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Volkswagen CC 2012, Workshop Manual

The Volkswagen CC 2012 Workshop Manual is a comprehensive guide providing detailed instructions and diagrams for maintaining and repairing your vehicle. Download this manual for free from manualshive.com, and equip yourself with the knowledge needed to confidently tackle any repair or maintenance task for your Volkswagen CC 2012.

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Contents

00 - Technical data   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

1

Identification   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1

1.1

Engine number/engine data   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1

2

General information   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3

2.1

Numbering of cylinders   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3

3

Safety information   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4

3.1

Safety precautions during work on fuel system   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4

3.2

Safety precautions when using testers and measuring instruments during a road test   . . . .

4

3.3

Safety precautions when working on the cooling system   . . . . . . . . . . . . . . . . . . . . . . . . . .

5

3.4

Safety precautions when working on ignition system   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5

4

Repair notes   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6

4.1

Rules for cleanliness   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6

4.2

Foreign objects in engine   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6

10 - Removing and installing engine   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7

1

Removing and installing engine   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7

1.1

Removing engine   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7

1.2

Separating engine and gearbox   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

1.3

Securing engine on engine and gearbox support   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

1.4

Installing engine   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

2

Assembly mountings   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

2.1

Assembly overview - assembly mountings   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

2.2

Removing and installing engine mounting   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

2.3

Adjusting assembly mountings   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

2.4

Checking adjustment of assembly mountings (engine and gearbox mountings)   . . . . . . . . 27

13 - Crankshaft group   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

1

Cylinder block (pulley end)   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

1.1

Assembly overview - cylinder block (pulley end)   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

1.2

Assembly overview - poly V-belt drive   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

1.3

Removing and installing poly-V belt   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

1.4

Removing and installing tensioner for poly V-belt   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

1.5

Removing and installing vibration damper   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

1.6

Removing and installing bracket for ancillaries   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

1.7

Removing and installing sealing flange on pulley end   . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

2

Cylinder block, gearbox end   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

2.1

Assembly overview - cylinder block, gearbox end   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

2.2

Removing and installing flywheel   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

2.3

Renewing crankshaft oil seal (gearbox end)   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37

3

Crankshaft   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40

3.1

Assembly overview - crankshaft   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40

3.2

Renewing needle bearing in crankshaft   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42

3.3

Crankshaft dimensions   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44

3.4

Measuring axial clearance of crankshaft   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44

3.5

Measuring radial clearance of crankshaft   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44

3.6

Allocation of main bearing shells   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45

3.7

Removing and installing sender wheel   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49

4

Pistons and conrods   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51

4.1

Assembly overview - pistons and conrods   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51

4.2

Removing and installing pistons   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52

4.3

Checking pistons and cylinder bores   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55

4.4

Separating new conrod   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56

CC 2012 ➤ , Passat 2011 ➤ , Passat Variant 2011 ➤

6-cylinder direct-injection engine (3.6 l engine, 4V) - Edition 06.2019

Contents    

i

Summary of Contents for CC 2012

Page 1: ...Workshop Manual CC 2012 Passat 2011 Passat Variant 2011 6 cylinder direct injection engine 3 6 l engine 4V Engine ID BWS CNN A Edition 06 2019 Service Service Department Technical Information ...

Page 2: ...echnical information should always be available to the foremen and mechanics because their careful and constant adherence to the instructions is essential to ensure vehicle road worthiness and safety In addition the normal basic safety precautions for working on motor vehicles must as a matter of course be observed Service All rights reserved No reproduction without prior agreement from publisher ...

Page 3: ...nder block pulley end 28 1 1 Assembly overview cylinder block pulley end 28 1 2 Assembly overview poly V belt drive 30 1 3 Removing and installing poly V belt 31 1 4 Removing and installing tensioner for poly V belt 32 1 5 Removing and installing vibration damper 32 1 6 Removing and installing bracket for ancillaries 33 1 7 Removing and installing sealing flange on pulley end 34 2 Cylinder block g...

Page 4: ...and installing camshaft adjuster 105 4 5 Removing and installing camshaft control valve 112 4 6 Removing and installing valve stem seals 116 5 Inlet and exhaust valves 119 5 1 Checking valve guides 119 5 2 Reworking valve seats 119 5 3 Valve dimensions 121 17 Lubrication 122 1 Sump oil pump 122 1 1 Assembly overview sump oil pump 122 1 2 Removing and installing oil spray jet 124 1 3 Removing and i...

Page 5: ...rol unit J623 189 6 2 Removing and installing engine motor control unit J623 with protective housing 190 7 High pressure pump 194 7 1 Assembly overview high pressure pump 194 7 2 Removing and installing high pressure pump 195 8 Lambda probe 199 8 1 Removing and installing lambda probe G39 199 8 2 Removing and installing Lambda probe G108 200 8 3 Removing and installing lambda probe after catalytic...

Page 6: ...CC 2012 Passat 2011 Passat Variant 2011 6 cylinder direct injection engine 3 6 l engine 4V Edition 06 2019 iv Contents ...

Page 7: ...t The four digit engine code can be found on the type plate the vehicle data label and on the engine control unit Note Fitting locations of vehicle data sticker Maintenance Booklet Vehicle data sticker Engine data Codes BWS CNNA Manufactured 12 10 05 11 Exhaust emissions fulfil EU 5 ULEV 2 Displacement cm3 3597 3580 Power kW at rpm 220 6600 206 6200 Torque Nm at rpm 350 2400 360 2800 Bore Diamete ...

Page 8: ... exceptional circumstances min 95 RON however with re duced performance CC 2012 Passat 2011 Passat Variant 2011 6 cylinder direct injection engine 3 6 l engine 4V Edition 06 2019 2 Rep gr 00 Technical data ...

Page 9: ...ders page 3 2 1 Numbering of cylinders Note Cylinder 1 is opposite the power delivery side Firing order 1 5 3 6 2 4 CC 2012 Passat 2011 Passat Variant 2011 6 cylinder direct injection engine 3 6 l engine 4V Edition 06 2019 2 General information 3 ...

Page 10: ...fuel pump would otherwise be activated when the driver s door is opened or the ignition is switched on Use one of the following options to interrupt the power supply Disconnect battery or Remove fuse for fuel pump G6 or Pull connector off fuel delivery unit flange Caution Observe the following during all assembly work particularly in the engine compartment due to the restricted space Route lines o...

Page 11: ...ng or hot components Note Cooling system is pressurised when engine is warm If nec essary release pressure before carrying out repairs Secure all hose connections with hose clips For allocation see Electronic Parts Catalogue ETKA Hose clip pliers VAS 6499 are recommended to install spring type clips Renew gaskets and seals The arrows on the coolant pipes and on the ends of the hoses must be aligne...

Page 12: ...rom their packing Install only clean parts do not remove new parts from pack aging until immediately before installing Do not use parts that have been kept unpackaged for example in toolboxes If system is open do not work with compressed air Try not to move the vehicle 4 2 Foreign objects in engine To prevent the ingress of foreign bodies during work on the engine seal open intake and exhaust duct...

Page 13: ...e 17 1 4 Installing engine page 19 1 1 Removing engine Special tools and workshop equipment required Lifting tackle 3033 Engine support T40074 Torque wrench V A G 1331 Torque wrench V A G 1332 Engine and gearbox jack V A G 1383 A Stepladder VAS 5085 CC 2012 Passat 2011 Passat Variant 2011 6 cylinder direct injection engine 3 6 l engine 4V Edition 06 2019 1 Removing and installing engine 7 ...

Page 14: ...Not illustrated Container for removed parts V A G 1698 A Cable tie High temperature grease G 052 133 A2 The engine is removed downwards with gearbox Bringing the lock carrier into the service position is not necessary CC 2012 Passat 2011 Passat Variant 2011 6 cylinder direct injection engine 3 6 l engine 4V Edition 06 2019 8 Rep gr 10 Removing and installing engine ...

Page 15: ...e engine compartment due to the restricted space Route lines of any kind and cables so that original routing is restored Ensure that there is sufficient clearance to all moving or hot components Disconnect earth strap at battery with ignition switched off Electrical system Rep gr 27 Battery Disconnecting and con necting battery Completely remove air filter housing with connecting hose to the throt...

Page 16: ...ff upwards Unscrew cable from alternator at fuse holder arrow Open cable duct latches on longitudinal member arrows CC 2012 Passat 2011 Passat Variant 2011 6 cylinder direct injection engine 3 6 l engine 4V Edition 06 2019 10 Rep gr 10 Removing and installing engine ...

Page 17: ...rs Disconnect plug in connector Pull off vacuum line and intake manifold from brake servo Seal lines so that no dirt is able to enter fuel system Observe rules for cleanliness page 6 WARNING The cooling system is under pressure when the engine is hot Danger of scalding due to steam and hot coolant Cover filler cap on expansion tank with a cloth and open care fully to release pressure Open and clos...

Page 18: ...arbox cover Drain coolant page 142 Release coolant hoses and pull them off heat exchanger arrows Release retaining clip arrow Pull off coolant hose 1 from top of radiator CC 2012 Passat 2011 Passat Variant 2011 6 cylinder direct injection engine 3 6 l engine 4V Edition 06 2019 12 Rep gr 10 Removing and installing engine ...

Page 19: ...air conditioner compressor from ancillary bracket Heating air conditioning Rep gr 87 Air conditioner com pressor Removing and installing air conditioner compressor from and to bracket Caution Danger of damage to coolant lines and hoses Do NOT stretch kink or bend refrigerant lines and hoses Secure air conditioner compressor as shown to bumper cov er with fastening strap T10038 and appropriate unde...

Page 20: ...is not under tension Do not damage wire mesh on decoupling element Unbolt front exhaust pipes from exhaust manifolds arrows Unbolt rear clamping sleeve and mounting for front exhaust pipe Remove front exhaust pipe with Lambda probes Note Lambda probes can remain screwed in Unscrew bolts 1 3 and remove pendulum support Insert engine bracket T40074 in engine and gearbox jack V A G 1383 A Remove adap...

Page 21: ...s Unbolt gearbox side of assembly mounting from gearbox bracket arrows from above Note To remove securing bolts use a stepladder VAS 5085 Engine with gearbox must be guided carefully when lowering to prevent damage to bodywork Carefully lower engine with gearbox 1 2 Separating engine and gearbox Condition For vehicles with automatic gearbox the work procedure may vary slightly Engine with gearbox ...

Page 22: ...S 6122 Disconnecting Clamp off coolant hoses using hose clamps 3093 or 3094 and remove hoses from gearbox oil cooler Seal union of gear oil cooler using suitable bungs plugs from engine bung set VAS 6122 CC 2012 Passat 2011 Passat Variant 2011 6 cylinder direct injection engine 3 6 l engine 4V Edition 06 2019 16 Rep gr 10 Removing and installing engine ...

Page 23: ...support gearbox using workshop hoist Remove lower engine gearbox securing bolts Press gearbox off from engine guiding the gearbox Remove remaining engine gearbox connecting bolts Connecting Reassembly is carried out in the reverse order note specified torques Specified torques Rep gr 34 Removing and installing gearbox Specified torques for gearbox 1 3 Securing engine on engine and gearbox support ...

