2065480/6

Field campaign
V8 Kovomo - Bentayga - Valve spring replacement (SC21/42)
Russische Föderation (5RU),Australia E04 Bentley rest Asia and Australia (6E04),China 796 VW Import Comp. Ltd (Vico), Beijing
(6796),Germany E02 Bentley rest Europe (6E02),Japan E03 Bentley Japan (6E03),Korea, (South) E08 Bentley South Korea
(6E08),United Arab Emirates E06 Bentley Middle East and Africa (6E06),United States E05 Bentley USA and rest America (6E05)
Bentley
Topic
Market
area
Brand
Transaction
2065480/6
No.
Campaign
EC25
number
Note
Type
US code
Vehicle data
Bentayga
Sales types
Type
MY Brand Designation Engine code Gearbox code Final drive code
4V14D9 2021 E
4V14D9 2022 E
*
*
*
*
*
*
Chas is numbers
Manufacturer Filler Type Filler MY Factory From To
Prod from Prod to
SJA
*
*
*
*
C
038424 039999
SJA
*
*
*
N C
011001 011069
Documents
Document name
master.xml
636install1-15.pdf
636removal1-16.pdf
hydraulicliftingtable636.pdf
sc2142vinlist.pdf
EC25
V8 Kovomo - Bentayga - Valve spring replacement (SC21/42)
Transaction No.: 2065480/6
Notes
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
(SC21/42) 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
New revision
number:
Type of change:
2065480/3
Incorrect part number - The parts set should have been 36A198115E and not 3SA198115E
2065480/4
Updated to reference the V8 Misfire TPI 2064776/- with new instructions added as the process is now different to that
published in Elsa Pro
2065480/5
See bullet points below
2065480/6
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
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
The repair manual is also referred to and MUST be followed when instructed
NOTE: The Work section also contains task applicable instructions which MUST also be referred to/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 referred to)
TIP: The removal and installation procedures have been devised specifically for this procedure, 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 EC25
Damage code
0066
Criteria
01
Labour
Labour Operation Code 15 65 56 99
Time
2100 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 -110 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
36A198115E
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
N90344501
O-Ring 45x3
2
N91019101
O-Ring 50x3
2
99970751741
O-Ring 22x3
2
N90365304
O-Ring 20x3
1
N90925001
O-Ring 17x3
3
8W0253115
Turbo to pre catalytic seal
2
8W0253725D
Clamp for turbochargers
2
8W0253115D
Downpipe to pre catalytic seal
2
N91130802
Downpipe to catalytic nut
6
Refer to ETKA and Rep.Gr 00 (Power
transmission fluids and capacities)
Differential oil (front and centre)
As required
Refer to ETKA and Rep.Gr 00 (Power
transmission fluids and capacities)
Transmission fluid
As required
Refer to ETKA and Rep.Gr 00 (Engine fluids
and capacities)
Engine coolant
As required
00004320935
Microgleit DF977S (Source locally)
As required
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
(SC21/42) 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
New revision
number:
Type of change:
2065480/3
Incorrect part number - The parts set should have been 36A198115E and not 3SA198115E
2065480/4
Updated to reference the V8 Misfire TPI 2064776/- with new instructions added as the process is now different to that
published in Elsa Pro
2065480/5
See bullet points below
2065480/6
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
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
green paint completion mark (Figure 6)
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
36A198115E
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
N90344501
O-Ring 45x3
2
N91019101
O-Ring 50x3
2
99970751741
O-Ring 22x3
2
N90365304
O-Ring 20x3
1
N90925001
O-Ring 17x3
3
8W0253115
Turbo to pre catalytic seal
2
8W0253725D
Clamp for turbochargers
2
8W0253115D
Downpipe to pre catalytic seal
2
N91130802
Downpipe to catalytic nut
6
Refer to ETKA and Rep.Gr 00 (Power
transmission fluids and capacities)
Differential oil (front and centre)
