Disregard all other positions.

–

Mark the position of the front subframe to the body
in all accessible areas -1-.

Preparing the engine lifting table
Before the sub frame, engine and automatic
transmission assembly can be removed from the
vehicle, the Hydraulic lifting table -VAS 6131- MUST
–

be prepared with the appropriate special tools.
Refer to "Engine and automatic transmission
hydraulic lifting table - To prepare".
→ Rep.-Gr.10

Lowering the engine and automatic transmission
assembly
Position the engine and transmission table under
the vehicle in the specified lifting locations.
–

In addition to marking the front subframes position,
install the subframe locating pins in the instructed
places. Refer to “Front subframe” – To fix position.
→ Rep.-Gr.10

Caution
Due to the weight of the engine and transmission
assembly, it is important that the vehicle is secured
safely to prevent instability of the vehicle on the
ramp with the assembly removed.
–

On both sides, remove and DISCARD the fixings 3- from the rear section of the front subframe.
Note

The rearmost fixing will have been removed during
the removal of the shear plates.

On both sides, remove and DISCARD the forward
– fixing -1- securing the front subframe section to
the body.

On both sides, remove and DISCARD the single
– fixing -2- securing the front subframe section to
the body.
Disregard position -1-.

–

Remove and DISCARD the fixings -1- that retain
the transmission rear crossmember to the body.
With the aid of an assistant, slowly lower the

– engine and automatic transmission assembly
completely out of the vehicle.

Caution
Check all relevant components are disconnected
before lowering the engine and automatic
transmission assembly, and that none of the
engine components are fouling as it is lowered
from the vehicle.

2. Remove exhaust downpipes, heatshields and catalytic converters:
Special tools and workshop equipment required


14 mm spanner -3150-



Tool set -T10395A-



Tool set for lambda probes -3337-

Removal

–

Remove the three fixings -A- (8 Nm) and the two
fixings -B- (9 Nm) from the heatshields -1 & 2Depress the clips -arrows- in readiness for the

– removal of the heatshields -1 & 2- away from the
inner heatshields.
Bank 2

–

Remove the fixing (8 Nm) -arrow- from the heatshield
-1-.

Remove the fixings -A- (8 Nm) and -B- (8 Nm) and
–

depress the remaining clips -arrows- to allow the two
halves -1- and -3- to separate away from one
another.
Note

The fixing clip with the arrow marked -C- is obscured
from view.
Bank 1

Remove the fixings -A- (8 Nm) and -B- (8 Nm) and
– depress the clips -arrows- to allow heatshields -2and -4- to separate from each other
Note
The fixing clip with the arrow marked -C- is obscured
from view.

–

Remove fixings -1- (8 Nm) and -2- (8 Nm) securing
the pressure line -3- to the engine.

Continuation for both sides

–

Release the electrical connection carrier assembly -1from the subframe.
Separate the electrical connection carrier assembly

–

(two halves) -1-, detach the temperature sensor
electrical connection -2- and release the wiring
harness.

–

Release the hose from the wiring at the clipping point
-3-.
Using Hose clip pliers -ASE 451 492 00 000-, release

– the "Springband" clamp -4- and detach the pressure
hose -5- from the "OPF" downpipe.
– Remove the fixing -arrow- securing the heatshield -6-.
–

Release the wiring harness -1- at the clipping point -2on the subframe.
Release the press-stud -arrow- and manoeuvre the

– heatshield -3- from the "OPF" temperature sensor
wiring harness -1-.

Using Hose clip pliers -ASE 451 492 00 000-, release
– the "Springband" clamp -arrow- and detach the hose
-2- from the "OPF" stub pipe -3-.
–

Remove the fixing -1- (23 Nm) from the lower support
bracket.

Remove and DISCARD the fixing -arrow- and clamp
–

and detach the downpipe -1- from the catalytic
converter -2-.

– DISCARD the sealing ring.

–

Release the relevant lambda wiring harness plug -1from its retaining clip -arrow-.
Note

Bank 1 shown.
It is not necessary to remove the lambda probe from the
catalytic converter.
–

Unclip the lambda wiring harness from the clipping
points.
Remove and DISCARD the fixing -arrow- (comprising

–

of screw, spring, bush and washer) from the "V-band"
clamp -1- between the catalytic converter -2- and
turbocharger.

–

–

–

Undo and remove the two fixings -arrows- (23 Nm)
and remove the catalytic converter.
DISCARD the sealing ring between the catalytic
converter and turbochargers.

On both sides, remove the fixing (20 Nm) -arrow- from
the side of the automatic transmission.

Bank 2 shown, bank 1 fixing is different

–

Remove the four fixings -arrows- (9 Nm) from the
heatshield -1-.
Slide the captive nuts -A- upwards from the support

– bracket to allow the heat shield assembly -1- to slide
upwards and away from the engine.

3. Remove rear high-pressure fuel line:
Special tools and workshop equipment required



Torque wrench -VAG 1331 -



Tool insert AF 17 -VAG 1331/6-

Consumables
Microgleit DF977S lubricant (refer to electronic parts
catalogue "ETKA")
Removal
Using a suitable tool, unclip the top part of the harness
– retainer -arrow- to allow the retainer to open up and
the harness to be removed detached.
–
–

Remove the fixing -1- (9 Nm), detach the P-clip -2- and
move the starter cable -3- to one side.
Remove and DISCARD the two fixings -4- and detach
the catalyst support bracket -5-.

–

Remove the fixings -1 to 3- (9 Nm) securing the RH
turbocharger coolant pipe.

On the top RH side of the engine, remove the fixing – arrow- (9 Nm), detach the turbocharger coolant pipe -1and DISCARD the O-ring.

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-.