Page 24: ...ate engine and gearbox page 15 Attach lifting tackle 3033 as follows and lift engine off engine and gearbox jack VAS 6100 using workshop hoist V A G 1383 A Vibration damper end position 3 Flywheel end position 11 CC 2012 Passat 2011 Passat Variant 2011 6 cylinder direct injection engine 3 6 l engine 4V Edition 06 2019 18 Rep gr 10 Removing and installing engine ...

Page 25: ...rticularly in the engine compartment due to the restricted space Route lines of any kind and cables so that original routing is restored Ensure that there is sufficient clearance to all moving or hot components When installing the engine and gearbox assembly make sure there is sufficient clearance to the subframe and radiator Align engine mountings as follows CC 2012 Passat 2011 Passat Variant 201...

Page 26: ...ect fuel supply line 1 and breather line 2 Install poly V belt page 31 Install noise insulation General body repairs exterior Rep gr 66 Noise insulation Assembly overview noise insula tion Add coolant page 142 Connect vehicle diagnostic tester Read all the event memories and delete any entries that may have been made during assembly Conduct test drive and generate readiness code Vehicle di agnosti...

Page 27: ... Specified torques for gearbox 2 Bolt Pendulum support to gearbox Renew 50 Nm 90 1 4 turn further 3 Bolt Pendulum support to gearbox Renew 50 Nm 90 1 4 turn further 4 Engine support 5 Bolt Engine support to en gine Renew 40 Nm 180 1 2 turn further 6 Engine mounting Removing and installing page 22 7 Bolt Engine mounting to body Renew 40 Nm 90 1 4 turn further 8 Connection 9 Bolts Connecting plate t...

Page 28: ...4 Removing and installing gearbox Specified torques for gearbox 17 Gearbox support 18 Bolts Gearbox mounting to gearbox support Renew 60 Nm 90 1 4 turn further 2 2 Removing and installing engine mount ing Removing Caution Observe the following during all assembly work particularly in the engine compartment due to the restricted space Route lines of any kind and cables so that original routing is r...

Page 29: ...hackle 10 222 A 12 on right lifting eye Fit support bracket 10 222 A with rack 10 222 A 1 as shown and take up weight of engine in installation position at right lifting eye Unscrew bolt 2 and lay filler neck 1 for washer fluid reservoir to front Unscrew bolts 5 and lay coolant expansion tank with hoses connected on engine CC 2012 Passat 2011 Passat Variant 2011 6 cylinder direct injection engine ...

Page 30: ...rve the following Specified torques page 21 2 3 Adjusting assembly mountings Special tools and workshop equipment required Support 10 222 A Rack 10 222 A 1 Hook 10 222 A 10 Shackle 10 222 A 12 Adapter 10 222 A 18 CC 2012 Passat 2011 Passat Variant 2011 6 cylinder direct injection engine 3 6 l engine 4V Edition 06 2019 24 Rep gr 10 Removing and installing engine ...

Page 31: ...d on the bolted on sheet metal of the wings These may otherwise be damaged Tighten shackle 10 222 A 12 on right lifting eye Fit support bracket 10 222 A with frame 10 222 A 1 as shown and take up weight of engine in installation position Adjusting engine mountings Unbolt engine side of assembly mounting from engine bracket arrows CC 2012 Passat 2011 Passat Variant 2011 6 cylinder direct injection ...

Page 32: ...unting Specified torques page 21 Adjusting gearbox mountings Renew gearbox mounting bolts arrows in succession if not already carried out when installing the engine and screw in hand tight On gearbox side ensure that edges of support arm 1 and gearbox mounting 2 are parallel Dimension x must be identical on both sides of mounting Tighten bolts for gearbox mounting Specified torques page 21 Further...

Page 33: ... be aligned par allel to the support arm 1 distance x must be identical at front and rear Only when there is a complaint of noise engine or gearbox con tacts longitudinal member when travelling around bends and dimension a lies outside 10 13 mm Adjusting assembly mountings page 24 CC 2012 Passat 2011 Passat Variant 2011 6 cylinder direct injection engine 3 6 l engine 4V Edition 06 2019 2 Assembly ...

Page 34: ...e 34 1 1 Assembly overview cylinder block pulley end 1 Poly V belt Removing and installing page 31 2 Vibration damper Removing and installing page 32 Removing and installing poly V belt page 31 3 Vibration damper securing bolt Removing and installing page 32 4 Bolt 10 Nm 5 Bolt 20 Nm 6 Poly V belt pulley for cool ant pump 7 Bolt 50 Nm 8 Tensioning device for poly V belt Removing and installing pag...

Page 35: ...or Removing and installing page 33 16 Bolt 25 Nm 17 Bolt 25 Nm 18 Air conditioner compressor Removing and installing Heating air conditioning Rep gr 87 Air conditioner compressor Removing and installing air conditioner compressor 19 Bolt Specified torques Heating air conditioning Rep gr 87 Air conditioner compressor Removing and installing air conditioner compressor 20 Idler roller 21 Bolt 40 Nm C...

Page 36: ...ary bracket 25 Nm 11 Alternator Removing and installing Electrical system Rep gr 27 Alternator Removing and installing alternator 12 Ancillary bracket Removing and installing page 33 2 dowel sleeves Make sure that ancillary bracket and air conditioner compressor are properly seated 13 Securing bolt for bottom ancillary bracket 25 Nm lower left bolt is a fitted bolt 25 Nm 14 Air conditioner compres...

Page 37: ...ection Position spanner 1 onto tensioning roller securing bolt and turn in direction of arrow until locking pin T10027 can be inserted on tensioning roller Remove poly V belt Installing poly V belt Note Before installing the poly V belt ensure that all units alterna tor air conditioner compressor are securely bolted on Check deflection rollers for ease of movement The poly V belt must not be kinke...

Page 38: ... overview noise insula tion 1 4 Removing and installing tensioner for poly V belt Remove poly V belt page 31 Unscrew bolt 2 and remove tensioning element 1 Install in reverse order During this step observe the following Bolted connection Torque setting Tensioning element on bracket for ancillaries 50 Nm 1 5 Removing and installing vibration damp er Special tools and workshop equipment required Cou...

Page 39: ...60 Nm 1 2 turn 180 further Install poly V belt page 31 1 6 Removing and installing bracket for an cillaries Removing Remove poly V belt page 31 Remove alternator C Electrical system Rep gr 27 Alternator Removing and installing alternator Remove air conditioner compressor Heating air condition ing Rep gr 87 Air conditioner compressor Removing and installing air conditioner compressor Unbolt ancilla...

Page 40: ...ed Torque wrench V A G 1331 Torque wrench V A G 1332 Counter hold tool T10172 Sealant D 176 501 A1 Cleaning solution D 291 091 A1 Removing Remove poly V belt page 31 CC 2012 Passat 2011 Passat Variant 2011 6 cylinder direct injection engine 3 6 l engine 4V Edition 06 2019 34 Rep gr 13 Crankshaft group ...

Page 41: ...pplying sealant bead cover sealing ring with a clean cloth The sealing compound bead must not be thicker than 2 to 3 mm Otherwise excessive sealing compound will enter the sump and may block the oil suction pipe strainer Observe use by date of sealant The sealing flange must be installed within 5 minutes after ap plying the silicone sealant Fit sealing flange 1 with guide sleeve of seal 2 on the c...

Page 42: ...hold T10044 with 5 mm spacers or counterhold T10172 5 Flywheel Removing and installing page 36 6 Needle bearing Renew Removing and installing page 42 7 Sealing ring Remove using extractor hook T20143 2 PTFE type oil seal Identification Without garter spring Do not additionally oil or grease the oil seal sealing lip Before installing remove oil residue from crankshaft journal using a clean cloth Re...

Page 43: ...inder block with washer arrow Bring counterhold T10044 to position A to loosen flywheel Mark position of flywheel in relation to engine Unscrew flywheel Installing Install in reverse order of removal observing the following Renew bolts Bring counterhold T10044 to position B to tighten flywheel Bolted connection Torque setting Flywheel to crankshaft 60 Nm turn 90 further 2 3 Renewing crankshaft oil...

Page 44: ... 36 Fit puller hook T20143 2 behind sealing lip of oil seal as shown in illustration Support puller hook T20143 2 on the cover for the timing chain and lever sealing ring off in direction of arrow CC 2012 Passat 2011 Passat Variant 2011 6 cylinder direct injection engine 3 6 l engine 4V Edition 06 2019 38 Rep gr 13 Crankshaft group ...

Page 45: ...0122 2 with dry oil seal on crank shaft journal Tap sealing ring into the timing chain cover as far as it will go using the thrust piece T10122 3 Further assembly is basically a reverse of the dismantling se quence CC 2012 Passat 2011 Passat Variant 2011 6 cylinder direct injection engine 3 6 l engine 4V Edition 06 2019 2 Cylinder block gearbox end 39 ...

Page 46: ...shaft prepare a suitable surface for storing the crankshaft so that it is not placed down on the sender wheel Item 6 page 41 and the sender wheel is not damaged If large quantities of metal chips and abraded material are found during engine repair this may indicate that the crank shaft bearings or conrod bearings are damaged To avoid any subsequent damage the following work must be carried out fol...

Page 47: ...located page 45 Before removing see notes page 40 Removing and installing needle bearing page 42 Axial clearance new 0 07 to 0 23 mm wear limit 0 30 mm Measure radial clearance using Plastigage new 0 02 0 06 mm wear limit 0 10 mm Do not rotate crankshaft when checking radial clearance Crankshaft dimensions crankshaft bearings 59 958 59 978 mm conrod bearings 53 958 53 978 mm Reworking the cranksha...

Page 48: ... equipment required Counter support e g KUKKO 22 1 VAS 251 621 Internal puller VAS 251 635 Pin VW 207 C Condition The front edges of the inner puller must be free of chips Gearbox has been removed CC 2012 Passat 2011 Passat Variant 2011 6 cylinder direct injection engine 3 6 l engine 4V Edition 06 2019 42 Rep gr 13 Crankshaft group ...

Page 49: ...ling Clean bearing seat in crankshaft and apply as thin coating of grease Drive needle bearing into crankshaft to installation depth using drift VW 207 C Installation depth dimension a 1 5 mm Note If the needle bearing is inadvertently driven in too far it must be renewed because it will be damaged when it is pulled out again CC 2012 Passat 2011 Passat Variant 2011 6 cylinder direct injection engi...

Page 50: ... gauge holder VW 387 onto cylinder block and set against crank web Press crankshaft against dial gauge by hand and set gauge to 0 Push crankshaft away from dial gauge and read off value Axial clearance New 0 07 0 23 mm Wear limit 0 30 mm 3 5 Measuring radial clearance of crank shaft Special tools and workshop equipment required Plastigage Condition Do not turn crankshaft when measuring radial clea...

Page 51: ...ufacturing date of crankshaft DDMMYY 2 Letters for allocation of bearing shells 3 Part number Check how main bearing shells are allocated according to manufacturing date Allocation of main bearing shells up to and including manu facturing date 230912 page 45 Allocation of main bearing shells from manufacturing date 240912 page 47 3 6 1 Allocation of main bearing shells up to and including manufact...