As required
Refer to ETKA and Rep.Gr 00 (Power
transmission fluids and capacities)
Transmission fluid
As required
Refer to ETKA and Rep.Gr 00 (Engine fluids
and capacities)
Engine coolant
As required
00004320935
Microgleit DF977S (Source locally)
As required
00004320993
Loctite 7515 primer (Source locally)
As required
Tools
Refer to the attached instructions for all tooling requirements
Work
VERY IMPORANT: The operative must ensure 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 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) Referring to Rep.Gr 10 - Remove the engine and transmission
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: 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
2) Referring to Rep.Gr 26 - Remove both catalytic converters and associated heatshields
3) It is imperative the attached instructions are followed in numerical order (as below), as each task has been individually generated to allow the
operative to conduct the rework with minimal disruption
Removal
1 - High-pressure fuel line
2 - Upper chain housing covers
3 - Oil mist separators
4 - Ignition coils
5 - High pressure fuel lines, banks 1 and 2
6 - High pressure fuel pumps
7 - Fuel rails
8 - CDA solenoids
9 - Fuel injectors
10 - Mechanical vacuum pump
11 - Pressure pipes
12 - Camshaft actuators
13 - Cylinder head cover
14 - Valve lifters (hydraulic tappets) 15
- Spark plugs
16 - 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 edge 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
TIP: When removing the original parts it is best practice to keep the new parts completely separate to eliminate cross contamination
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 applicable valve could drop
directly in the cylinder resulting in the possible requirement to remove the cylinder head to retrieve the valve
4) To complete the installation of the valve springs - Refer to the attached installation instructions in numerical order (as below)
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
5) Referring to Rep.Gr 26 - Refit both catalytic converters and associated heatshields
6) Referring to Rep.Gr 10 - Refit the engine and transmission
7) 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
NOTE: The headlamps only require adjustment if headlamp/fender is removed/damaged
8) Raise a non-technical DISS query attaching the following
•
Before and after screen shots of the wheel alignment results
•
Screen shots confirming the applicable drive assist systems have been successfully adjusted/calibrated
Warranty payments will not be approved without the submission of the requested results via the open DISS query
9) Conduct the PDI road test - On return confirm that no DTC’s are evident
Please ensure the Park brake is applied and the transmission is in the “NEUTRAL” position (not “Park” position)
VERY IMPORTANT: For Bentayga S models in North America, China and South Korea only
•
The operative must follow Step 10 to completion before proceeding directly to Step 12
For all other Bentayga models in North America, China and South Korea only (Not Bentayga S) the operative must follow step 11 to
completion before proceeding to Step 12
VERY IMPORTANT: For all Regions and all Bentayga models including Bentayga S (Not Bentayga S in North America,China and South
Korea only)
•
The operative must follow Step 11 to completion before proceeding directly to Step 12
10) Bentayga S models (North America, China and South Korea only)
• VERY IMPORTANT: Check and confirm that no DTC’s are evident
Or
No engine operation issues are evident - Save an online log to confirm that no DTC’s were evident at this stage of the
procedure
VERY IMPORTANT: Please ensure that no ignition cycles, Deletion of DTC’s or any other tests are run in between the
following steps as this will set the readiness code and prevent unrelated DTC’s from being evident
•
Run the engine basic setting routine - Select option 3.7 - Test for oxygen sensor interchange after catalytic converter