–

Remove the fixings -arrows- (9 Nm) and detach the
coolant pipe -1-. DISCARD the O-rings upon removal.

Bank 1

–
–
–

Release the lambda sensor cable -1- at the clipping point
-arrow-.
Disconnect the electrical connections -2- and release the
harness from the clipping points.
Remove the fixings -3- (8 Nm) and detach the fuel pump
crash assembly -4-.

Bank 2

–

Remove the three fixings -1- (8 Nm) and detach the fuel
pump crash assembly -2-.

Continuation for both sides

–
–
–

On the RH side of the engine, disconnect the harness
connector -1- from the pressure sensor -2-.
Remove the fixing -arrow- (9 Nm) securing the pressure
sender assembly.
Undo the union nut -3- securing the high-pressure pipe
to the fuel pump.

–

On the LH side of the engine, undo the union nut -4- (8
Nm + 50°).

– Remove the fixing -5- (9 Nm) securing the P-clip.
Note
Disregard items -1, 2 & 3-.

–

Remove the fixings -arrows- (9 Nm) securing the P-clips
and detach the fuel link pipe -1- from the engine.

4. Remove upper chain housing covers:

Caution
Dirt and contamination
Risk of damage to units or components
— Protect components from dirt and contamination.
— Secure components to prevent them from falling
down.
— Clean or replace dirty components.

Note
The procedure for removing and installing is described for one side as an example. The procedure for
the other side is practically identical.
Removal

– Unscrew fixings -2- (9 Nm).
–

Press off chain housing cover -1- at a suitable point
and set it down on a clean surface.

5. Remove oil mist separators:

Removal
– Remove the turbocharger heatshields upper sections.
Bank 1

– Disconnect the pipes -1- from the oil mist separator.

–

Loosen the captive fixings -2- (9 Nm) that retain the oil
mist separator to the cylinder head cover.

Note
The foremost fixing may be obstructed by sound
deadening, suitably peel back the material until the fixing is
accessible.
– Remove the oil separator and DISCARD the seal.
Bank 2

– Disconnect the vent lines -2- from the oil mist separator.

–

Loosen the captive fixings -2.....7- (9 Nm) that retain the
oil mist separator -1- to the cylinder head cover.
Note

Fixings -2, 4 and 6- may be obstructed by sound deadening,
suitably peel back the material until the fixings are accessible.
Oil filler cap shown not fitted for illustration purposes only.
– Remove the oil separator -1- and DISCARD the seal.

6. Remove ignition coils:
Consumables
Silicone paste -G052565A1- (refer to ETKA)
Removal
Bank 1

–

Remove the fixing -3- (55 Nm), the fixing -4- (20 Nm)
and the engine mount bracket -2-.
Note

Disregard -1-.

–
–

–

Disconnect the lower quick connect -1- and detach the
vent line.
Remove the nuts -2- (9 Nm) for the cylinder head
harness carrier.

Disconnect ALL harness connectors from the following
components;



-1- Ignition coils



-2- Cylinder deactivation solenoids



-3- Fuel pressure sensor



-4- Fuel injectors



-5- Camshaft position sensor

–

Carefully move the harness to one side to allow access to
the ignition coils.

Caution
Take care not to put too much tension on the harness.

– Remove the studs -1- (9 Nm) for the ignition coils.
– Carefully extract the ignition coil from the cylinder head.
Note
Number each ignition prior to removal to aid installation.

Bank 2

–

Disconnect the two electrical connections -2 & 3- and
release from their clipping points.

Note
Disregard -1-, previously disconnected.

Disconnect the lower ‘quick-connect’ (not shown) and
remove the vent line.
Disconnect the vacuum pipe ‘quick-connect’ from the
intake manifold.
–

Disconnect ALL electrical harness connectors from the
following components:



-1- Ignition coils



-2- Cylinder deactivation solenoids



-3- Fuel pressure sensor



-4- Fuel injectors

–

Remove the nuts -1- (9 Nm) and move the harness to
one side to allow access to the ignition coils.

Caution
Take care not to put too much tension on the harness.

– Remove the studs -2- (9 Nm) for the ignition coils.
– Carefully extract the ignition coil from the cylinder head.

Note
Number each ignition prior to removal to aid installation.

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



Torque wrench -VAG 1331 -



Tool insert AF 17 -VAG 1331/6-

Consumables
Microgleit DF977S lubricant (refer to electronic parts
catalogue "ETKA")
Removal
Bank 1

– Remove the fixing -1- (9 Nm) for the fuel line clamp.
– Unscrew the union nuts -2- and remove the fuel line.
Bank 2

– Remove the fixing (9 Nm) -1- for the fuel line clamp.
– Unscrew the union nuts -2- and remove the fuel line.

8. Remove high-pressure fuel pumps:
There are two high pressure fuel pumps fitted to the engine:
The High-pressure pump -N290- is mounted on the rear top surface of the bank one camshaft




cover.
The High-pressure pump -N402- mounted on the rear top surface of the bank two camshaft cover.

The removal of the high-pressure fuel pump is the same for both sides of the engine unless stated
otherwise.
Special tools and workshop equipment required



Torque wrench -VAG 1331 -



Tool insert AF 17 -VAG 1331/6-

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

–
–

Disconnect the harness connector -1- from the fuel
pump.
Disconnect the fuel pipe union -2- from the highpressure pump.

–
–

Lift the sound insulation material up to gain access to
the fuel pump fixings.
Remove the fixings -3- and carefully withdraw the fuel
pump from the camshaft cover.

9. Remove fuel rails:
The removal of the fuel rail is symmetrically the same on both banks of the engine unless stated
otherwise.
Removal
–

–

Lift the check valve assembly from the guide away from
the valve cover -arrow-.

Remove the sound proof material from the cylinder head