Stage 1 — Hand tight.



Stage 2 — 7 Nm.



Stage 3 — 10 Nm.

11.Install high pressure fuel pumps:
The installation of the high pressure fuel pump is the same for both sides of the engine unless stated
otherwise.
Special tools and workshop equipment required



Torque wrench -VAG 1331 -



Tool insert AF 17 -VAG 1331/6-

Consumables
Microgleit DF977S lubricant (refer to electronic parts
catalogue "ETKA")

Installation
Installation is the reverse of removal procedure, noting the
following.
Lightly lubricate roller tappet with engine oil (0W–40) and
– insert it so that the lug -arrow A- slides into the guide
notch. -arrow B-.
Using a suitable "breaker" bar, rotate the engine in the
–

direction of normal engine rotation and at the same time
press the roller tappet into the camshaft cover until it
reaches its lowest point.

–

Fit the high pressure pump into the camshaft cover
making sure that a NEW O-ring is fitted.

Caution
When installing the fixings -3- for the high pressure pump,
first fit them by hand.
When first installed, the high pressure pump will protrude
from the camshaft cover, therefore the following tightening
procedure MUST be adhered to.
Stage 1 — Sequentially hand tighten the fixings -3- two


turns at a time until the pump contacts the mating face to
prevent damage to the internal spring in the high
pressure pump.



–

Stage 2 — Torque tighten to 12 Nm.
ALWAYS lubricate the fuel pipe threads with Microgleit
DF977S lubricant prior to fitting.
Torque tighten all remaining fixings.

–
→ Rep.-Gr.00
– Upon completion check for leaks.

12. Install high-pressure fuel lines, banks 1 and 2:
Special tools and workshop equipment required



Torque wrench -VAG 1331 -



Tool insert AF 17 -VAG 1331/6-

Consumables
Microgleit DF977S lubricant (refer to electronic parts
catalogue "ETKA")
Installation
Installation is the reverse of removal procedure, noting the following.
–

Bank 1

–
–

Bank 2

ALWAYS lubricate the union threads -2- with Microgleit
DF977S lubricant prior to fitting.

The following procedure must be followed to ensure the high
pressure fuel pipes are correctly tightened to eliminate the
risk of fuel leaks.
Fit the fixing for the fuel pipe clamp first onto the cylinder
head BEFORE tightening the high pressure fuel pipes. Do
– not tighten until the fuel pipes have been torque
tightened.

Note
Hand tighten the high pressure fuel pipe unions before
torque tightening. Ensure the pipes are stress free before
tightening.
Fit the fuel rail union first, then fit the high pressure fuel
pump union.
Using the Torque wrench -VAG 1331 - and Tool insert AF
– 17 -VAG 1331/6- torque the high pressure fuel pipes -2- to
the following torque.


Stage 1 — Hand tighten.



Stage 2 — 8 Nm.



Stage 3 — + 50°.

Caution
During the torque tightening procedure, ensure the fuel
pipe remains central inside the union. Failure to do so may
cause damage to the brass fitment seal and cause a fuel
leak.
– Refit all previously removed components.
Torque tighten all remaining fixings.
–
→ Rep.-Gr.00

13.Install ignition coils:
Consumables
Silicone paste -G052565A1- (refer to ETKA)
Installation
Installation is the reverse of removal procedure, noting the
following.
–
–
–

Apply Silicone paste -G052565A1- to the area shown arrow- prior to refitting the ignition coils.
Push the ignition coils fully home to the abutment with
the camshaft cover face.
Ensure the correct electrical connector is fitted to each
ignition coil.

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

14. The following is applicable to both oil mist separators.
Installation
Installation is the reverse of removal procedure, noting the
following.
– RENEW the seal.
– Refit all previously removed components.
Torque tighten all remaining fixings.
–
→ Rep.-Gr.00

15. Install upper chain housing covers:
Installation

Note
Fitting and sealing components using liquid sealant.


Clean sealing faces to remove all traces of residual
sealant.



Sealing faces must be free of grease and oil.



Clean sealing faces with primer Loctite -7515-.



