC092617
SCBCZ13S6NC091290
SCBCX13S3NC092628
SCBCG2ZG2NC091303
SCBCG13S6NC092641
SCBCG2ZG4NC091304
SCBCF13SXNC092645
SCBCZ13S2NC091321
SCBCG2ZG6NC092650
SCBCZ13S0NC091365
SCBCG2ZGXNC092652
SCBCG2ZG5NC091456
SCBCG2ZG0NC092658
SCBCF13S5NC091502
SCBCG2ZG2NC092662
SCBCG2ZG0NC091509
SCBCG2ZG1NC092670
SCBCG13S2NC091597
SCBCG13S8NC092690
SCBCX13S4NC091598
SCBCF1ZG1NC092701
SCBCX13S0NC091601
SCBCX13S7NC092714
SCBCJ13S9NC091727
SCBCG2ZG8NC092729
SCBCX13S1NC091753
SCBCG2ZG9NC092738
SCBCZ13S8NC091761
SCBCG2ZGXNC092747
SCBCZ13S2NC091769
SCBCZ13S1NC092752
SCBCZ13S6NC091788
SCBCG2ZGXNC092764
SCBCG2ZG8NC091791
SCBCG2ZG5NC092767
SCBCG13S6NC091909
SCBCG2ZG5NC092770
SCBCX13S8NC091913
SCBCG2ZG8NC092777
SCBCG13S3NC091950
SCBCG2ZG3NC092783
SCBCG2ZG7NC092222
SCBCG13S0NC092795
SCBCG13S0NC092229
SCBCG2ZG4NC092808
SCBCG2ZG0NC092238
SCBCF13S7NC092814
SCBCF13S7NC092263
SCBCG2ZG1NC092829
SCBCG2ZG5NC092316
SCBCZ13S9NC092837
SCBCG2ZG0NC092322
SCBCG13S7NC092843
SCBCX13S1NC092336
SCBCZ13S5NC092849
SCBCF13S7NC092389
SCBCZ13S6NC092861
SCBCG2ZG5NC092395
SCBCZ13S0NC092872
SCBCG2ZG2NC092399
SCBCG13S7NC092907
SCBCG2ZG7NC092429
SCBCF13S3NC092910
SCBCF13S0NC092430
SCBCF1ZG0NC092916
SCBCZ13S3NC092462
SCBCJ13S1NC092919
SCBCF13S9NC092474
SCBCF1ZG9NC092929
SCBCG2ZG7NC092480
SCBCF13S3NC092941
SCBCJ13SXNC092482
SCBCG13S2NC092944
SCBCG2ZG8NC092486
SCBCG2ZG9NC092951
SCBCG13S2NC092488
SCBCG2ZG4NC092954
SCBCX13S2NC092510
SCBCG2ZG1NC092961
SCBCZ13S7NC092514
SCBCG2ZG5NC092963
SCBCJ13S3NC092520
SCBCX13SXNC092965
SCBCZ13SXNC092524
SCBCG2ZG4NC092971
SCBCG2ZG5NC092526
SCBCF13S5NC092973
SCBCZ13S5NC092530
SCBCG2ZG1NC092975
SCBCG2ZG4NC092534
SCBCX13S5NC092985
SCBCX13S2NC092538
SCBCX13S0NC092988
SCBCG2ZG8NC092990
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
SCBBZ53S3NC091928
SCBBG53S2NC090730
SCBBG6ZG0NC092209
SCBBZ53S4NC090738
SCBBG6ZG1NC092221
SCBBG53S0NC090774
SCBBZ53S7NC092225
SCBBG53S2NC090792
SCBBX53S0NC092234
SCBBG53S5NC090804
SCBBZ53S3NC092237
SCBBG53S0NC090824
SCBBZ53S6NC092247
SCBBZ53S1NC090874
SCBBG6ZG4NC092262
SCBBG53S1NC090878
SCBBZ53S8NC092315
SCBBG53S6NC090892
SCBBZ53S0NC092325
SCBBG53S5NC090902
SCBBG53S7NC092330
SCBBG53S5NC090947
SCBBZ53S7NC092337
SCBBG53S3NC090977
SCBBG53S0NC092346
SCBBZ53SXNC090985
SCBBG53S6NC092349
SCBBG53S6NC090987
SCBBG53S4NC092351
SCBBZ53S2NC090995
SCBBZ53S7NC092354
SCBBG53S5NC091001
SCBBG6ZG2NC092373
SCBBG53S9NC091017
SCBBZ53S8NC092377
SCBBG53SXNC091026
SCBBZ53S3NC092383
SCBBX53S3NC091126
SCBBX53SXNC092385
SCBBG53S9NC091146
SCBBZ53S2NC092388
SCBBG53S8NC091199
SCBBG6ZG2NC092390
SCBBG53S9NC091227
SCBBG53S7NC092392
SCBBG53S6NC091234
SCBBZ53S5NC092398
SCBBG53S1NC091240
SCBBG6ZG5NC092402
SCBBG53S7NC091243
SCBBZ53S7NC092404
SCBBG53S9NC091261
SCBBZ53S6NC092409
SCBBG53S0NC091262
SCBBG53S6NC092416
SCBBG53S6NC091279
SCBBG53S9NC092426
SCBBG53S4NC091300
SCBBG6ZG1NC092428
SCBBZ53S7NC091317
SCBBG6ZG7NC092434
SCBBG53S0NC091326
SCBBG6ZG2NC092440
SCBBG53S7NC091341
SCBBZ53S5NC092448
SCBBG53S2NC091344
SCBBG6ZG4NC092455
SCBBG53S3NC091353
SCBBG6ZGXNC092461
SCBBX53S8NC091400
SCBBZ53S3NC092464
SCBBX53S1NC091402
SCBBG53S1NC092467
SCBBG53S6NC091413
SCBBX53S7NC092473