•
Immediately run the Readiness test as per the following instructions:
•
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
11) For all Regions and all Bentayga models including Bentayga S (Not Bentayga S in North America, China and South
Korea)
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 5
•
Select Guided functions from 01 – Engine Control Module 1
•
Select Generate readiness code
•
Select Execute
Figure 5
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
12) Confirm no oil/fluid leaks are evident
13) Place a green paint completion mark as shown within the Identification section (Figure 6)
Identification
Green paint completion mark on the 12 volt battery vent hose (Figure 6)
Figure 6
Repair instructions Notes
SJAAL14V2MC038424
SJAAL34VXMC038506
SJAAL14VXMC038543
SJAAM2ZV7MC038544
SJAAL14VXMC038591
SJAAD14V0MC038595
SJAAL14V4MC038635
SJAAD14V1MC038637
SJAA514V5MC038640
SJAAL14V1MC038690
SJAAB14V3MC038709
SJAAB14V9MC038715
SJAAL14V9MC038727
SJAAL1ZV6MC038743
SJAAL1ZV2MC038772
SJAAD14V0MC038791
SJAAL14V8MC038797
SJAAL14V8MC038833
SJAAL14V8MC038850
SJAAL14V0MC038860
SJAAL14VXMC038865
SJAAD14V5MC038866
SJAAL14V1MC038897
SJAAD14V5MC038916
SJAAD14V7MC038920
SJAAL14V7MC038922
SJAAL14V5MC038949
SJAAL14V6MC038958
SJAAL34V3MC038962
SJAAB14V7MC038969
SJAAL14V6MC038975
SJAAD14V3MC038977
SJAAL14V5MC038983
SJAAL14V4MC039090
SJAAD14V9MC039129
SJAAL14V5MC039132
SJAAL14V9MC039134
SJAAL1ZV7MC039142
SJAAL14V2MC039153
SJAAB14V2MC039155
SJAAL14V8MC039156
SJAAD14V6MC039184
SJAAL14V6MC039186
SJAAM2ZV4MC039196
SJAAD14V3MC039210
SJAAL14V5MC039213
SJAAM2ZV1MC039298
SJAAD14V1MC039299
SJAAD14V6MC039301
SJAAM2ZV0MC039308
SJAAD14V0MC039312
SJAAD14V4MC039314
SJAAL14VXMC039319
SJAAL14VXMC039322
SJAAL14V7MC039326
SJAAL14V0MC039328
SJAAL14V2MC039329
SJAAL14V8MC039335
SJAAL1ZV1MC039346
SJAAD14V8MC039347
SJAAM2ZV1MC039348
SJAAL14V4MC039350
SJAAD14V5MC039354
SJAAM2ZV4MC039361
SJAAD14V4MC039362
SJAAD14V8MC039364
SJAAL1ZV7MC039366
SJAAL1ZV0MC039371
SJAAD14V0MC039374
SJAAL14V9MC039375
SJAAM2ZV1MC039379
SJAAM2ZV5MC039384
SJAAM2ZV0MC039387
SJAAM2ZV2MC039388
SJAAD14V0MC039391
SJAAD14V4MC039393
SJAAL14V4MC039400
SJAAM2ZV1MC039401
SJAAD14V3MC039403
SJAAD14V5MC039404
SJAAL14V3MC039405
SJAAD14V0MC039407
SJAAL14V9MC039408
SJAAL14V9MC039411
SJAAM2ZV6MC039412
SJAAD14VXMC039415
SJAAM2ZV7MC039418
SJAAM2ZV7MC039421
SJAAD14V0MC039424
SJAAD14V4MC039426
SJAAL34V8MC039427
SJAAD14VXMC039432
SJAAD14V5MC039435
SJAAD14V7MC039436
SJAAM2ZV2MC039438
SJAAD14V2MC039439
SJAAM2ZV0NC039441
SJAAD14VXMC039446
SJAAL14VXMC039448
SJAAD14V5MC039449
SJAAL14VXMC039451
SJAAD14V7MC039453
SJAAL14V5MC039454
SJAAD14V6MC039458
SJAAD14VXMC039463
SJAAM2ZV3MC039464
SJAAL1ZV4MC039471
SJAAD14V0MC039472
SJAAD14V2MC039473
SJAAL1ZV1MC039475
SJAAL1ZV9MC039479
SJAAL14V1MC039483
SJAAD14V7MC039484
SJAAL14V5MC039485
SJAAL14V7MC039486
SJAAD14V4MC039488
SJAAL14V0MC039491
SJAAD14V8MC039493
SJAAL14V1MC039497
SJAAD14V9MC039504
SJAAD14V0MC039505
SJAAL1ZV8MC039506
SJAAM2ZVXMC039509
SJAAM2ZV6MC039510
SJAAD14V1MC039514
SJAAM2ZV5MC039515
SJAAL1ZV0MC039516
SJAAD14V0MC039519
SJAAL1ZV2MC039520
SJAAL1ZV5MC039527
SJAAD14V3MC039529
SJAAD14V1MC039531
SJAAD14V5MC039533
SJAAD14V9MC039535
SJAAD14V2MC039537
SJAAD14V4MC039538
SJAAD14V6MC039539
SJAAL14V9MC039540
SJAAL14V0MC039541
SJAAL14V6MC039544
SJAAD14V5MC039547
SJAAD14V7MC039548
SJAAD14V8MC039557
SJAAD14VXMC039558
SJAAM2ZV3MC039559
SJAAM2ZVXMC039560
SJAAD14VXMC039561
SJAAM2ZV9NC039566
SJAAM14V9NC039570
SJAA514V4NC039571
SJAAM2ZV6NC039573
SJAAL14V2NC039574
SJAAM2ZVXNC039575
SJAAM2ZV1NC039576
SJAAM2ZV3NC039580
SJAAM2ZV5NC039581
SJAAM2ZV9NC039583
SJAAM2ZVXNC039589
SJAAM2ZV6NC039590
SJAAM14V6NC039591
SJAAM2ZV1NC039593
SJAAM2ZV7NC039596
SJAAM2ZV9NC039597
SJAAM2ZV0NC039598
SJAAM2ZV2NC039599
SJAAM2ZV0NC039603
SJAAM14V2NC039605
SJAAM2ZV8NC039607
SJAAM2ZVXNC039608
SJAAM2ZV1NC039609
SJAAM2ZV8NC039610
SJAAM2ZVXNC039611
SJAAM14VXNC039612
SJAAM2ZV5NC039614
SJAAL14V1NC039615
SJAAM2ZV0NC039617
SJAAM2ZV4NC039619
SJAAM2ZV2NC039621
SJAAM2ZV6NC039623
SJAAM2ZV3NC039627