Use liquid sealant Loctite -5970-BM-.

–
–

Apply liquid sealant Loctite -5970-BM- -arrow- on the
chain housing cover.
Install the chain housing cover within 5 minutes of
applying the liquid sealant.

– Install chain housing cover -1-.
– Fit chain housing cover -1- on cylinder head.
– Fit and tighten screws -2- (9 Nm) uniformly.

16. Install rear high-pressure fuel line:
Special tools and workshop equipment required



Torque wrench -VAG 1331 -



Tool insert AF 17 -VAG 1331/6-

Consumables
Microgleit DF977S lubricant (refer to electronic parts
catalogue "ETKA")
Installation
Installation is the reverse of removal procedure, noting the
following.
–

On both sides, lubricate the union threads -4- with
Microgleit DF977S lubricant prior to fitting the link pipe.

Note
Hand tighten the high pressure fuel pipe unions before
torque tightening. Ensure the pipes are stress free before
tightening.
Using Torque wrench -VAG 1331 - and Tool insert AF 17 – VAG 1331/6-, torque tighten the union fittings -4- to 8
Nm + 50°.

Caution
During the torque tightening procedure, ensure the fuel
pipe remains central inside the union. Failure to do so may
cause damage to the brass fitment seal and cause a fuel
leak.
– Fit NEW O-rings to the coolant pipes.
Fit the catalyst support bracket -5- and secure with NEW
fixings -4-, noting the information below:

Note
The fixings -1, 2 - for the catalyst support bracket (see
previous graphic) are different lengths. Ensure the fixings
are fitted in the correct location and torque tightened as
shown below.

Table 1 - Automatic transmission retaining bolt chart
Position Material

–

Size

Torque

1

Steel

M12 x 110 20 Nm + 60°

2

Steel

M12 x 75 20 Nm + 60°

Notes

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

17. Install catalytic converters, exhaust downpipes and heatshields:
Installation
Installation is the reverse of removal procedure, noting the following.
– Fit the lower heatshields.

–

Fit a NEW sealing ring between the catalytic converter
and the turbocharger.

– Fit a NEW V-band clamp -1- and fixing -arrow-.

–
–

Fit a NEW sealing ring between the catalytic converter
and exhaust downpipe.
Secure the exhaust downpipe -1- with a NEW V-band
clamp and fixing -arrow-.

Note
Position the downpipes together loosely back on to the
catalytic converter to correctly align the exhaust
components. Once the exhaust components are correctly
aligned THEN a final torque tighten can be applied.
Torque tighten the fixings in the sequence shown to
– ensure stress free alignment of the catalytic converter -2.
Stage

Fixing location

Stage 1 Catalytic converter to turbocharger "V-band" clamp

Torque figure
7 Nm

Stage 2 Catalytic converter to downpipe "V-band" clamp -arrow- 15 Nm

– Fit the upper heatshields.

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

18. Install engine:
Special tools and workshop equipment required



Hydraulic lifting table -VAS 6131-



Engine bung set -VAS 6122 or ASE40451200000-



Hose clip pliers -ASE45149200000-.



Vehicle tester.



Fuel connection cap (7.89 mm) (female) -WT 10259-.



Fuel connection cap (9.89 mm) (female) -WT 10260-.



Fuel connection cap (7.89 mm) (male) -WT 10250-.



Fuel connection cap (9.89 mm) (male) -WT 10251-.



Remote hose clip pliers -Such as VAS 6340- .



Ball joint splitting tool -T40010A-



Tensioning strap -T10038-



Ball joint splitting tool -T10444-

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

Caution
Check all relevant components and engine components
are clear whilst raising the engine and automatic
transmission assembly into the vehicle engine bay.
–

Align the front subframe with all previously marked lines 1- prior to tightening the mounting fixings.
Note

Insert all NEW fixings for the front subframe assembly and
transmission assembly to secure them to the body before
fully torque tightening the fixings.

Secure the front subframe with a NEW fixing -1- and fully
– torque tighten to (70) Nm +180°. Repeat on the other
side.