Page 52: ...ters and identify colour code to be installed based on table Letter on cylinder block Letter on crankshaft web Colour marking of bearing shell for cylinder block up per bearing shell Colour marking of bearing shell for bearing cap low er bearing shell A B C R red red A B C G yellow red A B C B yellow yellow A B C V blue yellow D E G R yellow red D E G G yellow yellow D E G B blue yellow D E G V bl...

Page 53: ...e the manufacturing date The manufac turing date is embossed on the crankshaft web Establish manu facturing date page 45 Main bearing shells of the correct thickness are allocated to the cylinder block and crankshaft at the factory Coloured dots are used to identify the thickness of the bearing shells If the cylinder block or crankshaft is changed the crankshaft bearing shells must be reallocated ...

Page 54: ...ow yellow A B C C blue yellow A B C B blue blue A B C A violet blue D E G F yellow red D E G E yellow yellow D E G D blue yellow D E G C blue blue D E G B violet blue D E G A violet violet H I K F yellow red H I K E yellow yellow H I K D blue yellow H I K C blue blue H I K B violet blue H I K A violet violet L M F yellow yellow L M E blue yellow L M D blue yellow L M C violet blue L M B violet vio...

Page 55: ...he crankshaft sender wheel must be free of oil and grease Note The second time the bolts are tightened the contact points in the sender wheel for the countersunk heads are deformed so far that the bolt heads seat on the crankshaft 3 arrows and the sender wheel is loose under the bolts The sender wheel can only be installed in one position the holes are offset Apply thin coating of locking fluid D ...

Page 56: ...t 1 to 10 Nm 90 1 4 turn further Then tighten new securing bolt 2 to 10 Nm 90 1 4 turn further CC 2012 Passat 2011 Passat Variant 2011 6 cylinder direct injection engine 3 6 l engine 4V Edition 06 2019 50 Rep gr 13 Crankshaft group ...

Page 57: ...kets in the piston crown point to the centre of the cylinder block Installing piston page 52 3 Locking ring Ensure firm seating 4 Connecting rod Renew as set only Mark allocation to cylin der Mark installation posi tion 5 Bearing shell Observe installation po sition Do not interchange used bearing shells The lugs on bearing shells must fit tightly in the recesses Axial clearance New 0 05 0 31 mm W...

Page 58: ...If difficult to remove heat piston to 60 C Remove and install using drift VW 222 A 4 2 Removing and installing pistons Special tools and workshop equipment required Drip tray for workshop hoist VAS 6208 Spring type clip pliers VAS 6499 Torque wrench V A G 1331 Pin VW 222 A CC 2012 Passat 2011 Passat Variant 2011 6 cylinder direct injection engine 3 6 l engine 4V Edition 06 2019 52 Rep gr 13 Cranks...

Page 59: ...t the piston to approx 60 C Remove retaining ring from piston pin eye Drive out piston pin using drift VW 222 A Installing Note To fit the pistons the funnel T10333 with inserted piston is positioned on the cylinder block so that the straight edge of the high funnel plate arrow points to the middle of the cylinder block Procedure Note Renew bolts that are tightened with specified tightening angle ...

Page 60: ...er block and the arrows 3 to the vibration damper Insert piston for relevant cylinder into funnel T10333 from above Short piston side arrow must project approx 15 mm out of lower edge of funnel Now place piston with piston fitting tool in respective cylinder bore The higher side of the piston fitting tool arrow must face middle of cylinder block for this CC 2012 Passat 2011 Passat Variant 2011 6 c...

Page 61: ...ring gap Special tools and workshop equipment required Feeler gauge Test sequence Push ring at right angles to cylinder wall from above down to approx 15 mm from bottom end of cylinder Push in using a piston without rings Piston ring Ring gap New Wear limit Rectangular section ring mm 0 30 0 45 1 0 Taper faced Napier ring mm 0 30 0 50 1 0 Oil scraper ring mm 0 20 0 90 1 2 Checking ring to groove c...

Page 62: ...ipment required Cylinder gauge VAS 6078 Test sequence Take measurements at 3 positions in both lateral direction A and longitudinal direction B Deviations from nominal dimension 0 08 mm Piston Cylinder bore Basic dimension mm 88 945 89 010 Note Cylinder bores must not be measured when cylinder block is mounted on engine and gearbox support VAS 6095 as meas urements may be incorrect 4 4 Separating ...

Page 63: ...d lightly in order to avoid damaging it Conrod is clamped below the dashed line Unscrew both bolts arrows about 5 turns Using a plastic hammer carefully knock against conrod bear ing cap in direction of arrow until it is loose CC 2012 Passat 2011 Passat Variant 2011 6 cylinder direct injection engine 3 6 l engine 4V Edition 06 2019 4 Pistons and conrods 57 ...

Page 64: ...r For fuel hose 2 10 Nm 3 Cap Renew seal if damaged 4 Cylinder head cover Removing and installing page 68 5 10 Nm With spacer sleeve and seal Renew seal if damaged 6 Gasket for cylinder head cover Renew if damaged or leaking Observe installation po sition 7 Lifting eye With bolted on retaining plate for knock sensor connector 8 23 Nm 9 Intake manifold support 10 23 Nm 11 10 Nm 12 10 Nm 13 Union To...

Page 65: ...g fluid D 000 600 A2 24 Union Bolt on before assembling cylinder head 25 O ring Renew 26 Sealing ring Renew 27 Cylinder head gasket Metal gasket Renew Renew cylinder head gasket page 60 After renewing renew entire coolant 28 Cylinder head Check for distortion page 60 Removing and installing page 60 After renewing renew entire coolant 29 Cylinder head bolt Renew Coat bolt with locking fluid D 197 3...

Page 66: ...Max permissible distortion 0 05 mm A cylinder head which is warped up to 0 1 mm may be reworked 1 2 Removing and installing cylinder head Special tools and workshop equipment required CC 2012 Passat 2011 Passat Variant 2011 6 cylinder direct injection engine 3 6 l engine 4V Edition 06 2019 60 Rep gr 15 Cylinder head valve gear ...

Page 67: ...arance to all moving or hot components Note All cable ties which were opened or cut during removal must be renewed at the same locations To prevent damage to removed components place them in the container for removed parts V A G 1698 Disconnect earth strap at battery with ignition switched off Electrical system Rep gr 27 Battery Disconnecting and connecting battery Remove noise insulation General ...

Page 68: ...with intake manifold support from cylinder head Unscrew front exhaust pipes from exhaust manifolds Remove high pressure pump page 195 Withdraw pump plunger Item 17 page 99 Detach following connectors 1 Hall sender G40 2 Inlet camshaft control valve 1 N205 3 Hall sender 2 G163 4 Exhaust camshaft control valve 1 N318 Pull off disconnect all further wiring necessary from cylinder head and move clear ...

Page 69: ... must face each other Remove chain tensioner for camshaft timing chain arrow Undo the two bolts 1 from the lower cover and then undo all the bolts arrows from the upper cover CC 2012 Passat 2011 Passat Variant 2011 6 cylinder direct injection engine 3 6 l engine 4V Edition 06 2019 1 Cylinder head 63 ...

Page 70: ...to hold it in position on the sprocket of the oil pump The timing chain cannot jump over Remove camshaft adjusters from camshafts Remove timing chain from sprocket for high pressure pump Unscrew securing bolts arrows and pull valve timing housing off camshafts Cover camshafts arrows with clean paper strips and wind adhesive tape around ends CC 2012 Passat 2011 Passat Variant 2011 6 cylinder direct...

Page 71: ...linder wall and piston Also prevent dirt and emery cloth particles from getting into coolant Carefully clean sealing surfaces of cylinder head and cylinder block Ensure that surfaces are not scored or scratched if abrasive paper is used grade must not be less than 100 Clean all tapped holes for cylinder head bolts Check cylinder head for distortion page 60 Installing Carefully remove metal particl...

Page 72: ...e will cause leakage Fit the new cylinder head gasket immediately Inscription Part No must be readable Additionally insert a little sealant D 176 501 A1 into the two 3 mm bores which lie on the sealant bead Set camshafts in cylinder head to TDC for No 1 cylinder Cams A of cylinder 1 must face each other Camshaft bar T10068 A must engage in grooves in both shafts Fit cylinder head CC 2012 Passat 20...

Page 73: ...1 Pre tighten all bolts to 15 Nm 2 Then tighten all bolts to 30 Nm 3 Use fixed wrench to turn 90 further 4 Use fixed wrench to turn 90 further Oil seals of camshafts and install valve timing housing when doing so the timing chain must be placed over the valves for camshaft adjustment Secure position of high pressure pump drive sprocket using adjusting tool T10363 The marking A on the drive cam for...

Page 74: ...lling cylinder head cover Special tools and workshop equipment required Sealant D 454 300 A2 Removing All cable ties which were opened or cut during removal must be renewed at the same locations Remove upper part of intake manifold page 181 Note Seal the intake ports in the intake manifold and in the cylinder head with a clean cloth Pull off or disconnect all other electrical wiring from cylinder ...

Page 75: ...anifold page 181 Note Renew cylinder head cover if damaged or leaking Ensure fuel hoses are seated correctly If necessary fill with coolant page 142 Torque settings Bolted connection Torque setting Cylinder head cover to cylinder head 10 Nm 1 4 Assembly overview vacuum pump CC 2012 Passat 2011 Passat Variant 2011 6 cylinder direct injection engine 3 6 l engine 4V Edition 06 2019 1 Cylinder head 69...

Page 76: ... and installing page 70 6 Seal Renew 7 Sealing ring Part of vacuum pump 1 5 Removing and installing vacuum pump Removing Pull cover 1 off air duct releasing clips on sides to do so Unclip air duct 2 CC 2012 Passat 2011 Passat Variant 2011 6 cylinder direct injection engine 3 6 l engine 4V Edition 06 2019 70 Rep gr 15 Cylinder head valve gear ...

Page 77: ...g ring in vacuum pump A for damage If the seal is damaged the vacuum pump must be renewed Turn the rotor in vacuum pump so that the flat sides of input shaft fit into rotor Push vacuum pump steadily as far as it will go into locating bore of cover Tighten the securing bolts arrows and refit the vacuum line A Specified torques page 69 1 6 Checking compression CC 2012 Passat 2011 Passat Variant 2011...

Page 78: ...d rear window heating must be switched off If the vehicle is equipped with an air conditioner it must be switched off On vehicles with automatic gearbox the selector lever must be in P or N position Test sequence Remove fuse for fuel pump control unit J538 from fuse hold er Fuse assignment Current flow diagrams Electrical fault finding and Fitting locations CC 2012 Passat 2011 Passat Variant 2011 ...

Page 79: ...8 to the locking button arrow and carefully pull the plug connector downwards Push puller T10095 A on from flat side of connector in the direction of the arrow and pull out ignition coil with output stage Unscrew spark plugs using spark plug socket and extension 3122 B CC 2012 Passat 2011 Passat Variant 2011 6 cylinder direct injection engine 3 6 l engine 4V Edition 06 2019 1 Cylinder head 73 ...

Page 80: ... to 18 Nm Install ignition coils with output stage page 213 After the test has been completed Connect vehicle diagnostic tester Perform vehicle system test vehicle diagnostic tester Guided Fault Finding Finish the vehicle system test so that any event entries stored during assembly can be cleared automatically Generate readiness code in connection with test drive Note safety precautions applicable...

