levels and top up as necessary.

1.

Remove engine:

Special tools and workshop equipment required



Hydraulic lifting table -VAS 6131-



Engine bung set -VAS 6122 or ASE40451200000-



Hose clip pliers -ASE45149200000-.



Vehicle tester.



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



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



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



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



Remote hose clip pliers -Such as VAS 6340- .



Ball joint splitting tool -T40010A-



Tensioning strap -T10038-



Ball joint splitting tool -T10444-

Torque tightening values
Unless otherwise shown, standard torque values apply.
→ Rep.-Gr.00
Single use items
Within this procedure there are single use items which must
be replaced and not reused. Ensure that new replacements
are available prior to starting this procedure.

WARNING
Fuel is highly flammable and extreme care must be
exercised whenever the system is opened (i.e. pipes or


unions disconnected, fuel cap removed) or when the
fuel system is drained. The following basic rules should
apply:-



Always ensure adequate ventilation.



Disconnect the battery.
Ensure that adequate firefighting equipment is



available in the vicinity of the vehicle.
Fuel system - Safety precautions.



→ Rep.-Gr.20
Fuel system - Rules for cleanliness.


→ Rep.-Gr.20
Before commencing work on and around the engine,
ensure that it has cooled sufficiently, failure to do so may
cause injury to personnel.
Avoid prolonged and repeated contact with oils and fluids
etc.


Always protect the skin with impervious gloves.



Always wear suitable eye protection.

Caution
Suitably blank or bung all disconnected electrical
connectors, electrical connections, hoses and pipe work to
prevent the ingress of dirt and moisture.

Plastic connectors and fittings can become brittle with age.
Do not use excessive force to remove hoses. Replace any
damaged fittings as necessary.
During removal, the orientation of fuel hoses must be
noted. The same hose orientation is required for fit, i.e.
flow direction, location markers and spring clamp
positions.
Do not over strain the connections.
Note
The following procedures regarding fitting and servicing of
"quick connects" must be observed:Disconnecting:- Using a cloth or soft brush, wipe the external
surface of the connector and male tube to remove loose dirt
and road salt. Twist the connector about the tube or flush
the joint with a mild penetrating oil such as WD40 or CRC
spray to remove any stubborn contaminants. Using an airline,
blow out any accumulated dirt and road salt from the
retainer area of the connector. Squeeze the side of the
connector and simultaneously pull the hose from the pipe
fitting. Do not allow dirt or any foreign matter to
contaminate the lines or allow the lines to drag on the floor.
Connecting:- Using a clean cloth, wipe the tube end. Check
the O-rings in the hose and the sealing surfaces on the pipe
for damage. Apply a coating of clean engine oil over the
entire male tube end surface, up to the bead. Push the "quick
connector" fitting over the tube until the retainer seats, with
an audible click. To ensure that a secure connection has been
made and has locked in position, pull back on the "quick
connector".
Note
Dispose of any collected oils, fuel or fluids in accordance with
local environmental regulations.
→ Rep.-Gr.20
Note
Some images show W12 variant for illustration purposes only,
however they are applicable to all variants unless otherwise
stated.

Removal
– Fit vehicle protection.
Discharge the air conditioning system. Refer to
–

"Refrigeration system — to discharge and charge".
→ Rep.-Gr.87
Deactivate the 48v system where fitted. Refer to "48v

–

system — to activate and deactivate".
→ Rep.-Gr.27
Place the vehicle on a ramp and set to "Jack" mode. Refer

–

to "Raising and supporting the car".
→ Rep.-Gr.99
Disconnect the battery. Refer to "Battery — to disconnect

–

and connect".
→ Rep.-Gr.27
Remove the front undersheet. Refer to "Front undersheet

–

– To remove and fit".
→ Rep.-Gr.66
Remove the front and rear sections of the side

undersheets on both sides, Refer to "Side undersheets –
– To remove and fit".
→ Rep.-Gr.66
Remove the front wheel arch liners. Refer to "Front wheel
–

arch liners — to remove and fit".
→ Rep.-Gr.66
Remove the engine strut brace. Refer to "Engine cross

–

brace - To remove and fit".
→ Rep.-Gr.50

–

Detach the fuel line rubber mount -1- from the
carrier bracket at the point shown -arrow-.
Remove and DISCARD the fixing -2- (50) Nm +

– 90° and detach the top engine mount bracket -3.
Note
The other fixing would have previously been
removed with the engine strut brace.
–
–

On the RH side, disconnect the two electrical
connections -1- and remove from the bracket -2-.
Remove the two fixings -arrows- and detach the
harness carrier bracket -2-.