SCBBG53S1NC091416
SCBBG6ZG7NC092479
SCBBG53S0NC091438
SCBBX53SXNC092483
SCBBG53S0NC091441
SCBBG6ZGXNC092492
SCBBG53SXNC091463
SCBBG6ZG5NC092495
SCBBX53S3NC091580
SCBBZ53S5NC092501
SCBBG53S2NC091599
SCBBX53S1NC092503
SCBBG6ZGXNC091729
SCBBG6ZG4NC092505
SCBBG53SXNC091737
SCBBZ53SXNC092509
SCBBX53S6NC091752
SCBBZ53S1NC092513
SCBBZ53S3NC091783
SCBBZ53S2NC092519
SCBBG6ZG6NC091789
SCBBZ53S8NC092525
SCBBZ53S4NC091792
SCBBG53S6NC092531
SCBBG6ZG9NC091799
SCBBX53S3NC092535
SCBBZ53S5NC091803
SCBBG6ZGXNC092539
SCBBG53S9NC091809
SCBBG6ZG5NC092545
SCBBG53S4NC091815
SCBBX53S1NC092548
SCBBG53S0NC091908
SCBBZ53S7NC092550
SCBBG53S6NC091914
SCBBZ53S0NC092552
SCBBG53S7NC092554
SCBBZ53S8NC092556
SCBBZ53S1NC092558
SCBBZ53SXNC092560
SCBBZ53S3NC092562
SCBBZ53S4NC092568
SCBBG53S9NC092572
SCBBX53S4NC092575
SCBBG53SXNC092578
SCBBZ53S3NC092593
SCBBZ53S2NC092598
SCBBG53S2NC092607
SCBBZ53SXNC092610
SCBBZ53S0NC092616
SCBBZ53S8NC092623
SCBBZ53S4NC092635
SCBBG53S1NC092646
SCBBZ53S6NC092653
SCBBG6ZGXNC092668
SCBBX53SXNC092676
SCBBZ53S2NC092682
SCBBX53S6NC092691
SCBBG53S7NC092702
SCBBX53S2NC092705
SCBBG53S8NC092708
SCBBZ53S3NC092710
SCBBX53S1NC092713
SCBBZ53SXNC092719
SCBBX53S2NC092722
SCBBG6ZG2NC092728
SCBBZ53S7NC092743
SCBBX53S9NC092751
SCBBX53S4NC092754
SCBBZ53S6NC092765
SCBBZ53S1NC092768
SCBBZ53S5NC092773
SCBBZ53SXNC092784
SCBBZ53S0NC092809
SCBBZ53SXNC092817
SCBBG53S6NC092819
SCBBG6ZG0NC092825
SCBBZ53S2NC092830
SCBBZ53S3NC092836
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.
WARNIN
G
For safety
reasons
suitably secure
the engine and
transmission to
the Hydraulic
lifting table VAS 6131This 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:
B2 - Engine/subframe - Front left
Plate -VAS 6131/10-1Support -VAS 6131/10-4Threaded support -VAS 6131/10-5Support pin -VAS 6131/10-10G2 - Engine/subframe - Front right
Plate -VAS 6131/10-1Support -VAS 6131/10-4Threaded support -VAS 6131/10-5Support pin -VAS 6131/10-13B6 - Engine/subframe - Rear left
Plate -VAS 6131/10-1Support -VAS 6131/10-4Threaded support -VAS 6131/10-5Pad -VAS 6131/13-02G6 - Engine/subframe - Rear right
Plate -VAS 6131/10-1Support -VAS 6131/10-4Threaded support -VAS 6131/10-5Pad -VAS 6131/13-02F16 - Transmission body mount - Rear centre right
Plate -VAS 6131/10-1Support -VAS 6131/10-4Threaded support -VAS 6131/10-5Pad -VAS 6131/13-02C16 - Transmission body mount - Rear centre Left
Plate -VAS 6131/10-1Support -VAS 6131/10-4Threaded support -VAS 6131/10-5Pad -VAS 6131/13-02Positioning 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
–
G2
Into the front right support boss.
– Engine/subframe - Front left - Position B2
Into the front left support boss.
–
– Engine/subframe - Rear left - Positions B6
As viewed from the front of the vehicle.
Into the rear right support boss.
– Engine/subframe - Rear Right - Position G6
Into the rear left support boss.
As viewed from the front of the vehicle.
Note
RH side shown, LH side symmetrically opposite.
– 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
PAGE INTENTIONALLY LEFT BLANK
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