SJAAM14V3NC039628
SJAAM2ZV3NC039630
SJAAM2ZV5NC039631
SJAAM2ZV7NC039632
SJAAM2ZV2NC039635
SJAAM14V2NC039636
SJAAM2ZV8NC039641
SJAAM2ZVXNC039642
SJAAM2ZV3NC039644
SJAAM14V3NC039645
SJAAM2ZV7NC039646
SJAAM2ZV9NC039647
SJAA514V2NC039648
SJAAM2ZV9NC039650
SJAAM14V6NC039655
SJAAM2ZVXNC039656
SJAAM2ZV3NC039658
SJAAM2ZV3NC039661
SJAAM14V9NC039665
SJAAM2ZV4NC039667
SJAAM2ZV6NC039668
SJAAM2ZV8NC039669
SJAAM2ZV6NC039671
SJAAM2ZV8NC039672
SJAAM2ZVXNC039673
SJAAM2ZV1NC039674
SJAAM2ZV7NC039677
SJAAM2ZV9NC039678
SJAAM2ZV7NC039680
SJAAM2ZV0NC039682
SJAAM2ZV6NC039685
SJAAL14V4NC039690
SJAAM2ZV3NC039692
SJAAM2ZV5NC039693
SJAAM14V5NC039694
SJAAM2ZV9NC039695
SJAAM2ZV4NC039698
SJAAM2ZV0NC039701
SJAAM2ZV4NC039703
SJAAM2ZV6NC039704
SJAAM2ZV3NC039708
SJAAM2ZV1NC039710
SJAAL14V8NC039711
SJAAM2ZV5NC039712
SJAAL14V2NC039722
SJAA514V7NC039726
SJAAM2ZV7NC039727
SJAAM2ZV0NC039729
SJAAM2ZV7NC039730
SJAAD14V6NC039736
SJAAM2ZV3NC039739
SJAAL14V4NC039740
SJAAM2ZV3NC039742
SJAAM2ZV9NC039745
SJAAD14V2NC039748
SJAAM2ZV1NC039755
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SJAAD14V0NC039764
SJAA514V8NC039766
SJAAD14V8NC039768
SJAAM2ZV1NC039769
SJAAL14V5NC039777
SJAAM2ZV2NC039778
SJAAM2ZV4NC039779
SJAAM2ZV2NC039781
SJAAM4ZV3NC039784
SJAAM2ZV1NC039786
SJAAM2ZV7NC039789
SJAAM2ZV3NC039790
SJAAM2ZV7NC039792
SJAAM2ZV0NC039794
SJAAM2ZVXNC039799
SJAAM2ZV4NC039801
SJAAM2ZVXNC039804
SJAAM2ZV1NC039805
SJAAM2ZV7NC039808
SJAAM2ZV9NC039809
SJAAM2ZV5NC039810
SJAAL14V7NC039814
SJAAM2ZV8NC039817
SJAAD14VXNC039819
SJAA514V5NC039823
SJAAM2ZV7NC039825
SJAAM2ZV9NC039826
SJAAL14V5NC039827
SJAAM2ZV4NC039829
SJAAM2ZV0NC039830
SJAAM2ZV2NC039831
SJAAD14VXNC039836
SJAAM2ZV3NC039837
SJAAM2ZV5NC039838
SJAAM2ZV3NC039840
SJAAM2ZV5NC039841
SJAAM2ZV7NC039842
SJAAM2ZV2NC039845
SJAAM2ZV6NC039847
SJAAM2ZV8NC039848
SJAAM2ZVXNC039849
SJAAM2ZV6NC039850
SJAAM2ZV8NC039851
SJAAM2ZVXNC039852
SJAAM2ZV1NC039853
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SJAAD14V3NC039855
SJAAM2ZV7NC039856
SJAAM2ZV2NC039859
SJAAM2ZV9NC039860
SJAAM2ZV0NC039861
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SJAAM2ZV4NC039863
SJAAM2ZV8NC039865
SJAAL14V9NC039880
SJAAM2ZV1NC039884
SJAAD14V1NC039885
SJAAD14V3NC039886
SJAAM2ZV7NC039887
SJAAM2ZV9NC039888
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SJAAM2ZV4NC039894
SJAAM2ZV6NC039895
SJAAM2ZVXNC039897
SJAAM2ZV3NC039899
SJAAM2ZV1NC039903
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SJAAM2ZV7NC039906
SJAAM2ZV9NC039907
SJAAM2ZV0NC039908
SJAAM2ZV2NC039909
SJAAD14V7NC039910
SJAAM2ZV0NC039911
SJAAD14V2NC039913
SJAAM2ZVXNC039916
SJAAM2ZV1NC039917
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SJAAM2ZV5NC039919
SJAAM2ZV1NC039920
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SJAAM2ZV9NC039924
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SJAAM2ZV2NC039926
SJAAD14V2NC039927
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SJAAM2ZV9NC011069
PAGE LEFT INTENTIONALLY BLANK
1 . 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.
2. 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.
3. 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.
4. 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.
5. 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.
6. 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.
7. 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.
8. 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.
9. 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.
10. 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.
11. 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-.
12. 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.
13.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.
14. 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-.
15. 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.
16 - 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 LEFT INTENTIONALLY 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 LEFT INTENTIONALLY 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