– Repeat the procedure on each valve.
When all valves are secured again, disconnect the
– compressed air connection and unscrew hose adapter VAS 5161A/35-.
– Do the same on the other cylinders.

2.Install spark plugs:
Special tools and workshop equipment required
Spark plug socket (14 mm) commercially available.
Installation
Installation is the reverse of removal procedure, noting the following:
– Torque tighten each spark plug to 23 Nm.

WARNING
Always fit a complete set of spark plugs of the same specification.

3. Install valve lifters (hydraulic tappets):
Installation
– Fit hydraulic tappet -2- on valve lever -3-.
–

Position hydraulic tappet -2- and safety clip -1- on valve
lever -3-.
Insert hydraulic tappet -2- and hook safety clip -1- into

– valve lever -3-. Check that the safety clip -1- is fitted
correctly.

– Fit hydraulic tappet -1- and valve lever -2-.
–

–
–
–

Lightly lubricate the hydraulic tappet -1- and valve lever 2-with engine oil (0W-40).

Insert hydraulic tappet -1- with the valve lever -2- into the
cylinder head together.
Position the pressure face of the valve lever -2- on the
valve pressure face.
After you have installed all hydraulic tappets and valve
levers, check that they are fitted correctly.
In particular, check that the safety clip is fitted correctly

– and that the pressure faces of the valve lever and valve
are positioned correctly.

4. Install cylinder head covers:
The following procedure covers both bank 1 and bank 2 camshaft covers.
Note
Cylinder heads are labelled Bank 1 (RHS) and Bank 2 (LHS) as viewed from the driver’s seat.
Special tools and workshop equipment required



Camshaft clamp kit -T40331-



Locating pins -T40116-

Installation
Installation is the reverse of removal, noting the following.

Note
The Camshaft clamp -T40331- must be fitted before removal
and installation.
→ Rep.-Gr.15

Note
Fitting and sealing components using liquid sealant.


Clean sealing faces to remove all traces of residual
sealant.



Sealing faces must be free of grease and oil.



Clean sealing faces with primer Loctite -7515-.



Use liquid sealant Loctite -5970-BM-.

Note
Before fitting the cylinder head cover, check that the rocker
arms are aligned correctly.
–

Apply liquid sealant Loctite -5970-BM- -1- on the cylinder
head.

Note
Install the cylinder head cover within five minutes of applying
the liquid sealant.

–

Fit and align cylinder head cover -1- on the cylinder head
using Locating pins -T40116- -2-.

– Fit cylinder head cover.

Note
Top image – Bank 1 (RHS)
Bottom image – Bank 2 (LHS)
–

Fit screws on the cylinder head cover uniformly and
tighten according to the specified tightening sequence.

Torque tightening: 9 Nm
– Locating pins -T40116- must now be pulled off.
–

Close off bearing tunnels with rubber caps. Exception: Left
intake side with brake booster vacuum pump.

5. Install camshaft actuators (includes setting timing):
The camshaft actuators are located at the rear of cylinder banks 1 and 2, behind the upper chain
housing covers.

WARNING
Before commencing work on and around the engine, ensure that it has cooled sufficiently, failure to
do so may cause injury to personnel.
Avoid prolonged and repeated contact with oils and fluids etc.


Always protect the skin with impervious gloves.



Always wear suitable eye protection.

Caution
Suitably blank open ports to prevent the ingress of dirt, moisture and foreign objects into the
engine. Failure to do so may cause irreparable damage to the engine.
Special tools and workshop equipment required


Counter hold tool -T90001- (not illustrated)



Ring wrench insert, a/f 41 -VAS 261 001- (not illustrated)



Camshaft clamp -T40331-



Socket E24 -T90000- (not illustrated)



Locking pin -T03006-



Hook wrench -VAS 261 005- (not illustrated)



Counterhold tool -T90002- (not illustrated)



Vehicle tester

Component overview
Camshaft control

1 - Actuator for camshaft controller
2 - Screws, M6 x 16
Tightening torque: 9 Nm
3 - Central screw for camshaft controller


Replace O-ring



Initial tightening: 27 Nm



Final tightening: 30 Nm +35º
4 - Actuator for outlet camshaft
5 - Actuator for intake camshaft
6 - Installation marking
7 - Valve lift adjustment
8 - Screw, M5 x 20

Tightening torque: 5 Nm

Tightening sequence for central screw for camshaft controller
(item -3-)
Result:

Cylinder bank:

Camshaft:

1.