earth connection to the EAWS control module.
Release the harness retainer -3- securing the

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
–
Remove the fixings -1 to 3- (9 Nm) securing the RH
turbocharger coolant pipe.
Remove the fixing -arrow- (9 Nm), detach the
– turbocharger coolant pipe -1-. DISCARD the O-ring and
washer.
Access to the fixing is tight.
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-.
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 -T10133-
Removal
Note
As the injectors are new, it may be possible to pull them out
manually, i.e. without the need for the puller tool. If this is
not possible, refer to the steps below.
– 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 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 -T03006Hook 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 -1–
together 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:
12345-
-T40331/1- – The letter "A" must be facing you
-T40331/9-T40331/2-T40331/4- – Outlet camshaft
-T40331/6- – Intake camshaft
Cylinder bank 2:
12345-
-T40331/1- – The letter "B" must be facing you
-T40331/9-T40331/3-T40331/10- – Outlet camshaft
-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.
Note
Prior to removal of the camshaft actuators mark the position
of both camshaft actuators, the timing chain and the
cylinder head cover to aid installation.
– 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 - Valve springs - To remove and fit
General Information
The engine and automatic transmission is required to be removed from the vehicle in order to carry
out this procedure. The cylinder head is to remain installed on the engine assembly whilst this
procedure takes place.
The automatic transmission does NOT require to be removed from the engine assembly.
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.
WARNING
Danger of objects or loads falling down
Risk of squashing or crushing
— Secure components to prevent them from falling down.
Caution
Dirt and contamination
Risk of damage to units or components
— Protect components from dirt and contamination.
— Clean or replace dirty components.
Special tools and workshop equipment required

Guide plate -VAS 5161A/38-
Removal and installation device for
valve keys -VAS 5161/A Valve stem seal puller -3364 Press-on tool -3365 Cylinder compression tester
Positioning of Hook -VAS 5161/6- &
Anchor -VAS 5161/5 M8- onto Guide
plate -VAS 5161A/38- for each
cylinder.
It is imperative that the following table
and accompanying image is followed
to ensure the correct positioning of the
Hook -VAS 5161/6- & Anchor -VAS
5161/5 M8- for access and correct
leverage.

