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.

7. 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
-2-.

– Remove the fixings -1.....10- in the sequence shown.
–

Detach the fuel rail from the cylinder head, ensuring that
the fuel injectors remain seated in the cylinder head.

8. Remove cylinder deactivation solenoids:
The cylinder deactivation solenoid system comprises of the following:
Camshaft lobe sliding element - which is part of the camshaft assembly and operates on a splined




section of the camshaft.
CDA activation/ deactivation solenoids (actuators) (4 per engine bank).

Removal

–
–
–

Remove the fixings -1- (5 Nm) for the relevant cylinder
deactivation solenoid.
Carefully remove the cylinder deactivation solenoid from
the cylinder head.
Repeat for all remaining cylinder deactivation solenoids,
noting the locations to aid installation.

9. Remove fuel injectors:
Special tools and workshop equipment required
Tool set for TSI engines -T10133Removal

– Apply Puller -T10133/2A- to the groove of the injector.
–
–

Apply Puller -T10133/16A- over Puller -T10133/2A-, and
extract the injector by turning the bolt -1-.
Repeat for all injectors, taking note of the locations to aid
installation.

10. Remove mechanical vacuum pump:
The mechanical vacuum pump is located at the front LH side
(bank 2) of the cylinder head -arrow-.
Removal

– Remove the fixing -1- retaining the engine harness -2-.
–
–
–

–

–

Detach the quick connect -3- from the pressure tube
breather.
Release the "Springband" clamp -arrow- and detach from
the hose -4-.
Release the pipe assembly -5- from the clipping points
for improved access.
From the top of the vacuum pump, disconnect the
vacuum line -2- and the push-on hose -1-.

Remove and DISCARD the three fixings -3- from the
vacuum pump.

– Carefully detach the vacuum pump from the engine.

11. Remove pressure pipes:
Special tools and workshop equipment required
Hose clip pliers -ASE 451 492 00 000-.
Removal
LH side (bank 2) only

– Pull the breather stub -1- out from the pressure pipe.
Continuation for both sides

On the appropriate side, release the two captive fixings – 2- (9 Nm) and detach the pressure pipe -3- from the
centre connecting hose -4-.
An additional fixing may be fitted dependent on model
year.

Caution
Blank off all open ports.
–

Remove and DISCARD the "O-rings" -arrows- from the
breather stub -1- and the pressure pipe -2-.

12. Remove camshaft actuators:
The camshaft actuators are located at the rear of cylinder banks 1 and 2, behind the upper chain
housing covers.
Special tools and workshop equipment required


Counterhold 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

Preliminary work
– For bank 2 only, remove the dipstick.

Note
Photos taken with a digital camera are helpful with
complicated line routing (engine wire harness).

Loosen tank ventilation sensor (USA) or dummy (cylinders

–

1–4) -1-.

– Unscrew and remove fastening screw -2-.
– Release and disconnect electric plug connection -3-.
Loosen tank ventilation sensor (USA) or dummy -1-

–

together with vent line -5- from holder -4-.

Loosen change-over valve for water pump -3- and

–

remove holder. Ref: Image

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
Remove camshaft actuator

Caution
Timing not set correctly


Risk of engine damage



Rough running engine



Loss of engine power

— Do not use force when fitting the staking tool.
— Make sure that the gap is equal on both sides.
— When inserting the staking tools, do not use force to
turn the camshafts against any resistance.
— The engine must be exactly at top dead centre.
— The opposite cylinder must be at ignition TDC.

Caution
Dirt and contamination
Risk of damage to units or components
— Protect components from dirt and contamination.
— Clean or replace dirty components.
Note

Do not clean the camshaft controller in a parts washer.
Only the outside can be cleaned using a clean, lint-free cloth.
Note
Never use the Camshaft clamps -T40331- as a counterhold
tool for loosening and tightening the camshaft controllers.

Note
The Counterhold tool -T90001- can only be inserted at one
position. The markings -1 and 2- must line up.

–

Turn engine clockwise to ignition TDC of cylinder 1. Check
markings on crankshaft and actuators.

– Secure camshafts.

–
–

Carefully lever out stoppers on the cylinder head cover
using a screwdriver.
Screw adapter -1- into the camshaft housing and tighten
to 9 Nm.

Cylinder bank 1: T40331/2, Cylinder bank 2: T40331/3

Note
It may be necessary for another person to carefully position
the camshafts at the actuators using Counterhold tool T90001- and Ring wrench insert, a/f 41 -VAS 261 001-.

Camshaft clamp -T40331- must be inserted.
Cylinder bank 1:

1 - -T40331/1- – The letter "A" must be facing you
2 - -T40331/93 - -T40331/24 - -T40331/4- – Outlet camshaft
5 - -T40331/6- – Intake camshaft

Cylinder bank 2:

1 - -T40331/1- – The letter "B" must be facing you
2 - -T40331/93 - -T40331/34 - -T40331/10- – Outlet camshaft
5 - -T40331/8- – Intake camshaft

–

Secure the crankshaft at the front of the engine using a
suitable 6mm locking pin/drill bit.

Caution
It may be necessary to rotate the
crankshaft to fit the tool securing
the crankshaft.
If the engine is turned over by hand using the crank damper
bolt, it MUST be turned “clockwise” -arrowed- to avoid the
possibility of loosening the bolt.
– Loosen and unscrew central valves -1-.
Counterhold tool -T90001- -2- with Ring wrench insert,
– a/f 41 -VAS 261 001- -3- must be fitted on the actuators.
Then loosen central valves -1- using Socket E24 -T90000-.

– Fix chain tensioner in place.
–
–

Press the chain tensioner piston back fully. To do this,
actuate the tensioning rail by hand.
Fix the chain tensioner -1- in place using Locking pin T03006- -3-.