Page 81: ...er for timing chain Gearbox side Removing and installing page 76 3 Bolt 23 Nm 4 Bolt Tighten in stages and in diagonal sequence 8 Nm 5 Sealing ring Qty 2 For camshaft control valve 1 N205 and ex haust camshaft control valve 1 N318 Renew if leaking or damaged Renewing page 78 6 Bolt 8 Nm 7 Hall sender Hall sender G40 and Hall sender 2 G163 8 O ring Qty 2 Renew 9 Dowel pins Qty 2 10 Upper cover for ...

Page 82: ...ylinder head gasket must be renewed Pull off cover from cylinder block horizontally Press crankshaft oil seal out of lower timing chain cover Installing Specified torques page 78 Caution The lubrication system can be soiled by sealant residue Care fully cover open parts of engine so that no sealant residue can fall into it Remove remaining sealant on the timing chain cover and cyl inder head using...

Page 83: ...le to clean upper sealing surface on cylinder head gasket and cylinder head Clean top and bottom of cylinder head gasket both faces must be free of oil and grease Cut off nozzle on tube at front marking of nozzle approx 2 mm Apply thin coating of sealant to upper and lower sealing sur faces of cylinder head gaskets to do this bend cylinder head gasket downwards very slightly arrows To coat the sur...

Page 84: ...er sealant has been applied Tighten bolts in 3 stages as follows A Pre tighten bolts 1 to 5 Nm B Tighten bolts 2 to 23 Nm C Tighten bolts 1 to 10 Nm Install crankshaft oil seal page 37 Install sump page 125 Install flywheel page 36 Install gearbox Rep gr 34 Removing and installing gear box 2 3 Removing and installing the camshaft control valve seal Special tools and workshop equipment required CC ...

Page 85: ...the cover Installing Do not lubricate seals Install seal with fitting sleeve 3378 in cover 1 and pull in flush using fitting sleeve 3253 6 from assembly tool 3253 2 4 Assembly overview valve timing housing CC 2012 Passat 2011 Passat Variant 2011 6 cylinder direct injection engine 3 6 l engine 4V Edition 06 2019 2 Cover for timing chain 79 ...

Page 86: ...Exhaust camshaft control valve 1 N318 Removing and installing page 112 7 8 Nm turn 180 further Renew Checking valve timing housing strainer for soiling Unclip the strainer 2 from rear of valve timing housing 1 and remove any dirt CC 2012 Passat 2011 Passat Variant 2011 6 cylinder direct injection engine 3 6 l engine 4V Edition 06 2019 80 Rep gr 15 Cylinder head valve gear ...

Page 87: ...alling camshafts page 101 Assembly overview page 79 Before installing valve timing housing check strainer for soiling page 79 2 Sealing ring Renew 3 Oil pump Removing and installing page 127 4 8 Nm Insert with locking fluid D 000 600 A2 5 Chain tensioner 50 Nm For camshaft timing chain Item 10 page 82 Only rotate engine when chain tensioner is instal led 6 Sealing ring Renew if damaged or leaking ...

Page 88: ... chain Item 19 page 82 Only rotate engine when chain tensioner is installed 17 Drive gear Built into crankshaft Ground down tooth aligned with main bearing joint TDC No 1 cylinder Adjusting timing chain for oil pump drive page 87 18 Locating pin without collar 10 Nm For guide rail Item 23 page 82 19 Timing chain Before removing mark direction of rotation installation position page 83 Installing ti...

Page 89: ...Gearbox removed Flywheel removed Sump removed Cover for timing chain removed Cylinder head cover removed Removing Turn engine by vibration damper to adjustment markings Ground tooth of drive sprocket arrow A must align with bear ing joint The marked hole arrow must be in line with the mark on the oil pump Note This position is reached only after every 4th full rotation CC 2012 Passat 2011 Passat V...

Page 90: ...it guide rail A and initially only tighten bolt 2 Note Some of the timing chain links are copper coloured These chain links are to be used as an aid to installation The 3 copper col oured chain links next to each other must be placed on the oil pump sprocket First fit timing chain onto oil pump sprocket Marking must align with middle copper coloured chain link A Fit timing chain onto chain drive s...

Page 91: ...2A into timing chain in such a way that copper coloured chain link is aligned with marking on camshaft adjuster Bolt camshaft adjuster onto camshaft and tighten bolt hand tight Check position of copper coloured chain links to adjustment markings Note The copper coloured chain links no longer align with the adjust ment markings once the crankshaft has been turned CC 2012 Passat 2011 Passat Variant ...

Page 92: ...e order of removal 3 3 Removing and installing chain drive sprocket for high pressure pump Removing Remove high pressure pump page 195 Remove camshaft adjuster for inlet camshaft 1 page 108 Undo and remove bolt 3 for guide rail Remove timing chain from chain drive sprocket Pull out bearing shaft 4 and remove chain drive sprocket 6 Installing Note Coat faces of chain drive sprocket and bearing shaf...

Page 93: ... for high pressure pump must be on top Place timing chain onto chain drive sprocket Ensure that chain runs tautly against guide rail Tighten bolt arrow for guide rail Install camshaft adjuster page 109 Installing high pressure pump page 195 3 4 Removing and installing timing chain and chain drive for oil pump Note Procedure is possible only with gearbox removed CC 2012 Passat 2011 Passat Variant 2...

Page 94: ...10363 Not illustrated Sealant D 176 501 A1 Removing Conditions Gearbox removed Flywheel removed Sump removed Cover for timing chain removed Cylinder head cover removed Removing timing chain for camshaft drive page 83 CC 2012 Passat 2011 Passat Variant 2011 6 cylinder direct injection engine 3 6 l engine 4V Edition 06 2019 88 Rep gr 15 Cylinder head valve gear ...

Page 95: ...ve sprockets together with timing chain from oil pump Installing Set crankshaft to TDC position Ground tooth of drive sprocket arrow must align with bearing joint Now turn oil pump shaft 1 with flat side arrow horizontal to mark 2 on oil pump Insert timing chain into guide rail and place on crankshaft CC 2012 Passat 2011 Passat Variant 2011 6 cylinder direct injection engine 3 6 l engine 4V Editio...

Page 96: ... already been used note marking for direc tion of rotation page 83 Install tensioner for timing chain arrows Specified torque Item 15 page 82 Remove Allan key A Check setting markings Ground tooth of drive sprocket arrow A must align with bear ing joint The marked hole arrow must be in line with the mark on the oil pump CC 2012 Passat 2011 Passat Variant 2011 6 cylinder direct injection engine 3 6...

Page 97: ...p equipment required Camshaft bar T10068 A Test sequence Remove noise insulation General body repairs exterior Rep gr 66 Noise insulation Assembly overview noise in sulation Remove upper part of intake manifold page 181 Remove cylinder head cover page 68 Position crankshaft in engine direction of rotation to TDC No 1 cylinder marking CC 2012 Passat 2011 Passat Variant 2011 6 cylinder direct inject...

Page 98: ...A using an open end spanner arrows Check adjustment markings of camshaft adjusters against mark ings on valve timing housing Arrows on camshaft adjusters must align with right notches on timing housing Markings on timing housing page 93 Note A slight offset between marking 32A and notch is permissi ble Position of copper coloured chain links can be disregarded CC 2012 Passat 2011 Passat Variant 20...

Page 99: ...Install upper part of intake manifold page 181 Markings on timing housing on FSI engines A View from flywheel end B View from vibration damper end The markings on camshaft adjusters must align with notches arrows 3 6 Adjusting valve timing Note Procedure is possible only with gearbox removed CC 2012 Passat 2011 Passat Variant 2011 6 cylinder direct injection engine 3 6 l engine 4V Edition 06 2019 ...

Page 100: ...ol T10363 Not illustrated Sealant D 176 501 A1 Conditions Gearbox removed Flywheel removed Sump removed Cover for timing chain removed Cylinder head cover removed Removing timing chain for camshaft drive page 83 CC 2012 Passat 2011 Passat Variant 2011 6 cylinder direct injection engine 3 6 l engine 4V Edition 06 2019 94 Rep gr 15 Cylinder head valve gear ...

Page 101: ...ve sprockets together with timing chain from oil pump Installing Set crankshaft to TDC position Ground tooth of drive sprocket arrow must align with bearing joint Now turn oil pump shaft 1 with flat side arrow horizontal to mark 2 on oil pump Insert timing chain into guide rail and place on crankshaft CC 2012 Passat 2011 Passat Variant 2011 6 cylinder direct injection engine 3 6 l engine 4V Editio...

Page 102: ... already been used note marking for direc tion of rotation page 83 Install tensioner for timing chain arrows Specified torque Item 15 page 82 Remove Allan key A Check setting markings Ground tooth of drive sprocket arrow A must align with bear ing joint The marked hole arrow must be in line with the mark on the oil pump CC 2012 Passat 2011 Passat Variant 2011 6 cylinder direct injection engine 3 6...

Page 103: ...age 82 To do this counterhold vibration damper using counterhold T10172 Note New sprocket bolt Install timing chain for camshaft drive page 84 CC 2012 Passat 2011 Passat Variant 2011 6 cylinder direct injection engine 3 6 l engine 4V Edition 06 2019 3 Chain drive 97 ...

Page 104: ... page 104 Installation sequence page 104 Removing and installing camshaft 3 Exhaust camshaft Check radial clearance with Plastigage wear limit 0 1 mm Runout max 0 01 mm Checking axial clear ance page 100 Identification page 100 Removing and installing page 101 4 5 Nm 1 8 turn 45 further 5 Sealing ring Renew if leaking When installing timing housing lubricate con tact surfaces of seals When replaci...

Page 105: ...sure pump With inner splines Bearing shaft fits in only one position 13 Bearing shaft Bearing shaft fits in only one position Coat bearing shaft with grease G 052 723 A2 Vacuum pump drive shaft 14 Valves Exhaust valve with sodium filling Do not rework only lapping in is permitted Valve dimensions page 121 15 Dowel sleeve 16 Cylinder head Check for distortion page 60 Removing and installing page 60...

Page 106: ...otters Camshaft identification Identification between cam pair for cylinders 4 and 5 of respective camshaft Camshaft Identification A exhaust camshaft 03H 101 index B inlet camshaft 03H 102 index 4 2 Measuring axial play of camshaft Special tools and workshop equipment required Universal dial gauge holder VW 387 Dial gauge Test sequence Perform measurements with support elements and roller rocker ...

Page 107: ...rkshop equipment required Torque wrench V A G 1331 Torque wrench V A G 1332 Camshaft bar T10068 A Adjusting tool T10363 Counterhold T10172 with pins T10172 1 CC 2012 Passat 2011 Passat Variant 2011 6 cylinder direct injection engine 3 6 l engine 4V Edition 06 2019 4 Valve gear 101 ...

Page 108: ...bearing caps 5 and 9 alternately and diagonally B Exhaust camshaft First remove bearing caps 2 and 14 Remove bearing caps 4 and 12 Remove bearing cap 8 Loosen bearing caps 6 and 10 alternately and diagonally Continuation for both camshafts Carefully remove camshafts and lay aside on clean surface Remove roller rocker fingers together with supporting ele ments and place them on a clean surface Ensu...