Cylinder Number VAS 5161/6 (hook) & VAS 5161/5 M8 (anchor) Position
Inlet
Exhaust
(Bank 1)
Left Valve
Right Valve
Left Valve
Right Valve
1
6
6
3
3
2
6
6
3
2
3
4/5
4/5
3
3
4
4/5
4/5
3
3
Inlet
Exhaust
(Bank 2)
Left Valve
Right Valve
Left Valve
Right Valve
5
6
6
3
3
6
6
6
3
3
7
4/5
4/5
3
3
8
4/5
4/5
3
3
Guide plate -VAS 5161A/38- - Hook VAS 5161/6- & Anchor -VAS 5161/5
M8Use the image and the table to
–
ensure correct positioning of tools.
 -E- Inlet side
 -A- Exhaust side
Note
The guide plate "VAS 5161A/38" will
only operate when installed as
described.
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.
Preliminary work
Remove the valve lifters and rocker
arms. Refer to "Valve lifter (hydraulic
– tappet) – To remove and fit".
→ Rep.-Gr.15
Remove the spark plugs. Refer to
the relevant section of "Spark plugs
– to remove and refit"
→ Rep.-Gr.28
Bank 1 only
Remove the "C" clip -1- by
inserting a suitable tool and
gently levering the clip off the
–
valve arm pivot -2-, then carefully
move the adjustment rod from
the pivot.
Remove the two fixings -arrowsand withdraw the wastegate
– actuator -3- from the
turbocharger assembly -4- and
carefully move aside.
Continuation
Caution
Ensure that ALL the sealer residue
is COMPLETELY removed off the
cylinder head mating faces prior to
installing the Guide plate -VAS
5161A/38-. If any sealer residue is
left it will severely effect the
removal and installation process of
the valve keys.
Removal
Install two M8x35 fixings -arrowssuch as the ones from the
"engine cross brace" (N 909 035
–
02), into the Guide plate -VAS
5161A/38- -1- by hand as shown.
These fixings will act as dowels.
Install the Guide plate -VAS
– 5161A/38- -1- onto cylinder
number one.
Image for illustration purposes only.
Insert two fixings -arrows- to
– secure the Guide plate -VAS
5161A/38- -1- to the cylinder head.
Note
Two coil pack fixings are ample in the
securing of the Guide plate -VAS
5161A/38- to the cylinder head.
On cylinders "four" and "eight" only
ONE fixing is used to secure the
Guide plate -VAS 5161A/38- to the
cylinder head.
Caution
RISK OF DEBRIS OR MATERIALS
ENTERING THE ENGINE.
ENSURE that suitable steps are
taken to protect any open ports or
oil ways during this procedure!
Insert the punch -VAS 5161/3A- 2- from the tool set Removal and
installation device for valve keys – VAS 5161A- in the guide plate and
loosen any tight valve keys by
tapping them "LIGHTLY " with a
soft mallet.
Screw in 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- by hand.
Image for illustration purposes only.
Screw in the hose adapter -1- from
a "Cylinder compression tester kit"
–
hand-tight into the relevant
cylinder spark plug thread.
Connect the compressed air hose
– to the hose adapter -1- from the
"Cylinder compression tester kit".
Build up overpressure in the
–
relevant combustion chamber.
WARNING
Compressed air is DANGEROUS!
ENSURE that the correct personal
protective equipment is worn during
the use of compressed air.
Caution
Ensure that the compressed air is
operating at a minimum of "6 BAR "
before continuing.
Insert the Valve key cartridge VAS 5161/8A- -4- into the Guide
–
plate -VAS 5161A/38- onto the
desired valve assembly.
Image for illustration purposes only.
Follow the table for the correct
positioning of the hook -VAS
– 5161/6- -2- and anchor -VAS
5161/5 M8- -3- for the removal of
each valve set of valve keys.
Engage the pressure fork -VAS
5161/2- -1- into the hook -VAS
5161/6- -2- and lever the Valve
–
key cartridge -VAS 5161/8Adownwards until it touches the
guide plate.
While applying downward hand
pressure to the pressure fork -VAS
