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Volkswagen Phaeton 2003, Workshop Manual

The Volkswagen Phaeton 2003 Workshop Manual is a comprehensive guide that provides detailed instructions on maintenance, repairs, and troubleshooting for your Volkswagen Phaeton. This essential manual can be easily downloaded for free from manualshive.com, ensuring you have the necessary information to keep your vehicle running smoothly.

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Contents

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

1

Technical data   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1

1.1

Engine number   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1

1.2

Engine data   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1

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

3

1

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

3

1.1

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

4

1.2

Securing engine on engine and gearbox support VAS 6095    . . . . . . . . . . . . . . . . . . . . . . 14

1.3

Installing engine   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

13 - Crankshaft group   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

1

Dismantling and assembling engine   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

1.1

Part I: assembly overview - chain drive   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

1.2

Part II: assembly overview - cylinder block   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

1.3

Removing and installing vibration damper   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

1.4

Removing and installing engine bracket and engine mounting on left or right side   . . . . . . 26

1.5

Removing and installing poly V-belt   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

2

Sealing flange and dual-mass flywheel   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

2.1

Assembly overview   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

2.2

Removing and installing seal, flywheel end   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

2.3

Removing and installing flywheel   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

2.4

Removing and installing drive plate   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

2.5

Renewing crankshaft oil seal, vibration damper end   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

2.6

Renewing crankshaft sealing flange -vibration damper side-   . . . . . . . . . . . . . . . . . . . . . . . . 37

3

Pistons and conrods   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40

3.1

Assembly overview   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40

3.2

Separating new conrod   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41

3.3

Checking piston and cylinder   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41

3.4

Piston and cylinder dimensions   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43

4

Crankshaft   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44

4.1

Assembly overview   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44

4.2

Fitting sender wheel to crankshaft   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45

4.3

Allocation of crankshaft bearing shells (classification)   . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46

15 - Cylinder head, valve gear   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48

1

Cylinder head   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48

1.1

Assembly overview   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48

1.2

Removing and installing cylinder head   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52

1.3

Checking valve timing   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56

1.4

Installing timing chain for intermediate shaft drive and camshaft drive   . . . . . . . . . . . . . . . . 58

1.5

Installing camshaft adjuster with timing chain for camshaft drive   . . . . . . . . . . . . . . . . . . . . 64

1.6

Removing and installing cylinder head cover   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68

1.7

Assembly overview - cover part   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71

1.8

Checking compression   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74

2

Valve gear   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76

2.1

Assembly overview - valve gear   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76

2.2

Removing and installing camshaft control valves   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79

2.3

Removing and installing camshafts   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82

2.4

Renewing valve stem seals   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87

2.5

Checking valve guides   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91

2.6

Reworking valve seats   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91

Phaeton 2003 ➤

6-cylinder injection engine - Edition 02.2014

Contents    

i

Summary of Contents for Phaeton 2003

Page 1: ...thorisedbyVolkswagenAG VolkswagenAGdoesnot guaranteeorac c e p t a n y l i a b i l i t y w i t h r e s p e c t t o t h e c o r r e c t n e s s o f i n f o r m a t i o n i n t h i s d o c u m e n t C o p y r i g h t b y V o l k s w a g e n A G Workshop Manual Phaeton 2003 6 cylinder injection engine Engine ID AYT BKL BRK Edition 02 2014 Service Service Department Technical Information ...

Page 2: ...roup 00 Technical data 10 Removing and installing engine 13 Crankshaft group 15 Cylinder head valve gear 17 Lubrication 19 Cooling 20 Fuel supply system 24 Mixture preparation injection 26 Exhaust system 28 Ignition system Technical information should always be available to the foremen and mechanics because their careful and constant adherence to the instructions is essential to ensure vehicle roa...

Page 3: ...verview 30 2 2 Removing and installing seal flywheel end 31 2 3 Removing and installing flywheel 33 2 4 Removing and installing drive plate 34 2 5 Renewing crankshaft oil seal vibration damper end 35 2 6 Renewing crankshaft sealing flange vibration damper side 37 3 Pistons and conrods 40 3 1 Assembly overview 40 3 2 Separating new conrod 41 3 3 Checking piston and cylinder 41 3 4 Piston and cylind...