Page 109: ...e roller rocker finger onto respective valve stem end or support ing element Ensure that all roller rocker fingers contact valve stem ends 1 correctly and that they are clipped into their respective support elements 2 Oil running surfaces of camshafts Carefully place camshaft into the corresponding camshaft bearing of the cylinder head Take note of camshaft marking page 100 Note installation posit...

Page 110: ...to 5 Nm 1 8 turn 45 further Install bearing caps 2 and 14 and tighten to 5 Nm 1 8 45 turn further Install bearing cap 8 and tighten to 5 Nm 1 8 45 turn fur ther Install bearing caps 4 and 12 tighten to 5 Nm 1 8 45 turn further Continuation for both camshafts Insert camshaft bar T10068 A in both shaft grooves Before installing check valve timing housing strainer for con tamination page 80 Before in...

Page 111: ...rface of cover Install cover start all securing bolts arrows and tighten light ly Then tighten all securing bolts Specified torque page 58 Install vacuum pump page 70 Install cylinder head cover page 68 Install upper part of intake manifold page 181 Further assembly is basically a reverse of the dismantling se quence 4 4 Removing and installing camshaft adjuster CC 2012 Passat 2011 Passat Variant ...

Page 112: ...rque wrench V A G 1332 Adjusting tool T10363 Not illustrated Sealant D 176 501 A1 Removing camshaft adjuster Remove upper part of intake manifold page 181 Remove cylinder head cover page 68 CC 2012 Passat 2011 Passat Variant 2011 6 cylinder direct injection engine 3 6 l engine 4V Edition 06 2019 106 Rep gr 15 Cylinder head valve gear ...

Page 113: ...lts for the cover arrows and remove the cover Remove noise insulation General body repairs exterior Rep gr 66 Noise insulation Assembly overview noise in sulation Turn crankshaft in direction of engine rotation to TDC No 1 cylinder marking from below using counterhold T10172 Cams A of cylinder 1 must face each other CC 2012 Passat 2011 Passat Variant 2011 6 cylinder direct injection engine 3 6 l e...

Page 114: ... slightly with an open end spanner Secure position of high pressure pump chain drive sprocket using adjusting tool T10363 The marking A on the drive cam for high pressure pump must be on top Note If the journal for vacuum pump drive is not vertical remove the camshaft bar T10068 A Turn the crankshaft further in the di rection of rotation until the journal is vertical and the camshaft bar T10068 A ...

Page 115: ...lling camshaft adjuster Condition Crankshaft is at TDC position Chain drive sprocket for high pressure pump is fixed in place with adjusting tool T10363 Camshafts have been fixed in place with camshaft bar T10068 A First install camshaft adjuster for inlet camshaft as follows Note Due to a fitted key camshaft adjusters can only be bolted on in one position arrows at camshaft mounting Put on inlet ...

Page 116: ...mshaft adjuster 32A into camshaft tim ing chain Previously counted 16 rollers must lie between teeth at arrow markings 24E and 32A Connect camshaft adjuster 32A with camshaft timing chain onto exhaust camshaft Observe the following The arrow 1 on camshaft adjuster 32A must align with right notch 2 of timing housing Markings on timing housing page 93 Note It must be possible to easily position the ...

Page 117: ...nner arrow Note Camshaft bar T10068 A must be removed while this is done Note that all the securing bolts for the sprockets must be re newed Tighten securing bolts of inlet and exhaust camshaft adjusters to 60 Nm 1 4 turn 90 further Clean sealing surfaces for rear cover Coat sealing surface with sealant D 176 501 A1 CC 2012 Passat 2011 Passat Variant 2011 6 cylinder direct injection engine 3 6 l e...

Page 118: ...ing and installing camshaft control valve Special tools and workshop equipment required Torque wrench V A G 1783 TORX bit set V A G 1766 Ratchet insert 1 4 VAS 6234 Torx screwdriver T10072 Not illustrated CC 2012 Passat 2011 Passat Variant 2011 6 cylinder direct injection engine 3 6 l engine 4V Edition 06 2019 112 Rep gr 15 Cylinder head valve gear ...

Page 119: ...oving connectors mark each connector and compo nent to which it belongs Detach following connectors 1 Hall sender G40 2 Valve 1 for N205 3 Hall sender 2 G163 4 Exhaust camshaft control valve 1 N318 Lay wiring harness to side Unscrew coolant pipes from cover Remove vacuum pump page 70 Unscrew the three cylinder head cover bolts arrows Unscrew coolant hoses at top and bottom of cover CC 2012 Passat ...

Page 120: ... timing housing must be free of dirt and soiling Ensure the camshaft control valves are protected from knocks and impacts Only unpack the new camshaft control valves immediately prior to installation The camshaft control valves must not be pulled into their seat with the securing bolts Only insertion by hand is per mitted Moisten oil seal with clean engine oil Carefully insert camshaft adjustment ...

Page 121: ...ked Note Sealant D 176 501 A1 hardens quickly Slide cover slightly diagonally onto camshaft adjustment valves Ensure that cylinder head cover gasket is not pushed back 1 Push cover upwards under gasket for cylinder head cover 2 Push cover against cylinder head onto dowel pins Check that gasket arrows is correctly seated It must not have been pushed back CC 2012 Passat 2011 Passat Variant 2011 6 cy...

Page 122: ...rows of cylinder head cover to specified torque Specified torque Item 5 page 58 Install vacuum pump page 70 Further assembly is basically a reverse of the dismantling se quence 4 6 Removing and installing valve stem seals CC 2012 Passat 2011 Passat Variant 2011 6 cylinder direct injection engine 3 6 l engine 4V Edition 06 2019 116 Rep gr 15 Cylinder head valve gear ...

Page 123: ... assembly device 2036 with adapter plates 2036 1 Spark plug socket 3122 B Valve stem seal puller 3364 Valve stem seal fitting tool 3365 Adapter T40012 1 Torque wrench V A G 1331 CC 2012 Passat 2011 Passat Variant 2011 6 cylinder direct injection engine 3 6 l engine 4V Edition 06 2019 4 Valve gear 117 ...

Page 124: ...rk plug thread connect to compressed air line with commercially available adapter and apply constant pressure At least 6 bar Remove valve springs using valve lever VW 541 1 A and press tool VW 541 6 Note Tight valve cotters can be loosened by tapping lightly on assem bly lever Pull off valve stem seals using valve stem seal puller 3364 Installing To prevent damage to new valve stem seals place pla...

Page 125: ...cial tools and workshop equipment required Depth gauge Valve seat refacing tool Procedure Note When repairing engines with leaking valves it is not sufficient to rework or renew valve seats and valves Particularly on high mileage engines it is necessary also to check valve guides for wear page 119 Valve seats are only to be reworked to the extent required to yield a proper surface appearance Befor...

Page 126: ...ust valve mm 31 8 Long exhaust valve mm 10 2 Measured distance minus minimum dimension max permissi ble reworking dimension Example Measured distance 10 6 mm Minimum dimension 10 2 mm Max permissible reworking dimension 0 4 mm Reworking inlet valve seat a 32 8 mm diameter b max permissible reworking dimension 1 c 0 9 to 1 5 mm d max 38 0 mm r2 radius 2 0 mm Z bottom surface of cylinder head α 45 v...

Page 127: ...e dimensions Valve dimensions Note Do not rework valves Only lapping in is permitted Valve dimensions for inlet valves Dimension Short inlet valve Long inlet valve a mm 33 20 33 20 b mm 5 98 5 98 c mm 102 46 136 36 α 44 40 44 40 Valve dimensions for exhaust valves Dimension Short exhaust valve Long exhaust valve a mm 30 20 30 20 b mm 5 97 5 97 c mm 102 20 136 20 α 44 40 44 40 CC 2012 Passat 2011 P...

Page 128: ...e repair this may indicate that the crank shaft bearings or conrod bearings are damaged To avoid any subsequent damage the following work must be carried out following the repair Thoroughly clean oil channels Renew oil spray jets Renew engine oil cooler Renewing oil filter The oil level must not be above the max marking on the dip stick danger of damage to the catalytic converter Markings page 131...

Page 129: ...nstalling page 105 Install camshaft adjust er with timing chain for camshaft drive page 105 7 Bolt 60 Nm 1 4 turn 90 further Renew 8 Bolt 8 Nm Install with locking fluid 9 Sealing ring Renew Lubricate before assembling 10 Oil spray jet For crankshaft bearings 2 to 7 For piston cooling Opening pressure 2 0 bar Removing and installing page 124 11 Sealing ring Renew if damaged Lubricate before assemb...

Page 130: ...ult finding and Fitting locations 20 Bolt 10 Nm 21 Securing bolts for oil sump 12 Nm 22 Bolt 10 Nm 23 Oil filter housing With engine oil cooler Assembly overview page 133 24 Bolt 23 Nm 25 Oil pressure switch Checking page 135 26 Sealing ring Renew Lubricate before assembling 27 Sealing ring Renew Lubricate before assembling 1 2 Removing and installing oil spray jet Special tools and workshop equip...

Page 131: ...ing a 6 mm punch 1 3 Removing and installing sump Special tools and workshop equipment required Torque wrench V A G 1331 Socket XZN 8 T40159 Not illustrated Used oil collector and extractor V A G 1782 Sealant D 176 501 A1 Hand drill with plastic brush Scraper Safety glasses CC 2012 Passat 2011 Passat Variant 2011 6 cylinder direct injection engine 3 6 l engine 4V Edition 06 2019 1 Sump oil pump 12...

Page 132: ...essible Remove sump bolts on the gearbox side arrows using bit XZN 8 T40159 Remove remaining sump bolts and remove sump Loosen sump with light blows of a rubber headed hammer if necessary Remove sealant residues from cylinder block with a flat scra per Remove sealant residues on sump with a rotating brush e g an electric drill with plastic brush attachment wear eye pro tection Clean sealing surfac...

Page 133: ...lts slightly Tighten sump bolts to 11 Nm Tighten bolts securing sump to gearbox to 45 Nm Note Let sealing compound dry for approx 30 minutes after installing oil sump Only then fill with engine oil Further assembly is basically a reverse of the dismantling se quence 1 4 Removing and installing oil pump Note To remove the oil pump the gearbox must be removed Procedure Remove gearbox Remove flywheel...

Page 134: ...osition of timing chains to sprockets of oil pump using a permanent marker Remove chain tensioner for camshaft timing chain arrow Fix chain tensioner spring using 3 mm Allan key A Remove chain tensioner for oil pump drive chain arrows Unscrew securing bolt for sprockets completely and remove sprockets with timing chains from oil pump CC 2012 Passat 2011 Passat Variant 2011 6 cylinder direct inject...

Page 135: ...rt securing bolts for oil pump with locking fluid Install oil pump coat securing bolts arrows with locking agent then tighten bolts Specified torque Item 8 page 123 Set crankshaft to TDC position Ground tooth of drive sprocket arrow must align with bearing joint CC 2012 Passat 2011 Passat Variant 2011 6 cylinder direct injection engine 3 6 l engine 4V Edition 06 2019 1 Sump oil pump 129 ...

Page 136: ...t be in line with the mark on the oil pump If sprocket cannot be fitted turn oil pump shaft slightly Carefully pull sprocket off oil pump and swing upwards a little In this position fit the camshaft timing chain The marking made during removal must align Fit sprocket onto oil pump shaft again and tighten hand tight CC 2012 Passat 2011 Passat Variant 2011 6 cylinder direct injection engine 3 6 l en...