5161/2-, turn the knurled screw –
arrow- on the Valve key cartridge VAS 5161/8A- back and forth to
press the valve keys apart.
Once the valve keys have
successfully separated, the
knurled screw -arrow- will move
– inwards on its own, and retain the
valve keys within the Valve key
cartridge -VAS 5161/8Aautomatically.
Caution
Do NOT touch the knurled screw on
the Valve key cartridge -VAS
5161/8A- again until instructed.
Relieve the hand pressure from
the fork -VAS 5161/2- -1- and
–
remove Valve key cartridge -VAS
5161/8A- -4-.
Using a flexible magnet or by hand,
remove the valve-spring cap -1–
followed by the valve spring -2- then
DISCARD the spring.
Installation of valve spring:
Caution
INLET AND EXHAUST VALVE
SPRINGS ARE DIFFERENT!
ENSURE that the CORRECT springs
are fitted to the CORRECT valves.
Refer to ETKA for the correct part
numbers for Inlet and Exhaust
springs.
Care point.
Image for illustration purposes only.
Caution
All valve springs -1- (INLET and
EXHAUST) MUST be installed with
the tightest spring coils -highlightedclosest the cylinder head assembly arrow-! Failure to adhere to this will
cause catastrophic valve train failure.
Insert the NEW correct valve
– spring and valve-spring cap into
position.
Image for illustration purposes only.
Insert the Valve key cartridge – VAS 5161/8A- -4- into the Guide
plate -VAS 5161A/38-.
Engage the pressure fork -VAS
5161/2- -1- into the hook -VAS
5161/6- -2- and lever the Valve
–
key cartridge -VAS 5161/8A- -4downwards until it touches the
guide plate.
Pull the knurled screw -arrow– upwards on the Valve key
cartridge -VAS 5161/8A-.
Whilst still pulling up on the
knurled screw, slowly release the
–
pressure on the pressure fork VAS 5161/2- -1-.
The valve keys are now secured on
the valve stem.
Fully remove the Valve key
– cartridge -VAS 5161/8A- from the
Guide plate -VAS 5161A/38-.
Perform a visual check, ensuring
that both valve keys -1- are
–
secured correctly to the valve stem
-2- as shown.
Note
If the valve keys are not secured to
the valve stem after the installation
process, remove the valve keys and
REPEAT the installation process until
correct retention has been achieved.
Repeat the procedure on each
–
remaining valve.
When all the valves are secured
again, ONLY then can the
–
compressed air connection be
disconnect.
Unscrew hose adapter from the
–
spark plug hole.
Continue this procedure on all
remaining cylinders.
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-.
Installation
Installation is the reverse of the
– removal procedure, noting the
following.
Subsequent work
Install the spark plugs. Refer to the
relevant section of "Spark plugs to
– remove and refit"
→ Rep.-Gr.28
Install the valve lifter (hydraulic
tappet) and valve lever. Refer to
"Valve lifter (hydraulic tappet) – To
–
remove and fit".
→ Rep.-Gr.15
PAGE INTENTIONALLY LEFT BLANK
Valve springs - To remove and fit
General Information
The engine and automatic transmission is required to be removed from the vehicle in order to carry
out this procedure. The cylinder head is to remain installed on the engine assembly whilst this
procedure takes place.
The automatic transmission does NOT require to be removed from the engine assembly.
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.
WARNING
Danger of objects or loads falling down
Risk of squashing or crushing
— Secure components to prevent them from falling down.
Caution
Dirt and contamination
Risk of damage to units or components
— Protect components from dirt and contamination.
— Clean or replace dirty components.
Special tools and workshop equipment required