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

Unscrew central valves and remove actuators from
camshafts and from the timing chain.

Caution
Secure the timing chain to prevent it from falling down.

13.Remove cylinder head cover:
The following procedure covers both bank 1 and bank 2 camshaft covers.
Removal

Note
The procedure for removing and installing is described for one side as an example. The procedure for
the other side is practically identical, except where shown.

Bank 1

– Remove the fixings -arrows- (20 Nm).
– Remove the bracket-1-.

Continuation for both sides

– Remove cylinder head cover -1-.
–
–

Unscrew screws -2- slowly and uniformly from
the outside in.
Remove cylinder head cover -1- (with camshaft
clamp fitted) and set it down on a clean surface.

14. Remove valve lifters (hydraulic tappets):
Removal
–

If you intend to re-use hydraulic tappets, safety clips and valve levers: Mark allocation of the
components using a coloured marker.

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

Take hydraulic tappet -1- with valve lever -2- out of the
cylinder head together.
Note

If you intend to re-use hydraulic tappets and valve levers,
check that the components are not damaged.
–

Check component allocation and check that all
components are fitted.

– Remove hydraulic tappet -2- from valve lever -3-.
– Open safety clip -1- carefully.
– Remove safety clip -1- and hydraulic tappet -2-.

15. Remove spark plugs:
Special tools and workshop equipment required
Spark plug socket (14 mm) commercially available.
Removal

Note
Ensure the area around the spark plugs is free from dirt and debris.
– Using a suitable socket, remove the spark plugs.

Note
When spark plugs are removed, place a suitable clean cloth in the spark plug bore to prevent any dirt
ingress.

16. Remove valve springs:
The following procedure is carried out with the engine and automatic transmission removed from the
vehicle but with the cylinder installed.
Special tools and workshop equipment required



Guide plate -VAS 5161A/38Removal and installation device for valve keys -VAS



5161A-



Valve stem seal puller -3364-



Press-on tool -3365-

General information

Note



In the Guide plate -VAS 5161A/38- -1- there are four bore
holes -a, b, c, d- for mounting on the cylinder head.
Depending on the installation situation, observe the use of
the bores and secure the Guide plate -VAS 5161A/38- with
the supplied screws, M5x40 -2-.


-E- Intake side



-A- Outlet side

For (Bank 1)
-

Using a suitable tool remove the “C-Clip” -1- that
retains the “Waistgate actuator rod” to the turbocharger.

-

Remove the two fixings -arrows- and remove the waistgate
Actuator. This will allow greater access.

Before attempting to remove the valve keys (collets) firstly
Ensure that all galleries in the area being worked are suitably

Covered with lint free cloths, to ensure NO foreign bodies
enter the engine .

–

Guide plate -VAS 5161A/38- -1- must now be
secured on the cylinder head.
Guide plate -VAS 5161A/38- -1- on the cylinder head
must be aligned above the relevant combustion
chamber. Observe markings "A – Outlet side / E –
Intake side" while doing this.

It is imperative that all the sealant is removed from the
– mating faces of the cylinder heads before proceeding further.
-

Insert the two fixings -arrows-, then install
two suitable M8 dowel bolts -2- finger tight ONLY.
(The engine cross brace fixings are suitable for
this instance)

–

Now tighten the fixings -arrows- to 9 Nm.
(for the two rear cylinders, only one securing fixing
–arrow- can be used)

Fit punch -2- -VAS 5161/3A- -2- from tool set Removal
and installation device for valve keys -VAS 5161A- on
–

the valve-spring plate and loosen any tight valve keys
by tapping them with a plastic hammer.
-

–

Disregard all other position

Screw the sealing pin -VAS 5161/10- -2- from tool set
“Removal and installation device for valve keys” -VAS 5161A-

into the Guide plate -VAS 5161A/38-. Hand tight ONLY.
–
–

Screw the hose adapter -VAS 5161A/35- -1- hand-tight into
the respective spark plug thread.
Connect compressed air to the hose adapter -VAS 5161A/35-1-.

Note
Minimum pressure: 6 bar
–

Remove the valve springs using “Removal and installation
device for valve keys” -VAS 5161A-.
Screw the retainer -VAS 5161/6- -2- with guided fork and

–

M8 threaded bolt -VAS 5161/5- -3- into the guide
plate.

–
–

Insert assembly cartridge -VAS 5161/8A- -4- into the
bore over the valve spring to be removed.
Engage pressure fork -VAS 5161/2- -1- in the retainer –
VAS 5161/6- -2- and press assembly cartridge down.
At the same time, turn the knurled screw -arrow- on

– the assembly cartridge clockwise until the tips engage
in the valve collets.
Turn the knurled screw -arrow- back and forth to
–

press the valve collets apart and capture them in the
assembly cartridge. The knurled screw slips in as far as it
will go into the assembly cartridge.

–

Relieve tension on pressure fork -VAS 5161/2- -1- and
remove assembly cartridge -VAS 5161/8A- -4-.

– Remove valve keys from the assembly cartridge.
Remove valve spring with valve-spring plate and mark
–

installation position. DISCARD spring.

To remove the valve keys from the cartridge
-VAS 5161/8A-If the valve keys were removed from the assembly
cartridge, they must first be inserted into the
insertion device –VAS 5161/18- -1- from the tool

set “Removal and installation device for valve keys”
-VAS 5161A-.
-Insert the valve keys into the insertion device -VAS
5161/18- -1- .
-The large diameter of the valve keys must be facing
upwards.
-Press the assembly cartridge -VAS 5161/8A- onto
the valve keys from above and pick up the valve
keys from the insertion device -VAS 5161/18- -1-.