Page 137: ... Nm 1 4 turn 90 further To do this counterhold vibration damper using counterhold T10172 Install timing chain cover page 76 Further assembly is carried out in the reverse order of removal 1 5 Engine oil Oil capacities Without oil filter 5 0 l With oil filter 5 5 l Engine oil specifications Maintenance Booklet Service tables Checking engine oil level Test conditions Engine oil temperature min 60 C ...

Page 138: ...stick again and read oil level Markings on oil dipstick 1 Max mark 2 Min mark a Area above hatched field up to max mark Do not top up with engine oil b Oil level within hatched field engine oil can be topped up c Area from min mark up to hatched field top up max 0 5 l of engine oil CC 2012 Passat 2011 Passat Variant 2011 6 cylinder direct injection engine 3 6 l engine 4V Edition 06 2019 132 Rep gr...

Page 139: ... the crank shaft bearings or conrod bearings are damaged To avoid any subsequent damage the following work must be carried out following the repair Thoroughly clean oil channels Renew oil spray jets Renew engine oil cooler Renewing oil filter The oil level must not be above the max marking on the dip stick danger of damage to the catalytic converter Markings page 131 Checking engine oil level CC 2...

Page 140: ...ant hose Ensure firm seating Connection diagram for coolant hoses page 138 8 Coolant hose Ensure firm seating Connection diagram for coolant hoses page 138 9 Hose clamp 10 Bolt 23 Nm 11 Oil pressure switch F1 20 Nm 0 9 bar switch If seal is leaking nip open and renew Checking page 135 12 Oil drain plug 10 Nm 13 O ring Renew Lubricate before assembling 14 Threaded cover 25 Nm 15 O ring Renew Lubric...

Page 141: ...il pressure and oil pressure switch Special tools and workshop equipment required Oil pressure tester V A G 1342 Adapter V A G 1342 14 Voltage tester V A G 1527 B Adapter set V A G 1594C CC 2012 Passat 2011 Passat Variant 2011 6 cylinder direct injection engine 3 6 l engine 4V Edition 06 2019 2 Oil filter oil pressure switch 135 ...

Page 142: ...on Checking oil pressure switch Remove noise insulation General body repairs exterior Rep gr 66 Noise insulation Assembly overview noise in sulation Remove oil pressure switch F1 and screw into tester Screw tester into oil filter bracket in place of oil pressure switch Note Note the installation position of the adapter the conical union of the adapter must be screwed to the pressure hose of the te...

Page 143: ... 0 5 5 bar Over 2 000 rpm maximum 7 0 bar If the specifications are not attained Check strainer in oil suction pipe Item 12 page 123 for dirt Check control piston of oil pressure safety valve in oil pump for dirt Check oil pipe at bottom of cylinder block Item 14 page 124 for leaks Note Mechanical damage e g to bearings could also be the cause for oil pressure being too low The oil pressure safety...

Page 144: ... Rep gr 82 coolant circuit Secure all hose connections with the correct type of hose clips same as original equipment Electronic parts catalogue Hose clip pliers VAS 6340 or hose clip pliers VAS 6362 are recommended for installation of spring type clips The arrow markings on coolant pipes and on ends of hoses must align when installing CC 2012 Passat 2011 Passat Variant 2011 6 cylinder direct inje...

Page 145: ...t hose 8 Lower coolant hose 9 Radiator cooler 10 Lower side coolant pipe 11 Non return valve Observe installation po sition Arrow on non return valve points in direction of flow 12 Engine oil cooler 13 Continued coolant circula tion pump V51 14 Coolant pipe With thermostat hous ing 15 Coolant pump 16 Thermostat 17 Cylinder block 18 Rear coolant pipe CC 2012 Passat 2011 Passat Variant 2011 6 cylind...

Page 146: ... 1274 8 Adapter for cooling system tester V A G 1274 9 Cooling system tester V A G 1274 B Note To perform the leakage test correctly first run a self test on the cooling system tester V A G 1274 B CC 2012 Passat 2011 Passat Variant 2011 6 cylinder direct injection engine 3 6 l engine 4V Edition 06 2019 140 Rep gr 19 Cooling ...

Page 147: ... system tester V A G 1274 B is leaking and should not be used Checking cooling system for leaks Engine at operating temperature WARNING The cooling system is under pressure when the engine is hot Danger of scalding due to steam and hot coolant Cover filler cap on expansion tank with a cloth and open care fully to release pressure Open cap 1 on coolant expansion tank CC 2012 Passat 2011 Passat Vari...

Page 148: ...ling system tester V A G 1274 B is disconnected from the connecting hose or the connector V A G 1274 B 1 it is essential that the pressure is relieved To do this press pressure relief valve on cooling system tester V A G 1274 B until pressure gauge displays value of 0 Check pressure relief valve in cap Fit cooling system tester V A G 1274 B with adapter V A G 1274 9 onto coolant filler cap Build u...

Page 149: ... when the engine is hot Danger of scalding due to steam and hot coolant Cover filler cap on expansion tank with a cloth and open care fully to release pressure Carefully open filler cap on coolant expansion tank Remove noise insulation General body repairs exterior Rep gr 66 Noise insulation Assembly overview noise in sulation CC 2012 Passat 2011 Passat Variant 2011 6 cylinder direct injection eng...

Page 150: ...d allow remaining coolant to drain out Note Follow disposal regulations for coolant Filling with coolant Caution Only distilled water may be used for mixing coolant additives The use of distilled water ensures optimum protection against corrosion CC 2012 Passat 2011 Passat Variant 2011 6 cylinder direct injection engine 3 6 l engine 4V Edition 06 2019 144 Rep gr 19 Cooling ...

Page 151: ...alibrated for the coolant additives G12 and G12evo The scale 2 of the refractometer is calibrated for the coolant additive G13 If it is not possible to ensure that the same type of coolant additive is filled always determine anti freeze protection using the scale for G13 Frost protection must be guaranteed down to 25 C as a min imum and in countries with arctic conditions down to approx 36 C Incre...

Page 152: ...6096 WARNING The cooling system is under pressure when the engine is hot Danger of scalding due to steam and hot coolant Cover filler cap on expansion tank with a cloth and open care fully to release pressure Check coolant level and top up as needed When engine is at normal operating temperature the coolant level must be at the upper mark when engine is cold in the middle of the shaded field Insta...

Page 153: ...Hose connections are secured with spring type clips In case of repair only use spring type clips Hose clip pliers VAS 6340 or hose clip pliers VAS 6362 are recommended for installation of spring type clips When installing coolant hoses position them so they are free of stress and do not come into contact with other components The arrows on the coolant pipes and on the ends of the hoses must be ali...

Page 154: ...If installed 17 To additional cooler If installed 18 From bottom of radiator 19 Non return valve Observe installation position Arrow on non return valve points in direction of flow 20 Lower side coolant pipe 21 25 Nm 22 To gear oil cooler If installed 23 Continued coolant circulation pump V51 Removing and installing page 153 24 8 Nm 25 Thermostat Checking page 153 Removing and installing page 152 ...

Page 155: ... 32 Seal Renew 33 Union 34 10 Nm 35 From bottom of expansion tank 2 2 Removing and installing coolant pump Special tools and workshop equipment required Support bracket 10 222 A with rack 10 222 A 1 CC 2012 Passat 2011 Passat Variant 2011 6 cylinder direct injection engine 3 6 l engine 4V Edition 06 2019 2 Coolant pump regulation of cooling system 149 ...

Page 156: ...n Assembly overview noise in sulation Unbolt bracket for exhaust system arrows Remove pendulum support Drain coolant page 142 Remove poly V belt page 31 Caution The racks 10 222 A 1 must not be placed on the bolted on sheet metal of the wings These may otherwise be damaged Tighten shackle 10 222 A 12 on right lifting eye Fit support bracket 10 222 A with rack 10 222 A 1 as shown and take up weight...

Page 157: ...tudinal member right side The side surface of the engine support 2 should be located parallel to the support arm 1 Tighten new bolts for engine assembly mounting and engine bracket Specified torque page 21 Install pendulum support Install poly V belt page 31 Add coolant page 142 Install front right wheel housing liner General body repairs exterior Rep gr 66 Wheel housing liner Removing and install...

Page 158: ...t page 142 Unscrew bolts arrows and remove coolant connection with coolant hose Remove thermostat from coolant pipe Installing Note There should be a metal sleeve arrow in the coolant connection If this is missing the coolant connection must be replaced Clean sealing surface for O ring Insert thermostat into coolant pipe CC 2012 Passat 2011 Passat Variant 2011 6 cylinder direct injection engine 3 ...

Page 159: ...er Selection of functions and components Remove thermostat page 152 Heat thermostat in water Starts to open at 80 C Opening at 94 C 9 mm 2 5 Removing and installing continued cool ant circulation pump V51 Location of continued coolant circulation pump V51 The continued coolant circulation pump V51 is secured to an cillary unit bracket arrow To remove ancillary bracket must be removed from cylinder...

Page 160: ... and installing page 155 After renewing renew entire coolant 4 Seal 5 Cap Check using cooling system tester V A G 1274 and adapter for cooling system tester V A G 1274 9 Pressure relief valve must open at between 1 4 and 1 6 bar 6 Connector 7 5 Nm 8 Expansion tank Check cooling system for leaks using cooling system tester V A G 1274 and adapter for cooling system tester V A G 1274 8 9 Holder For r...

Page 161: ...age 157 18 Lower coolant hose To connection for thermostat 19 Retaining clip 20 Radiator outlet coolant temperature sender G83 21 O ring Renew 3 2 Removing and installing radiator Special tools and workshop equipment required Adapter for cooling system tester V A G 1274 8 CC 2012 Passat 2011 Passat Variant 2011 6 cylinder direct injection engine 3 6 l engine 4V Edition 06 2019 3 Radiator radiator ...

Page 162: ...emoving and installing bumper cover Remove radiator cowl with fans page 157 Drain coolant page 142 Pull all coolant hoses off radiator Note For illustration purposes the air deflector elements are not shown Unscrew bolts 1 from radiator mounting Swing radiator and condenser back slightly and lift out of lower supports When doing this pull lock carrier on left support 1 down slightly CC 2012 Passat...

Page 163: ... Insert radiator and condenser into lower supports Swing radiator and condenser forwards and tighten radiator mounting 1 Perform further installation in reverse order paying attention to the following If a new radiator is fitted the old coolant must not be reused Add coolant page 142 Bolted connection Torque setting Condenser to radiator 5 Nm Radiator cowl to radiator 5 Nm Radiator mounting to loc...

Page 164: ... noise in sulation Unclip coolant hose from the radiator cowl Disconnect connector 1 and unscrew lower securing bolts for radiator cowl arrows Remove radiator cowl together with fans downwards Installing Install in reverse order of removal observing the following Bolted connection Torque setting Radiator cowl to radiator 5 Nm CC 2012 Passat 2011 Passat Variant 2011 6 cylinder direct injection engi...

Page 165: ... electrical wiring clear Unscrew nuts arrows and remove radiator fans Installing Install in reverse order Bolted connection Torque setting Radiator fan to radiator cowl 10 Nm CC 2012 Passat 2011 Passat Variant 2011 6 cylinder direct injection engine 3 6 l engine 4V Edition 06 2019 3 Radiator radiator fan 159 ...