Guide plate -VAS 5161A/38-
Removal and installation device for
valve keys -VAS 5161/A Valve stem seal puller -3364 Press-on tool -3365 Cylinder compression tester
Positioning of Hook -VAS 5161/6- &
Anchor -VAS 5161/5 M8- onto Guide
plate -VAS 5161A/38- for each
cylinder.
It is imperative that the following table
and accompanying image is followed
to ensure the correct positioning of the
Hook -VAS 5161/6- & Anchor -VAS
5161/5 M8- for access and correct
leverage.

Cylinder Number VAS 5161/6 (hook) & VAS 5161/5 M8 (anchor) Position
Inlet
Exhaust
(Bank 1)
Left Valve
Right Valve
Left Valve
Right Valve
1
6
6
3
3
2
6
6
3
2
3
4/5
4/5
3
3
4
4/5
4/5
3
3
Inlet
Exhaust
(Bank 2)
Left Valve
Right Valve
Left Valve
Right Valve
5
6
6
3
3
6
6
6
3
3
7
4/5
4/5
3
3
8
4/5
4/5
3
3
Guide plate -VAS 5161A/38- - Hook VAS 5161/6- & Anchor -VAS 5161/5
M8Use the image and the table to
–
ensure correct positioning of tools.
 -E- Inlet side
 -A- Exhaust side
Note
The guide plate "VAS 5161A/38" will
only operate when installed as
described.
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.
Preliminary work
Remove the valve lifters and rocker
arms. Refer to "Valve lifter (hydraulic
– tappet) – To remove and fit".
→ Rep.-Gr.15
Remove the spark plugs. Refer to
the relevant section of "Spark plugs
– to remove and refit"
→ Rep.-Gr.28
Bank 1 only
Remove the "C" clip -1- by
inserting a suitable tool and
gently levering the clip off the
–
valve arm pivot -2-, then carefully
move the adjustment rod from
the pivot.
Remove the two fixings -arrowsand withdraw the wastegate
– actuator -3- from the
turbocharger assembly -4- and
carefully move aside.
Continuation
Caution
Ensure that ALL the sealer residue
is COMPLETELY removed off the
cylinder head mating faces prior to
installing the Guide plate -VAS
5161A/38-. If any sealer residue is
left it will severely effect the
removal and installation process of
the valve keys.
Removal
Install two M8x35 fixings -arrowssuch as the ones from the
"engine cross brace" (N 909 035
–
02), into the Guide plate -VAS
5161A/38- -1- by hand as shown.
These fixings will act as dowels.
Install the Guide plate -VAS
– 5161A/38- -1- onto cylinder
number one.
Image for illustration purposes only.
Insert two fixings -arrows- to
– secure the Guide plate -VAS
5161A/38- -1- to the cylinder head.
Note
Two coil pack fixings are ample in the
securing of the Guide plate -VAS
5161A/38- to the cylinder head.
On cylinders "four" and "eight" only
ONE fixing is used to secure the
Guide plate -VAS 5161A/38- to the
cylinder head.
Caution
RISK OF DEBRIS OR MATERIALS
ENTERING THE ENGINE.
ENSURE that suitable steps are
taken to protect any open ports or
oil ways during this procedure!
Insert the punch -VAS 5161/3A- 2- from the tool set Removal and
installation device for valve keys – VAS 5161A- in the guide plate and
loosen any tight valve keys by
tapping them "LIGHTLY " with a
soft mallet.
Screw in 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- by hand.
Image for illustration purposes only.
Screw in the hose adapter -1- from
a "Cylinder compression tester kit"
–
hand-tight into the relevant
cylinder spark plug thread.
Connect the compressed air hose
– to the hose adapter -1- from the
"Cylinder compression tester kit".
Build up overpressure in the
–
relevant combustion chamber.
WARNING
Compressed air is DANGEROUS!
ENSURE that the correct personal
protective equipment is worn during
the use of compressed air.
Caution
Ensure that the compressed air is
operating at a minimum of "6 BAR "
before continuing.
Insert the Valve key cartridge VAS 5161/8A- -4- into the Guide
–
plate -VAS 5161A/38- onto the
desired valve assembly.
Image for illustration purposes only.
Follow the table for the correct
positioning of the hook -VAS
– 5161/6- -2- and anchor -VAS
5161/5 M8- -3- for the removal of
each valve set of valve keys.
Engage the pressure fork -VAS
5161/2- -1- into the hook -VAS
5161/6- -2- and lever the Valve
–
key cartridge -VAS 5161/8Adownwards until it touches the
guide plate.
While applying downward hand
pressure to the pressure fork -VAS
5161/2-, turn the knurled screw –
arrow- on the Valve key cartridge VAS 5161/8A- back and forth to
press the valve keys apart.
Once the valve keys have
successfully separated, the
knurled screw -arrow- will move
– inwards on its own, and retain the
valve keys within the Valve key
cartridge -VAS 5161/8Aautomatically.
Caution
Do NOT touch the knurled screw on
the Valve key cartridge -VAS
5161/8A- again until instructed.
Relieve the hand pressure from
the fork -VAS 5161/2- -1- and