Secure the front subframe with a NEW fixing -2- and fully
– torque tighten to (70) Nm +180°. Repeat on the other
side.
Disregard all other positions.
Fit the shear plates, refer to "Front subframe shear plates
–

- To remove and fit".
→ Rep.-Gr.40

–

Secure the rear section of the front subframe with NEW
fixings -3- and fully torque tighten to (70) Nm +180°.
Note

The rearmost fixing will have been installed with the refitting
of the shear plates.

–

Secure the transmission mounting to the body with NEW
fixings -1- and fully torque tighten to (25) Nm + 90°.

WARNING
Ensure that ALL the subframe and transmission to body
securing fixings are FULLY tightened to specification as
described. Only then is it safe to remove the Hydraulic
lifting table -VAS 6131-.
DO NOT remove the Hydraulic lifting table -VAS 6131- until
it is safe to do so.
–

ALWAYS fit NEW O-rings when connecting the "ATF" lines
-1-.

Secure the air spring damper to the lower trailing arm -1– with NEW fixings -2- but DO NOT yet torque tighten.
Repeat on the opposite side.

Fit the upper trailing arm -1- on the wheel bearing
– housing, secure with a NEW fixing -2- and torque tighten
to 85 Nm. Repeat on the opposite side.

On both sides of the vehicle, raise the wheel bearing
housing and torque tighten the fixings -2- to the specified
–

value. Refer to "Raising the wheel bearing housing - To
tighten bolts".
→ Rep.-Gr.40

Only after torque tightening the lower lever fixings [-2
–

above-] can the track rod end -1- be fitted. Secure the
track rod -1- with a NEW fixing -2- and torque tighten to
(85) Nm.

On both sides of the vehicle, secure the caliper with NEW
– fixings -1- and -2- and torque tighten both to 30 Nm,
then plus a further 90°.

–

–

On both sides of the vehicle install the fixings -2- (8 Nm)
to secure the brake line -1- to the wheel bearing housing .

Secure the steering rack universal joint -1- with a NEW
fixing and torque tighten to (20) Nm +90°.

Disregard the direction arrow.

Ensure the anti-roll bar wiring and steering rack harness is
– positioned correctly between the subframe -1- and the
rear support -2-.

Before refitting the under body earth strap, ensure the
– earth connection and bodywork is free of dirt and
corrosion.
–

–

Torque tighten the fixing (20 Nm) "Counter hold stud" -2for the earth connection.

Re-connect the four engine harness connections in the
order of -D, C, B & A- on the engine control module -1-.

Apply a light film of spline grease (available in "ETKA") to
– the final drive splines -arrows- before refitting the
propshaft.

On the LH side of the engine, REPLACE the O-ring and
– install the refrigerant pipe into the compressor, then
secure with the fixing -arrow- (25 Nm).
Refit the engine strut brace. Refer to "Engine cross brace –

To remove and fit".
→ Rep.-Gr.50

–

Install the NEW fixing -2- (50) Nm + 90° for the top
engine mount bracket -3-.

Disregard all other positions.

Before refitting the engine bay earth strap, ensure the
– earth connection and bodywork is free of dirt and
corrosion.
–

Torque tighten the fixing -1- (20 Nm) for the engine earth
strap.

–

Fit NEW O-rings before torque tightening the fixings -1to 20 Nm.
Vacuum fill the cooling system. Refer to "Draining and

–

filling coolant"
→ Rep.-Gr.19
Charge the air conditioning system. Refer to

–

"Refrigeration system - To discharge and charge"
→ Rep.-Gr.87
Connect the battery. Refer to "Battery - To disconnect

–

and connect"
→ Rep.-Gr.27
Clear any diagnostic faults with the Vehicle tester.

–
→ Rep.-Gr.97
Reset the vehicle geometry. Refer to" Vehicle geometry –

Wheel alignment and ride heights"
→ Rep.-Gr.44

–

Briefly run the engine and check for leakage of any fluids
or exhaust gases.

WARNING
Use vehicle exhaust extraction equipment to extract the
gases from the workshop.
–

Road test the vehicle, check for leaks and re check all fluid