Page 166: ...oolant tem perature sender G83 8 Fuel pressure regulating valve N276 in the high pressure pump 9 Fuel pressure sender G247 in the fuel rail for Cylin ders 2 4 and 6 Checking page 186 10 Engine speed sender G28 Removing and installing page 215 11 Knock sensor 2 G66 Fitting location be tween cylinder 4 and cylinder 6 12 Oil pressure switch F1 0 9 bar switch Checking page 135 13 Continued coolant cir...

Page 167: ...d installing page 112 4 Exhaust camshaft control valve 1 N318 Removing and installing page 112 5 Hall sender 2 G163 For exhaust camshaft 6 Heater element for crank case breather N79 in the connection noz zles for crankcase breather 7 Throttle valve module J338 with throttle valve drive G186 angle sensor 1 for throttle valve drive G187 and angle sensor 2 for throttle valve drive G188 Removing and i...

Page 168: ...g installation work 3 1 Safety precautions during work on fuel system page 4 Observe rules for cleanliness 4 1 Rules for cleanliness page 6 WARNING If the battery is not disconnected the fuel pump fuse must be removed The fuel pump may otherwise be activated by the driver door contact switch Fuse assignment Cur rent flow diagrams Electrical fault finding and Fitting lo cations The fuel pressure in...

Page 169: ... 166 The long No 1 3 and 5 cylinder injectors must not be separated 10 Fuel low pressure hose Between high pressure pump and fuel rail Always renew fuel hose because when pulling off it will be damaged by the corrugated pipe connection 11 Spring type clip 12 Fuel high pressure pipe 28 Nm Make sure that fuel pipe does not touch other components To install first tighten union nuts hand tight Loosen ...

Page 170: ...at high pressure pump to 40 Nm 17 Union To loosen and tighten union nut counterhold with a wrench on connection Before installing high pressure pipe first tighten connection to 40 Nm 18 Fuel distributor For cylinders 2 4 and 6 If the fuel rail is removed the injector O ring support washer spring element and combustion chamber seal must always be renewed page 170 Tighten evenly from inside to outsi...

Page 171: ...g mois ten lightly with clean en gine oil 2 Support washer Renewing page 170 3 Spring element Renew Ensure firm seating 4 Sealing ring Renew Before installing mois ten lightly with clean en gine oil 5 Combustion chamber seal Renewing page 170 6 Injection valve Removing and installing page 166 Assembly overview injectors for cylinders 2 4 and 6 CC 2012 Passat 2011 Passat Variant 2011 6 cylinder dir...

Page 172: ... combustion chamber seal must always be renewed page 170 Vehicles from June 2013 onwards After installing the injec tors the adaption values must be deleted Vehicle diagnostic tester Guided Functions Delete injector s adaption values Note safety precautions before starting installation work 3 1 Safety precautions during work on fuel system page 4 Observe rules for cleanliness 4 1 Rules for cleanli...

Page 173: ...ith fuel rail page 178 Injectors for cylinders 2 4 and 6 Removing fuel rail page 178 Continuation for all cylinders Manually press the O ring upwards as shown and remove it from the injector Bolt hammer T10133 3 and puller T10133 15 to each oth er CC 2012 Passat 2011 Passat Variant 2011 6 cylinder direct injection engine 3 6 l engine 4V Edition 06 2019 2 Injectors 167 ...

Page 174: ...he spring element arrow must not be pulled off before the in jector is pulled out Tap injector carefully to remove it CC 2012 Passat 2011 Passat Variant 2011 6 cylinder direct injection engine 3 6 l engine 4V Edition 06 2019 168 Rep gr 24 Mixture preparation injection ...

Page 175: ...ot be pulled into their seat with the fuel rail bolts Otherwise the spring element will be damaged Ensure injectors are correctly seated and positioned in cylin der head Injectors for cylinders 1 3 and 5 Install lower part of intake manifold with fuel rail page 178 Injectors for cylinders 2 4 and 6 Installing fuel rail page 178 Continuation for all cylinders Check spring elements they must not be ...

Page 176: ...flon Remove upper part of intake manifold page 181 Remove injectors page 166 Clean injector carefully Carefully cut oil seal open with a knife arrow as shown Avoid contact between knife blade and valve body under all circum stances Remove old seal and clean seal groove in area of seal arrow Remove any deposits coking with a brass wire brush CC 2012 Passat 2011 Passat Variant 2011 6 cylinder direct...

Page 177: ...the injec tor from front Slide the seal with assembly sleeve T10133 6 further onto the injector The seal is not yet seated in its groove Remove assembly sleeve T10133 6 and assembly cone T10133 5 Push seal into annular groove by hand Fit spacer sleeve T10133 11 onto valve body Now push calibration sleeve T10133 7 over seal as far as it will go until it is touching the spacer sleeve T10133 11 Pull ...

Page 178: ...embly cone T10133 13 and push the latter onto the injector as shown Slide support washer 1 into first groove arrow on injector using calibration sleeve T10133 14 knurled side faces to wards injector Turn the calibrating sleeve T10133 14 round knurled side no longer faces towards injector Slide calibration sleeve over support washer 1 in direction of arrow as far as it will go onto retaining plate ...

Page 179: ...asher 2 Note The combustion chamber seal Teflon arrow must not be oiled to install the injector Also renew the seal Item 3 page 165 with the injectors for cylinders 1 3 and 5 Installing injectors CC 2012 Passat 2011 Passat Variant 2011 6 cylinder direct injection engine 3 6 l engine 4V Edition 06 2019 2 Injectors 173 ...

Page 180: ...tle valve module J338 4 Filter element 5 Air mass meter G70 6 Sealing ring Renew if damaged 7 Air filter upper part 8 Bolt 2 Nm 9 Connection Clipped into upper part of air filter 10 8 Nm 11 Cover 12 Air duct Secured to lock carrier 13 Bolt 5 Nm 14 Seal Renew if damaged 15 Rubber mounting 16 Bolt 10 Nm 17 Holder For air filter 18 Connection Not fitted in all vehicles For hot air intake 19 Air filte...

Page 181: ...ntake air preheating Special tools and workshop equipment required Chilling spray commercially available Note Only installed on vehicles for cold climate zones Checking regulating flap Remove air filter upper section and filter insert page 174 Check position of control flap 1 Spray thermocouple arrow with cold spray At above 14 C the regulating flap must have completely closed the hot air connecti...

Page 182: ...erview intake manifold Note If an injector is removed the injector O ring support washer spring element and combustion chamber seal must always be renewed page 170 Note safety precautions before starting installation work 3 1 Safety precautions during work on fuel system page 4 Observe rules for cleanliness 4 1 Rules for cleanliness page 6 CC 2012 Passat 2011 Passat Variant 2011 6 cylinder direct ...

Page 183: ...le valve drive electric throttle opera tion G188 If renewed adapt engine control unit to throttle valve module Vehicle diagnostic tester Guided Func tions Removing and installing page 184 11 Sealing ring Renew 12 Bolt 3 5 Nm 13 Connection For crankcase ventilation With heater element for crankcase breather N79 From cylinder head cover 14 Sealing ring Renew 15 Front intake manifold support 16 Seal ...

Page 184: ...ew page 162 20 Bolt 30 Nm 90 1 4 turn further Renew Tighten fuel rails evenly from inside to outside 21 Bolt 8 Nm 22 Seal Renew if damaged Before installing lightly moisten with clean engine oil and insert into upper part of intake manifold 4 2 Removing and installing lower part of in take manifold with fuel rail Special tools and workshop equipment required Torque wrench V A G 1331 Assembly tool ...

Page 185: ...icularly in the engine compartment due to the restricted space Route lines of any kind and cables so that original routing is restored Ensure that there is sufficient clearance to all moving or hot components Disconnect earth strap at battery with ignition switched off Electrical system Rep gr 27 Battery Disconnecting and connecting battery Remove noise insulation General body repairs exterior Rep...

Page 186: ...washer spring element and combustion chamber seal page 170 Lightly moisten O rings between injector and fuel rail with clean engine oil Fit lower part of intake manifold with a new gasket Set fuel rail and evenly press onto injectors Caution The injectors must not be pulled into their seat with the fuel rail bolts Otherwise the spring element will be damaged Fit all intake manifold and fuel rail s...

Page 187: ... Intake manifold lower part to cylinder head 8 Nm Fuel rail to cylinder head 4 30 Nm 90 1 4 turn further High pressure pump to cylinder head 10 Nm Union nuts for high pressure fuel line 28 Nm Union nuts for fuel rail connect ing line 28 Nm 4 Renew 4 3 Removing and installing intake manifold upper part Special tools and workshop equipment required Torque wrench V A G 1331 Assembly tool T10118 CC 20...

Page 188: ...k particularly in the engine compartment due to the restricted space Route lines of any kind and cables so that original routing is restored Ensure that there is sufficient clearance to all moving or hot components Unclip cover rail for ignition cable harness arrows and re move forwards from retaining lugs A Position assembly tool T10118 on locking button arrow and carefully pull off all connector...

Page 189: ...manifold Unscrew securing bolt for rear intake manifold support 1 Unscrew securing bolts for front of intake manifold support 2 Unscrew securing bolts from the intake manifold upper and lower parts Remove upper part of intake manifold and place on suitable surface Note Block off intake ports in lower part of cylinder head with a clean cloth CC 2012 Passat 2011 Passat Variant 2011 6 cylinder direct...

Page 190: ...ake manifold First tighten securing bolts for upper part of intake manifold lower part evenly from inside out 1 5 Specified torque 10 Nm Then tighten the intake manifold support securing bolts Further assembly is basically a reverse of the dismantling se quence Specified torques page 176 4 4 Removing and installing throttle valve module J338 Removing Open hose clamps arrow and remove breather pipe...

Page 191: ...ing the following Specified torques page 176 Make sure that gasket is correctly seated in intake manifold If throttle valve module J338 is renewed adapt engine con trol unit to throttle valve module J338 Vehicle diagnostic tester Guided Functions CC 2012 Passat 2011 Passat Variant 2011 6 cylinder direct injection engine 3 6 l engine 4V Edition 06 2019 4 Intake manifold 185 ...

Page 192: ...l tools and workshop equipment required Assembly tool T10118 Open ring spanner with 3 8 drive width across flats 27 mm flared spanner Pressure sensor tester VAS 6394 1 Adapter VAS 6394 3 Test adapter VAS 5570 Vehicle diagnostic tester CC 2012 Passat 2011 Passat Variant 2011 6 cylinder direct injection engine 3 6 l engine 4V Edition 06 2019 186 Rep gr 24 Mixture preparation injection ...

Page 193: ...efully opening the connection Pull connector off fuel pressure sender G247 A and re move fuel pressure sender using open ring spanner Unscrew plug 2 and screw fuel pressure sender G247 into tester VAS 6394 1 Specified torque 22 Nm Moisten tapered seal of adapter VAS 6394 3 using clean engine oil and screw into fuel rail arrow Specified torque 22 Nm CC 2012 Passat 2011 Passat Variant 2011 6 cylinde...