–
remove Valve key cartridge -VAS
5161/8A- -4-.
Using a flexible magnet or by hand,
remove the valve-spring cap -1–
followed by the valve spring -2- then
DISCARD the spring.
Installation of valve spring:
Caution
INLET AND EXHAUST VALVE
SPRINGS ARE DIFFERENT!
ENSURE that the CORRECT springs
are fitted to the CORRECT valves.
Refer to ETKA for the correct part
numbers for Inlet and Exhaust
springs.
Care point.
Image for illustration purposes only.
Caution
All valve springs -1- (INLET and
EXHAUST) MUST be installed with
the tightest spring coils -highlightedclosest the cylinder head assembly arrow-! Failure to adhere to this will
cause catastrophic valve train failure.
Insert the NEW correct valve
– spring and valve-spring cap into
position.
Image for illustration purposes only.
Insert the Valve key cartridge – VAS 5161/8A- -4- into the Guide
plate -VAS 5161A/38-.
Engage the pressure fork -VAS
5161/2- -1- into the hook -VAS
5161/6- -2- and lever the Valve
–
key cartridge -VAS 5161/8A- -4downwards until it touches the
guide plate.
Pull the knurled screw -arrow– upwards on the Valve key
cartridge -VAS 5161/8A-.
Whilst still pulling up on the
knurled screw, slowly release the
–
pressure on the pressure fork VAS 5161/2- -1-.
The valve keys are now secured on
the valve stem.
Fully remove the Valve key
– cartridge -VAS 5161/8A- from the
Guide plate -VAS 5161A/38-.
Perform a visual check, ensuring
that both valve keys -1- are
–
secured correctly to the valve stem
-2- as shown.
Note
If the valve keys are not secured to
the valve stem after the installation
process, remove the valve keys and
REPEAT the installation process until
correct retention has been achieved.
Repeat the procedure on each
–
remaining valve.
When all the valves are secured
again, ONLY then can the
–
compressed air connection be
disconnect.
Unscrew hose adapter from the
–
spark plug hole.
Continue this procedure on all
–
remaining cylinders.
Installation
Installation is the reverse of the
– removal procedure, noting the
following.
Subsequent work
Install the spark plugs. Refer to the
relevant section of "Spark plugs to
– remove and refit"
→ Rep.-Gr.28
Install the valve lifter (hydraulic
–
tappet) and valve lever. Refer to
"Valve lifter (hydraulic tappet) – To
remove and fit".
→ Rep.-Gr.15
PAGE INTENTIONALLY LEFT BLANK
1.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.
2. 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.
3. 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

(use a plastic scraper and scotch pads).

Sealing faces must be free of grease and oil.

Clean sealing faces with primer Loctite -7515-.

Use liquid sealant Loctite -5970-BM-.
Caution
The primer MUST be used prior to applying the sealant,
failure to do so may result in oil leakage.
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.
4. 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


Note
A second technician is advised when tightening the
camshaft actuators.
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.
-
–
Close off bearing tunnels with rubber caps. Exception: Left
intake side with brake booster vacuum pump.
5. 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
6. 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.
–
Secure the vacuum pump to the cylinder head. Torque
tighten the fixings in the sequence -1-3- as follows:

Stage 1 — 5 Nm

Stage 2 – 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
7. 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.
– Remove items -5 & 7- and retain for refitment.
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 combustion chamber ring -6-, seal and O-ring-3- and
backing ring -2-.
Refit items -5 & 7-.
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.
8. 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
9. 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.
10. 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.
11. 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
12.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
13. 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
14. 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-.
Caution


The primer MUST be used prior to applying the sealant,
failure to do so may result in oil leakage.
–
–
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.
15. 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.
–
Torque tighten all remaining fixings.
→ Rep.-Gr.00
16. 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
17. 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.