Page 4: ...system 120 1 1 Assembly overview fuel tank with attachments and fuel filter 120 1 2 Dismantling and assembling right side fuel delivery unit fuel gauge sender and suction jet pump 122 1 3 Assembly overview fuel delivery unit fuel gauge sender and suction jet pump on left side 124 1 4 Schematic diagram of fuel lines and components in fuel tank 126 1 5 Safety precautions when working on fuel supply ...

Page 5: ...fault memory 167 26 Exhaust system 169 1 Parts of exhaust system 169 1 1 Assembly overview exhaust manifold with starter catalytic converters and attachments 170 1 2 Exhaust pipes with main catalytic converters and silencers with mountings 172 1 3 Removing and installing exhaust manifolds and exhaust pipes with starter catalytic converters 174 2 Secondary air system 176 2 1 Assembly overview parts...

Page 6: ... n o t p e r m i t t e d u n l e ssauthorisedbyVolkswagenAG VolkswagenAGdoesnot guaranteeorac c e p t a n y l i a b i l i t y w i t h r e s p e c t t o t h e c o r r e c t n e s s o f i n f o r m a t i o n i n t h i s d o c u m e n t C o p y r i g h t b y V o l k s w a g e n A G Phaeton 2003 6 cylinder injection engine Edition 02 2014 iv Contents ...

Page 7: ... AYT BKL BRK1 Manufactured 05 02 09 03 05 04 Cylinder arrangement VR2 VR2 VR2 Cylinder angle 15 0 15 0 15 0 Capacity l 3 2 3 2 3 2 Output kW at rpm 177 6200 177 6200 177 6200 Torque Nm at rpm 315 2400 315 2400 315 2400 Bore mm 84 0 84 0 84 0 Stroke mm 95 9 95 9 95 9 Compression ratio 11 25 10 85 10 85 Valves per cylinder 4 4 4 RON min 98 unleaded3 98 unleaded3 98 unleaded3 1 Emissions limit in acc...

Page 8: ...ot guaranteeorac c e p t a n y l i a b i l i t y w i t h r e s p e c t t o t h e c o r r e c t n e s s o f i n f o r m a t i o n i n t h i s d o c u m e n t C o p y r i g h t b y V o l k s w a g e n A G Engine code AYT BKL BRK Variable intake manifold yes yes yes Camshaft timing control yes4 yes4 yes4 4 Two independently variable camshafts Phaeton 2003 6 cylinder injection engine Edition 02 2014 2...

Page 9: ... g h t b y V o l k s w a g e n A G 10 Removing and installing engine 1 Removing and installing engine Special tools and workshop equipment required Lifting tackle 3033 Assembly tool 3213 Engine and gearbox sup port VAS 6095 Drip tray V A G 1306 Workshop hoist VAS 6100 Scissor type assembly platform VAS 6131 Not illustrated Left engine support VAS 6131 3 1 Right engine support VAS 6131 3 2 Universa...

Page 10: ...ype clip pliers VAS 5024 A Guide rods 3411 Torque wrench V A G 1331 Torque wrench V A G 1332 Not illustrated Universal subframe support VAS 6131 1 3 Universal gearbox console support VAS 6131 1 4 Securing pins VAS 6131 1 5 Securing pins VAS 6131 1 6 Container for removed parts V A G 1698 Grease G 000 100 Cable ties Removing engine page 4 Securing engine to assembly stand page 14 Installing engine ...

Page 11: ...connecting batteries The procedure must be strictly followed Switch off ignition and all electrical consumers First disconnect drive battery on right in luggage compartment Electrical system Rep gr 27 Disconnecting and recon necting batteries Then disconnect second battery on left in luggage compart ment Electrical system Rep gr 27 Disconnecting and reconnecting batteries Procedure All cable ties ...

Page 12: ... are under pressure Wear eye protection and gloves to avoid injuries and skin contact Before loosening hose connections wrap a cloth around the connection Then release pressure by carefully pulling hose off connection Disconnect fuel supply and fuel return lines and line to activa ted charcoal filter Note Press buttons on hose couplings to do this Seal lines with a clean cloth so that fuel system ...

Page 13: ...ounting at exhaust pipe junction arrow with guide pins 3411 Loosen double clamp between catalytic converter and centre silencer and slide clamp forward Remove catalytic converters front silencer page 172 Re moving and installing parts of exhaust system Replace bolts with large washers on propshaft intermediate bearing one by one with bolts not having washers Remove propshaft heat shield from vehic...

