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.


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

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
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.

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