Page 194: ...e displayed on tester VAS 6394 1 with ac tual value displayed on vehicle diagnostic tester A maximum pressure deviation of 5 bar is permissible If the deviation is greater than 5 bar renew fuel pressure sender G247 WARNING The tester VAS 6394 is under extreme fuel pressure With engine running detach connector from fuel pressure sender G247 This reduces fuel pressure to approx 6 bar Switch off igni...

Page 195: ...er and carry out the guided function Replacing engine control unit Removing Switch off ignition Remove wiper arms and plenum chamber cover General body repairs exterior Rep gr 50 Bulkhead Removing and installing plenum chamber cover Push retaining frame down in direction of arrow and remove engine control unit Push locking devices of connectors in direction of arrow and pull off connectors CC 2012...

Page 196: ...to be replaced connect vehicle diagnostic tester and carry out the guided function Replacing engine control unit The shear head bolt threads may coated with locking com pound To simplify removal the shear head bolts can be heat ed using hot air blower VAS 1978 14 When doing this ensure that no adjacent cables connectors or components are damaged Removing Switch off ignition Remove wiper arms and p...

Page 197: ...iver between both locking plates arrow Carefully press screwdriver in direction of arrow and bend retaining bar 1 upwards at the same time Bend retaining bar 1 in direction of arrow until it can be pulled off connector CC 2012 Passat 2011 Passat Variant 2011 6 cylinder direct injection engine 3 6 l engine 4V Edition 06 2019 6 Engine control unit 191 ...

Page 198: ...it retaining bar 1 onto connectors and press it in direction of arrow Push guide pin 2 to stop into hole on valve timing housing Bolt retaining bar with new shear head bolts onto the engine control unit arrows until the bolt heads shear off CC 2012 Passat 2011 Passat Variant 2011 6 cylinder direct injection engine 3 6 l engine 4V Edition 06 2019 192 Rep gr 24 Mixture preparation injection ...

Page 199: ... of the arrow Install wiper arms and plenum chamber cover General body repairs exterior Rep gr 50 Bulkhead Removing and in stalling plenum chamber cover CC 2012 Passat 2011 Passat Variant 2011 6 cylinder direct injection engine 3 6 l engine 4V Edition 06 2019 6 Engine control unit 193 ...

Page 200: ...m Make sure that fuel pipe does not touch other components Install free of tension To install first tighten union nuts hand tight Loosen and tighten with socket T10456 Before installing first tighten connection at high pressure pump to 40 Nm 2 Low pressure hose Note installation marks Renew when removed page 195 3 Spring type clip Note the position of the spring clips 4 Plunger Check for damage oi...

Page 201: ...e high pressure pump Note safety precautions before starting installation work 3 1 Safety precautions during work on fuel system page 4 Observe rules for cleanliness 4 1 Rules for cleanliness page 6 Pull cover 1 off air duct releasing clips on sides to do so Unclip air duct 2 CC 2012 Passat 2011 Passat Variant 2011 6 cylinder direct injection engine 3 6 l engine 4V Edition 06 2019 7 High pressure ...

Page 202: ... to avoid injury and contact with the skin Wrap a cloth around the connection before loosening hose connections Then reduce pressure by carefully opening the connection Remove low pressure hose 1 Remove high pressure line 2 using socket T10456 To do this counterhold at high pressure pump connections with a wrench Note The low pressure hose must always be renewed because when pulling off it will be...

Page 203: ...n engine oil Install high pressure pump and tighten securing bolts arrows Item 7 page 195 Tighten union for high pressure pipe and low pressure pipe at high pressure pump High pressure pipe union 40 Nm Low pressure line union 28 Nm Caution The low pressure hose must always be renewed because when pulling off it will be damaged by the corrugated pipe connection Make sure low pressure hose and high ...

Page 204: ... pipe A using socket T10456 uni formly while counterholding the high pressure pipe in direction of arrow Make sure high pressure hose A and low pressure hose B do not touch each other after bolts have been tightened Specified torque 28 Nm Install engine lifting eye CC 2012 Passat 2011 Passat Variant 2011 6 cylinder direct injection engine 3 6 l engine 4V Edition 06 2019 198 Rep gr 24 Mixture prepa...

Page 205: ...ousing with connection hose Separate electrical connector 1 black connector for lamb da probe G39 Move lambda probe wiring aside Undo bolts of Lambda probe G39 1 and remove it Installing When reusing Lambda probe lubricate threads with high tem perature paste G 052 112 A3 Paste may not come into contact with slots on probe body Screw Lambda probe G39 1 into exhaust pipe of bank 1 Identifying featu...

Page 206: ...ith high tem perature paste G 052 112 A3 Paste may not come into contact with slots on probe body Screw lambda probe 2 G108 2 into exhaust pipe of bank 2 Identifying feature brown connector Specified torque 50 Nm Restore the original cable routing Continue installation in reverse order of removal 8 3 Removing and installing lambda probe after catalytic converter G130 and lambda probe 2 after catal...

Page 207: ...icate threads with high tem perature paste G 052 112 A3 Paste may not come into contact with slots on probe body Screw Lambda probe after catalytic converter G130 into ex haust pipe of bank 1 Identifying feature Black connector Screw Lambda probe 2 after catalytic converter G131 into exhaust pipe of bank 2 Identifying feature brown connector Specified torque 50 Nm Restore the original cable routin...

Page 208: ...er In initial equipment component with centre silencer Can be re newed individually for repair purposes Separate exhaust sys tem page 203 5 Retainer Renew if damaged 6 Centre silencer Combined in one unit with rear silencer as original equipment Can be renewed individually for repair purposes Separate exhaust sys tem page 203 7 Mounting For centre silencer Renew if damaged Secure to underbody page...

Page 209: ...haust pipes from silencers Note The connecting pipe can be cut through at the cutting location in order to remove and install or renew the centre and rear silencers separately Cutting location is marked by an indentation on the circumfer ence of exhaust pipe Special tools and workshop equipment required Pneumatic sabre saw V A G 1523 A or CC 2012 Passat 2011 Passat Variant 2011 6 cylinder direct i...

Page 210: ...ssary for the installation position of the clamp page 205 Separating point on exhaust pipe arrows 1 for rear left si lencer Marking arrow 2 is necessary for the installation position of the clamp page 205 Install rear silencer and connect it to the middle silencer with a clamp Installation position and specified torque of clamp page 205 Adjust the exhaust system so that distance a on left and righ...

Page 211: ... that end of bolt arrow does not extend be yond lower edge of clamp Installation position of clamp rear for repair Align the clamp with the mark on the exhaust pipe Specified torque 25 Nm Install clamp so that end of bolt arrow does not extend be yond lower edge of clamp Bolted connection faces rear CC 2012 Passat 2011 Passat Variant 2011 6 cylinder direct injection engine 3 6 l engine 4V Edition ...

Page 212: ...te G 052 112 A3 M8 25 Nm M10 40 Nm 2 Front exhaust pipes 3 Lambda probe 2 G108 50 Nm Bank 2 probe 1 Brown connector 6 pin Installed in exhaust gas stream of cylinders 4 5 and 6 Grease only thread with G 052 112 A3 G 052 112 A3 must not get in to slots in probe body Removing and installing page 199 4 Lambda probe 2 after cata lytic converter G131 50 Nm Bank 2 probe 2 Brown connector 4 pin Installed...

Page 213: ...Lambda probe G39 50 Nm Bank 1 probe 1 Black 6 pin connector Installed in exhaust gas stream of cylinders 1 2 and 3 Grease only thread with G 052 112 A3 G 052 112 A3 must not get into slots in probe body Removing and installing page 199 2 2 Removing and installing catalytic con verter Removing Pull cover 1 off air duct releasing clips on sides to do so Remove air duct 2 Remove air filter housing wi...

Page 214: ...cessible from above arrow from the exhaust manifolds Remove centre noise insulation General body repairs ex terior Rep gr 66 Noise insulation Assembly overview noise insulation Remove drive shaft protection for right drive shaft CC 2012 Passat 2011 Passat Variant 2011 6 cylinder direct injection engine 3 6 l engine 4V Edition 06 2019 208 Rep gr 26 Exhaust system ...

Page 215: ...vehicle underbody Expose electric cables to Lambda probes Unbolt bracket for exhaust system arrows Remove cross members A and B for underbody if present Disconnect exhaust system at clamping sleeve 1 Remove front exhaust pipe with catalytic converters and front silencers from exhaust manifold Installing Install in reverse order noting the following Renew seals gaskets and self locking nuts Coat st...

Page 216: ...gine will not be burnt in the engine and will damage the Lambda probes Renew self locking nuts 1 Heat shield bracket on the cylinder head 2 Bolt 20 Nm 3 Bolt 20 Nm 4 Seal Bank 1 Cylinders 1 2 and 3 Renew 5 Exhaust manifold Bank 1 Cylinders 1 2 and 3 Coat studs with high temperature paste G 052 112 A3 Removing and installing page 211 6 Nut Renew 25 Nm 7 Heat shield 8 Bolt 20 Nm 9 Intake manifold su...

Page 217: ...ecuring nuts at top and bottom arrows of both ex haust manifolds Remove exhaust manifold to rear Installing Install in reverse order noting the following Note Renew seals gaskets and self locking nuts Coat studs with high temperature paste G 052 112 A3 Bolted connection Torque setting Exhaust manifold on cylinder head 25 Nm re new Front exhaust pipe to exhaust manifold 40 Nm re new Heat shield for...

Page 218: ...4 Removing and installing page 213 2 Connector black Use assembly tool T10118 to pull off 3 Holder For connector for knock sensor 1 G61 4 20 Nm 5 Connector Black 3 pin Gold plated contacts on sensor and connector 6 Knock sensor 1 G61 Location cylinder block exhaust side 7 20 Nm The specified torque in fluences the function of the knock sensor 8 Exhaust camshaft adjuster Identification 32A With sen...

Page 219: ...onnector Black 2 pin Gold plated contacts on sensor and connector 17 Inlet camshaft adjuster Identification 24E With sender wheel for Hall sender G40 Removing and installing page 105 18 Spark plug 18 Nm Remove and install with spark plug socket and extension 3122B Type and electrode gap page 215 19 Valve timing housing For camshaft adjustment 1 2 Removing and installing ignition coils with output ...

Page 220: ...tool T10118 to the locking button arrow and carefully pull the plug connector downwards Push puller T10095 A on from flat side of connector in direction of arrow and pull out ignition coil with output stage CC 2012 Passat 2011 Passat Variant 2011 6 cylinder direct injection engine 3 6 l engine 4V Edition 06 2019 214 Rep gr 28 Ignition system ...

Page 221: ...engine speed sender and lay cable to side Unscrew bolt 2 and ease out the engine speed sender 1 with slight turning movements Installing Install in reverse order of removal observing the following Fit gasket Moisten oil seal lightly with clean engine oil Specified torque for bolt 2 8 Nm Do not tilt engine speed sender 1 when fitting it so that the seal is not damaged Remove noise insulation Genera...

Page 222: ... setting 18 Nm Change interval Maintenance Booklet Service tables 5 Current spark plugs Electronic parts catalogue ETKA CC 2012 Passat 2011 Passat Variant 2011 6 cylinder direct injection engine 3 6 l engine 4V Edition 06 2019 216 Rep gr 28 Ignition system ...

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