Page 14: ...scalding Cover cap with cloth and open carefully Open and close expansion tank cap to release pressure in cooling system Drain coolant page 115 Pull off coolant hoses from continued coolant circulation pump V51 If engine is to be separated from gearbox Note If engine and gearbox are to be separated following removal the subframe must first be removed Disconnect drive shafts from gearbox Running ge...

Page 15: ...hout subframe page 11 Prepare scissor type assembly platform VAS 6131 for further procedure Install engine supports VAS 6131 3 1 1 left and VAS 6131 3 2 2 right on scissor type assembly platform VAS 6131 The arrows on the supports point in direction of travel Secure the bolts in the following positions left engine support 1 C6 and D5 right engine support 2 E6 and F5 The universal supports VAS 6131...

Page 16: ...l i t y w i t h r e s p e c t t o t h e c o r r e c t n e s s o f i n f o r m a t i o n i n t h i s d o c u m e n t C o p y r i g h t b y V o l k s w a g e n A G B Mounting on right of engine arrow Guide universal supports for the subframe in the respective mountings arrow Guide the universal supports in the gearbox console arrows Unscrew subframe bolts 1 2 and 3 Phaeton 2003 6 cylinder injection ...

Page 17: ...emove bolts 1 for engine carrier 1 1 1 Removing engine and gearbox without subframe Disconnect drive shafts from gearbox Running gear axles steering Rep gr 40 Repairing drive shafts Removing and installing drive shafts Remove subframe Repairing front suspension Rep gr 40 Removing and installing subframe lower suspension link and anti roll bar Preparing scissor type assembly platform VAS 6131 for f...

Page 18: ...f o r m a t i o n i n t h i s d o c u m e n t C o p y r i g h t b y V o l k s w a g e n A G Secure the bolts in the following positions left engine support 1 C6 and D5 right engine support 2 E6 and F5 Remove both middle gearbox console bolts arrows Position assembly platform under power unit The engine sup ports must be guided into their respective mountings A Mountings on left of engine arrows B ...

Page 19: ... y l i a b i l i t y w i t h r e s p e c t t o t h e c o r r e c t n e s s o f i n f o r m a t i o n i n t h i s d o c u m e n t C o p y r i g h t b y V o l k s w a g e n A G Guide the universal supports of the gearbox console in the mountings arrows Position the middle support as shown beneath the gearbox arrow Remove both outer gearbox bracket bolts arrows Phaeton 2003 6 cylinder injection engin...

Page 20: ...ox Lower assembly platform with engine and gearbox only enough so as to facilitate unhooking of the selector lever cable Continuation for all vehicles Check that all connections between bulkhead and engine have been separated Remove engine and gearbox downwards Note The engine has to be guided carefully when removing to prevent damage to the bodywork 1 2 Securing engine on engine and gearbox suppo...

Page 21: ...ywheel end position 11 Lift engine off with workshop hoist VAS 6100 and secure on engine and gearbox support VAS 6095 as shown 1 3 Installing engine Caution When doing any repair work especially in the engine compart ment pay attention to the following due to the cramped condi tions Route all the various lines e g for fuel hydraulics acti vated charcoal filter system coolant refrigerant brake flui...

Page 22: ... Aligning scissor type assembly platform Special tools and workshop equipment required Positioning tool VAS 6131 17 Individual parts of positioning tool Dot lasers VAS 6131 17 1 Adapters M14x1 5 VAS 6131 17 2 Adapters M12x1 5 VAS 6131 17 3 Adapters M10 VAS 6131 17 4 Screw appropriate adapters A into threaded holes for secur ing subframe to longitudinal member on left and right Screw dot lasers VAS...

Page 23: ...stem 6 speed manual gearbox 01E 0A1 Rep gr 30 Repairing clutch control mechanism Assembly overview hydraulic system Continuation for all vehicles Install air conditioner compressor Heating air conditioning Rep gr 87 Air conditioner compressor bracket Install vane pump for power assisted steering Running gear axles steering Rep gr 48 Vane pump Install poly V belt page 28 Reconnect all lines hoses a...

Page 24: ... shafts to gearbox Running gear axles steering Rep gr 40 Repairing drive shafts Removing and installing drive shafts 1 3 1 Additional information and assembly work for vehicles with air conditioner Note The opening of the refrigerant circuit can only be carried out in workshops which have trained personnel and the neces sary range of tools and workshop equipment To prevent damage to condenser and ...