On both sides of the vehicle release the hose clips
– -1- (5.5) Nm and remove the charge hoses -3from the pressure pipes.
Disregard all other positions.
Remove the horns. Refer to "Twin horns - To
–

remove and fit".
→ Rep.-Gr.96

On both sides, unclip the horn wiring harness from
– the front support -arrows- and move away from
engine.
Remove the air intake hoses. Refer to "Air intake
–

ducts - To remove and fit".
→ Rep.-Gr.21
Remove the air intake duct from behind the

– radiator. Refer to "Radiator air guide - To remove
and fit".

→ Rep.-Gr.19
Remove the engine cooling fan. Refer to "Cooling
–

fan — To remove and fit".
→ Rep.-Gr.19

–

On both sides, disconnect the electrical
connection -1- to the boost pressure sensor.

Disregard all other positions.

On the lower LH side, release the quick connect – arrow- and detach the bottom radiator hose
connection and drain into a suitable container.
–

Once the coolant system has fully drained, refit the
hose connection and secure with the clip -arrow-.

At floor level

Using Hose clip pliers -ASE45149200000- , release
– the "Springband" clamps -arrows- and disconnect
the two hoses from the coolant pump.

In order, disconnect the four engine harness
– connections -A, B, C & D- from the engine control
module -1-.
Note
Suitably mark each harness connector to the relevant
control unit to aid installation.

– Release the harness at the clipping point -A-.
Remove the fixing -B- (9 Nm) to allow the
– harnesses -1- to be manoeuvred through the inner
wing aperture.

On the LH side of the engine bay, remove the two
– fixings -1- (20 Nm), disconnect the "HVAC" pipes
and DISCARD the O-rings.

On the LH side of the engine bay, disconnect the
– vacuum line "quick connect" -1- to the brake
booster.
–
–

Release the harness edge clip -2- from the
bracket.
Unclip the wiring harnesses from their clipping
points -3-.
Release the harness clipping points -4- and fold

– the harness over the top of the engine so that it is
clear of the vehicle body.
On the LH side of the engine bay, disconnect the
– vacuum line "quick connect" -arrow- to the vacuum
reservoir.

On the RH side of the engine bay and using
Hose clip pliers -ASE45149200000-, release the
– "Springband" clamp -1- and disconnect the
vacuum hose -2- to the expansion tank valve
line.
Disregard all other positions.

–

Disconnect the engine bay earth strap -1- (20)
Nm.

Image for illustration purposes only.

On the RH side of the engine bay, press the
– latch in -1- on the engine bay charging post
and release the cover -2-.

–

Remove the fixing -2- (20 Nm) and detach the
starter cable.
Note

Disregard items -1 & 3-.

– Unclip the starter cable from the chassis -1-.

On the RH side of the engine bay, disconnect
– the fuel feed line "quick connect" -1- and
detach the fuel line -2-.
Using Hose clip pliers -ASE45149200000- ,
– release the "Springband" clamp -3- and
disconnect the vent line -4-.

On the LH side of the engine, remove the
–

fixing -arrow- (25 Nm), detach the refrigerant
line from the compressor and DISCARD the Oring.

On both sides (where "OPF" [Otto Particulate
Filter] is fitted), disconnect the electrical
– connection -1- from the exhaust pressure
sensor and detach at the clipping point -arrow.

Vehicle raised

–

On the LH side of the vehicle where "EAWS" is
fitted:
Remove the fixing -2- (5.5 Nm) securing the






Release the harness retainer -3- securing the









earth connection to the EAWS control module.






harness -1- to the body.