Bank 2

Outlet

2.

Bank 2

Intake

3.

Bank 1

Intake

4.

Bank 1

Outlet

Installing camshaft actuators – setting the timing

Note
No TDC markings on cylinder head cover.
● In the event that there are no TDC markings on the
cylinder head covers, raise a DISS query with Aftersales
technical support.

Note
Camshaft actuator must not be disassembled!
Friction plate in camshaft actuator




–
–
–

The camshaft actuator must never be disassembled.
To replace the friction plate -1-, lever it out carefully using
a small slotted screwdriver -2-.
Check whether the crankshaft, the camshafts and the
chain tensioners are fixed.
Fit new friction plates between the camshaft actuators
and camshaft stub.
Allocate actuators to the camshafts. The actuator with the
black surface is for the outlet side.

Distinguishing features of actuators
-1- Actuator for intake camshaft
-2- Actuator for exhaust camshaft
-3- TDC markings

Position the actuators on the camshafts and fit timing
–

chain. Make sure that the markings on the actuators -1match the cylinder head covers -2-.

Note
If there are no markings -2- on the cylinder head cover,
raise a DISS query with Aftersales technical support.

– Replace O-rings -1- on the central valves -2-.
–

Lever out old O-ring -1- using a plastic wedge and
dispose of it.

– Coat groove on central valve and new O-ring with oil.
Carefully slide O-ring over the thread and shoulder -3– of the central valve and press it on using a plastic
wedge.
–

Do not use sharp-edged tools, such as a screwdriver.
Never mask the thread with tape.

– Remove lock on the chain tensioner -3-.

WARNING
If the tensioner pin is removed without chain guide lever
in place, the piston & spring may fly out! (depending on
version fitted).
– Screw in central valves.
–

Pre-tension the timing chain and pre-tighten central
valves.

Caution
Observe specified tightening sequence!


1. Outlet, cylinder bank 2



2. Intake, cylinder bank 2



3. Intake, cylinder bank 1



4. Outlet, cylinder bank 1
Use Hook wrench -VAS 261 005- -1- to pre-tension the

–

actuators anti-clockwise and use Socket E24 -T90000- 2- and a torque wrench -3- to pre-tighten the central
valves.

Initial tightening: 27 Nm.
– Remove all staking tools.
–

Camshaft clamp -T40331- and adapter can now be
removed.

–

The tool securing the crankshaft at the front of the
engine can now be removed.

– Secure central valves.
Counterhold tool -T90001- -1- and Counterhold tool – T90002- -2- must be fitted on the actuators. To do this,
turn the engine clockwise until the tool engages.
– Tighten central valves using Socket E24 -T90000- -3-.


Final tightening: 30 Nm.



Final tightening: + 35°.

Subsequent work
– Fit change-over valve for water pump -3- and holder.
Vacuum System for reference:
-1- Brake booster vacuum pump
-2- Vacuum line
-3- Electric change-over valve for water pump
-4- Control valve for boost pressure control, cylinders 1 to 4
-5- Control valve for boost pressure control, cylinders 5 to 8
-6- Brake booster connection
-7- Vacuum unit connection
–
–

Secure tank ventilation sensor (USA) or dummy (cylinders
1-4) -1-.
Position tank ventilation sensor (USA) or dummy -1together with vent line -5- on holder -4-.

– Screw in and tighten fastening screw -2-.
– Plug in electric plug connection -3-.
– For bank 2 only, fit the dipstick.

6. Install pressure pipes:
Special tools and workshop equipment required



Hose clip pliers -ASE 451 492 00 000-.