Page 25: ...yVolkswagenAG VolkswagenAGdoesnot guaranteeorac c e p t a n y l i a b i l i t y w i t h r e s p e c t t o t h e c o r r e c t n e s s o f i n f o r m a t i o n i n t h i s d o c u m e n t C o p y r i g h t b y V o l k s w a g e n A G 13 Crankshaft group 1 Dismantling and assembling engine Overview Phaeton 2003 6 cylinder injection engine Edition 02 2014 1 Dismantling and assembling engine 19 ...

Page 26: ... perform the following repairs Thoroughly clean oil channels Renew oil non return valve Renew oil spray jets Renew oil cooler Renew oil filter Part I page 20 Part II page 23 Removing and installing poly V belt page 28 1 1 Part I assembly overview chain drive 1 Valve timing housing Lightly lubricate contact surfaces of oil seals be fore installing Removing and installing page 82 Removing and instal...

Page 27: ...stalling page 58 14 60 Nm 1 4 turn 90 further Renew Use counterhold T10069 to loosen and tighten 15 Chain tensioner with tensioning rail For timing chain Item 17 page 21 Before installing release locking splines in chain tensioner using a small screwdriver and press tension ing rail against chain tensioner Only rotate engine when chain tensioner is installed 16 Drive sprocket Built into crankshaft...

Page 28: ...nd installing camshafts 24 Guide rail For camshaft timing chain Item 3 page 20 25 Exhaust camshaft control valve 1 N318 For exhaust camshaft Before removing mark connector belonging to component Removing and installing page 79 26 Inlet camshaft control valve 1 N205 For inlet camshaft Before removing mark connector belonging to component Removing and installing page 79 27 Guide rail For camshaft ti...

Page 29: ... return valve Note installation posi tion Clean if badly soiled or renew if necessary See note page 19 5 Knock sensor 1 G61 Fitting location be tween cylinder 1 and cylinder 3 6 20 Nm The torque setting influ ences the function of the knock sensor 7 10 Nm 8 Oil pump drive cover 9 O ring Renew Lubricate before instal ling 10 Oil pump drive 11 Cylinder block Removing and installing sealing flange an...

Page 30: ...w Lubricate before installing 24 12 Nm 25 Seal Renew 26 Oil filter housing left engine bracket Dismantling and assembling page 98 Coolant hose schematic diagram page 114 Right engine bracket and specified torque page 25 Removing and installing engine bracket and engine mounting on left or right side page 26 27 23 Nm 28 To thermostat housing 29 25 Nm 30 Fitting bolt 25 Nm 31 Compact bracket For alt...

Page 31: ... g h t b y V o l k s w a g e n A G Note If a new engine is installed the 3 bores on the face end arrows must be sealed by means of bolts Right engine bracket Specified torque for securing bolt 1 40 Nm 1 4 turn 90 fur ther Specified torque for securing bolt 2 60 Nm Removal of the engine bracket and the engine mounting page 26 1 3 Removing and installing vibration damp er Special tools and workshop ...

Page 32: ...er ring of vibration damper for cracks and separation If rubber joint is damaged renew vibration damper Clean thread in crankshaft with a threaded chaser M18 x 1 5 Renew securing bolt for vibration damper Lock vibration damper using counterhold T10069 Tighten securing bolt using torque wrench V A G 1601 Specified torque 100 Nm 1 2 turn 180 Note Turning further in several stages is permitted Instal...

Page 33: ...et from above Fit adapter 10 222 A to support bracket 10 222 A 16 with the higher side for the spindle guide upwards as illustra ted Now fit adapter 10 222 A 19 to support bracket 10 222 A on left and right Set support bracket 10 222 A on lon gitudinal members Hook engine with two shackles 10 222 A 12 on adapter 10 222 A 16 and slightly take up weight of engine Remove the vacuum hose 1 from the ri...

Page 34: ...t Engine bracket can now be removed Installing Installation is basically the reverse of the removal procedure When installing ensure dowel pin of engine mounting is cor rectly seated in engine bracket First insert all bolts by hand and then tighten all bolts to pre scribed torque Specified torque for securing bolt 1 40 Nm 1 4 turn 90 fur ther Specified torque for securing bolt 2 60 Nm Specified to...