Disconnect the harness connections -2- and -5-



only.
Note

The remaining connections -1, 3 and 4- can be left
connected to the module.

Continuation

Under the LH side of the chassis, disconnect the
– power steering power feed -1- and remove the
fixing -2- (20 Nm) for the earth connection.

Caution
Counter holding the earth stud -2- is strongly
advised when loosening and tightening.

Front subframe front brace

– Remove fixings -1- (55 Nm).
– Remove fixings -2- (30 Nm).
– Remove fixing -3- (6 Nm).
– Remove fixings -4- (23 Nm).
– Remove the front subframe front brace.

Front subframe rear brace

– Remove fixings -1- (30 Nm).
– Remove fixings -2- (30 Nm).
– Remove the front subframe rear brace.

Remove and DISCARD the fixing (85 Nm) -2–

and remove track rod end -1- from the wheel
bearing housing using Ball joint splitting tool T40010A- .

Remove and DISCARD the bolt -2- (20 Nm +90°)
–

for the steering rack universal joint -1-. Push the
steering column universal joint backwards arrow- off the steering rack pinion.

On both sides, disconnect the electrical
– connection -arrow- from the exhaust
temperature sensor.
–
–
–

Detach the harness edge clip -1- from the
subframe.
Detach the carrier -2- from the rear section of
the subframe.
Separate the carrier -2- from the top cover -3and release the harness connection.
Note

RH shown, LH symmetrically opposite.
Disconnect the harness interconnect -1- and unclip
– from the subframe -2- (located in the right hand
wheel arch).
Remove the shear plates, refer to "Front subframe
–

shear plates - To remove and fit".
→ Rep.-Gr.40

Using Remote hose clip pliers -Such as VAS 6340-,
– release the "Springband" clamps -arrows- and
detach the coolant hoses -1- and -2-.
Note
There will be some residual coolant in these hoses,
use a suitable container to catch the residual and
bung up the hoses to prevent further drips.

On both sides, disconnect the harness connection
– for the brake pad wear indicator -1- from the
holder -2- -arrow A- and disconnect it -arrow B-.
Note
The pad wear indicator must be renewed if the
retaining clip is lost or broken.

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

On both sides, remove and DISCARD the fixings – 1- and -2- securing the caliper to wheel bearing
housing and remove the caliper.
–

Using Tensioning strap -T10038-, suspend the
caliper from the vehicle body.

Caution
Do not allow the caliper to hang under its own
weight as this could stress and damage the brake
hose.

–

On both sides, disconnect the harness connector 2- for the wheel speed sensor.
Note

Disregard items -1- and -3-

–

On both sides, remove the fixings -arrows- and
remove the brake disc from the vehicle.

Image for illustration purposes only.

WARNING


Brake discs are heavy. Remove carefully.
Do not allow grease or fluids to come into
contact with the brake pad linings and discs, as



the braking efficiency of the vehicle will become
severely affected.

On both sides, remove the fixings -2- and remove
– the sensor harness and bracket -1- from the wheel
bearing housing.

–

On both sides, remove and DISCARD the fixing -2on joint pin for upper trailing arm -1-.

–

On both sides, remove and DISCARD fixing -2- from
lower trailing arm -1- and air spring damper.
Remove the centre section of the exhaust system.

–

Refer to "Exhaust centre section - to remove and fit".
→ Rep.-Gr.26
Remove the propshaft. Refer to "Propshaft - To

–

remove and fit".
→ Rep.-Gr.39
On the front RH side, remove the automatic

– transmission pipes -1- from the bottom of the
radiator assembly.
Note
To detach the ATF lines release the "quick connect"
unions -A- from the retaining latch -B-.
Push the "quick connect" outwards -C- and detach the
pipe.
Note
Please place a suitable container underneath the
vehicle to catch any escaping fluid.
Dispose of any waste fluids according to local
environmental regulations.
Suitably blank off any open connections to prevent
ingress of dirt and moisture.
On both sides of the vehicle, undo the worm drive
–

clamp -1- (5.5) Nm, then disconnect the boost hose 3- off the intercoolers and suitably bung both the
pipe and the intercooler.