Installation
Installation is the reverse of removal procedure, noting the
following.
– RENEW any "O-rings".
– Refit all previously removed components.
Torque tighten all fixings as per removal.
–
→ Rep.-Gr.00

7. Install mechanical vacuum pump:
Installation
Installation is the reverse of removal procedure, noting the
following.
–

Ensure the mating faces between the vacuum pump and
cylinder head are clean and free of dirt and residual oil.

– RENEW the "O-ring" -1- for the vacuum pump.

–

Using NEW fixings -3-, secure the vacuum pump. Torque
tighten in the sequence shown:



Stage 1 — Hand tighten



Stage 2 — 5 Nm



Stage 3 – 9 Nm

Drive gear
–

Ensure that the drive gear in the camshaft -arrowedaligns with the slot in the vacuum pump -arrowed-.

Camshaft keyway

Drive gear in vacuum pump

–

Ensure all wiring and hoses are clipped in their original
positions.

Torque tighten all remaining fixings.
–
→ Rep.-Gr.00

8. Install fuel injectors:
Special tools and workshop equipment required
Tool set for TSI engines -T10133-

Dismantling the injector
–

Pull the O-ring -3- and spacer ring -2- off from the
injector -1- and DISCARD.

– Unclip the sealing element -5- and DISCARD.
Carefully remove the old combustion chamber sealing
–

ring -6- and DISCARD. To do so, very carefully cut the
sealing ring with a knife or prise off with a suitable nonmetallic tool.

Note
Take care not to damage the sealing groove on the injector.
The injector must be renewed if the groove is damaged.
Installation
Installation is the reverse of removal procedure, noting the
following.

Note
Renew sealing element -5-, combustion chamber ring -6-,
seal and O-ring-3- and backing ring -2-.
Renew spacer ring if damaged.
Lubricate O-rings of injectors lightly with clean engine oil.
–

Clean the bore in cylinder head with Nylon cylinder
brush -T10133/4-.

–

Fit Assembly cone -T10133/5- with a NEW combustion
chamber sealing ring -1- onto the injector -2-.

Using the Assembly sleeve -T10133/6- push the
– combustion chamber sealing ring onto Assembly cone T10133/5- as far as it will go.
Turn around Assembly sleeve -T10133/6- and slide the
– combustion chamber sealing ring into the groove of the
injector.

Note
The combustion chamber sealing ring is widened when it is
pushed onto the injector. After pushing it on, it therefore has
to be compressed again. This is done in four stages, as
described below.








Push Calibration sleeve -T10133/7- onto the injector as
far as it will go and simultaneously turn it 180°.
Pull Calibration sleeve -T10133/7- off again by turning in
the opposite direction.
Push Calibration sleeve -T10133/8- onto the injector as
far as it will go and simultaneously turn it 180°.
Pull Calibration sleeve -T10133/8- off again by turning in
the opposite direction.

–

Fit the parts from the injector repair kit onto the injector 1-:
To ease injector installation into the fuel rail, lubricate

– new O-ring lightly with clean engine oil before installing
it.
Note
The combustion chamber ring seal -6- must NOT be
lubricated.

Caution
Use Press tool -T10133/9-, push the injector into the
cylinder head as far as it will go. DO NOT push the injector
in by force.
– Replace all previously discarded parts.
–

Replace low pressure injector O rings and the fuel supply
pipes and clamps.

9. Install cylinder deactivation solenoids:
Installation
Installation is the reverse of removal procedure, noting the
following.
–
–

RENEW the "O-rings" on the cylinder deactivation
solenoids.
Before refitting the solenoids, apply a small amount of
CLEAN engine oil to the "O-ring".
Torque tighten all fixings as per removal.

–
→ Rep.-Gr.00

10. Install fuel rails:
The installation of the fuel rails is symmetrically the same on both banks of the engine unless stated
otherwise.
Installation
Installation is the reverse of removal procedure, noting the
following.
– Torque tighten the fixings in the sequence shown.