Page 35: ...roller Screw M8 50 bolt into threaded hole A and thus secure ten sioning roller Note Screw in bolt only far enough to remove poly V belt because ten sioning roller housing may otherwise be damaged Remove poly V belt Installing poly V belt Note Before installing poly V belt ensure that all ancillaries alter nator air conditioner compressor power assisted steering vane pump are secured tightly When ...

Page 36: ...95 to carry out repairs Assembly overview page 30 Removing and installing seal at flywheel end page 31 Removing and installing flywheel page 33 Removing and installing drive plate page 34 Renewing crankshaft oil seal vibration damper end page 35 2 1 Assembly overview 1 100 Nm 1 2 turn 180 further Renew Use counterhold T10069 to loosen and tighten Tighten using torque wrench V A G 1601 2 Vibration ...

Page 37: ...ng remove oil residue from crankshaft journal using a clean cloth Removing and installing page 31 9 Spacer 10 Intermediate plate For gearbox attachment When installing bolt to cylinder block first and only then fit sump 11 Shim determining drive plate distance page 34 Only use individually 12 60 Nm 1 2 turn 180 further Renew Use counterhold T10069 to loosen and tighten 13 Dual mass flywheel Removi...

Page 38: ... o p y r i g h t b y V o l k s w a g e n A G Puller hooks T20143 Removing oil seal on flywheel end Fit puller hooks T20143 2 behind sealing lip of oil seal as shown in illustration Support puller hook T20143 2 on sealing flange and lever seal out in direction of arrow Installing oil seal at flywheel end Pull oil seal A by the outside over the sleeve T10122 1 onto pulling sleeve T10122 2 Separate t...

Page 39: ...s w a g e n A G Now drive it into sealing flange to stop using thrust piece T10122 3 2 3 Removing and installing flywheel Special tools and workshop equipment required Counterhold T10044 Removing Note To avoid damaging the dual mass flywheel during removal the bolts B must not be removed using a pneumatic or impact driver The bolts B must be unscrewed by hand without power tools Turn flywheel A so...

Page 40: ...old T10044 on cylinder block with washer arrow Bring counterhold T10044 to position A to loosen flywheel Mark position of flywheel in relation to engine Unbolt flywheel Installing Installation is carried out in the reverse order When installing note the following Renew bolts Bring counterhold T10044 to position B to tighten flywheel Specified torque Component Nm Flywheel to crankshaft 60 90 1 1 90...

Page 41: ...te Installing Prerequisites The intermediate plate Item 10 page 31 must be bolted securely to the cylinder block The spacer Item 9 page 31 must be fitted on the crank shaft Attach drive plate to crankshaft using at least 3 old securing bolts and tighten to 30 Nm Measure dimension a using depth gauge Specification 18 0 20 0 mm If specification is not attained Remove drive plate again and fit approp...

Page 42: ...f o r m a t i o n i n t h i s d o c u m e n t C o p y r i g h t b y V o l k s w a g e n A G Special tools and workshop equipment required Puller hooks T20143 1 Counterhold T10069 Assembly tool T10215 Torque wrench V A G 1601 Torque wrench V A G 1332 Removing Remove poly V belt page 28 Remove vibration damper To do this lock vibration damper using counterhold T10069 Fit puller hooks T20143 1 behind...

Page 43: ... and lever seal out in direction of arrow Installing Remove oil residue from crankshaft journal using clean cloth Slide guide sleeve T10215 1 1 onto front of crankshaft journal Now slide oil seal 2 carefully over guide sleeve as far as possible Press oil seal in to stop with fitting sleeve T10215 2 3 To do this use old vibration damper securing bolt 4 Note Renew securing bolt for vibration damper ...

Page 44: ...s w a g e n A G Special tools and workshop equipment required Counterhold T10069 Assembly tool T10215 Torque wrench V A G 1601 Torque wrench V A G 1332 Removing Set lock carrier to service position General body repairs exterior Rep gr 50 Service position Remove poly V belt page 28 Remove vibration damper To do this lock vibration damper using counterhold T10069 Remove sump page 101 Unbolt sealing ...

Page 45: ...pplying sealant bead cover sealing ring with a clean cloth The sealing compound bead must not be thicker that 2 3 mm Otherwise excessive sealing compound will enter the sump and may block the oil suction pipe strainer Observe expiry date of sealing compound The sealing flange must be installed within 5 minutes after ap plying the silicone sealant Push guide sleeve T10215 1 1 at front onto cranksha...

Page 46: ...41 Mark cylinder number and installation position relative to conrod Low point of piston crown faces to centre of cylinder block Installing piston page 43 3 Circlip 4 Conrod Renew as set only Mark cylinder number B Installation position marks A must be above one another Separate new conrod page 41 5 Bearing shell Note installation posi tion Do not interchange used bearing shells The lugs on bearin...

Page 47: ...sing drift VW 222 A 3 2 Separating new conrod On new conrods it is possible that the breaking point is not fully separated Proceed as follows when the conrod bearing cap cannot be removed by hand Mark cylinder allocation of conrod Item 4 page 40 Lightly clamp the conrod in a vice using aluminium vice clamps as shown in the illustration Note To prevent damage to the conrod only clamp conrod in ligh...

Page 48: ...lar section ring mm 0 20 0 40 1 0 Tapered stepped ring mm 0 20 0 40 1 0 Oil scraper ring mm 0 25 0 50 1 0 Checking ring to groove clearance Special tools and workshop equipment required Feeler gauges Clean annular groove before check Piston ring Clearance New Wear limit Rectangular section ring mm 0 04 0 09 0 15 Tapered stepped ring mm 0 03 0 06 0 15 Oil scraper ring mm 0 02 0 06 0 15 Checking pis...

Page 49: ... workshop equipment required Piston fitting tool T10147 Note If a new piston fitting tool is used to install the pistons first pass piston with oiled piston rings twice through the tool and remove any resulting metal shavings if necessary Only then install piston with piston rings Procedure Push piston into oiled piston fitting tool T10147 by hand Low point of piston crown must face lug on the pis...

Page 50: ... engine on engine and gearbox support VAS 6095 to carry out repairs Assembly overview page 44 Fitting sender wheel to crankshaft page 45 4 1 Assembly overview 1 Bearing cap Bearing cap 1 vibration damper end Bearing cap 5 with re cesses for thrust wash ers Bearing shell retaining lugs in cylinder block and bearing caps must align 2 30 Nm 1 2 turn 180 fur ther Renew 2 x 90 further is permit ted 3 B...

Page 51: ... 90 further Renew 8 Oil spray jet For crankshaft bearings 2 7 For piston cooling Opening pressure 2 0 bar Removing and installing page 97 See note page 19 4 2 Fitting sender wheel to crankshaft Special tools and workshop equipment required Torque wrench V A G 1331 Locking fluid D 000 6000 A2 Procedure Ensure that contact surfaces of crankshaft and sender wheel are free of oil and grease Note The s...

Page 52: ...Nm 1 4 turn 90 further 4 3 Allocation of crankshaft bearing shells classification 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 Always insert bearing shell for cylinde...

Page 53: ... determine the colour marking for installation with regard to the table Letter on cylinder block Letter on crankshaft web Colour marking of bearing shell for bearing cap Colour marking of bearing shell for cylinder block A B C D E R Red Yellow A B C D E G Red Yellow A B C D E B Yellow Yellow A B C D E V Blue Yellow G H I R Red Yellow G H I G Red Yellow G H I B Yellow Yellow G H I V Blue Yellow K L...

Page 54: ... is installed The plastic protectors fitted to protect the open valves must be removed only immediately before the cylinder head is fitted When replacing the cylinder head the complete coolant must be renewed Disconnect the batteries before removing the cylinder head Electrical system Rep gr 27 Disconnecting and recon necting batteries Removing and installing intake manifold page 68 remov ing and ...

Page 55: ...ng mark running direction instal lation position page 22 Installing page 58 10 Combination valve Removing and installing page 176 Removing and installing parts of secondary air system Checking page 178 11 O ring For sealing oil channel Renew Lubricate before installing 12 Hall sender 2 G163 For exhaust camshaft Before removing mark connector belonging to component 13 Chain tensioner 40 Nm For cams...

Page 56: ...head gasket for assembly page 73 With O ring for sealing oil channel Item 11 page 49 23 60 Nm 1 4 turn 90 further Renew Contact surface of sender wheel must be dry around bolt head when assembled To remove and install counterhold using 32 mm open end spanner on camshaft page 82 Removing and installing camshafts 24 Exhaust camshaft adjuster Identification 32A Rotate engine only with camshaft adjust...

Page 57: ... m a t i o n i n t h i s d o c u m e n t C o p y r i g h t b y V o l k s w a g e n A G 31 Cylinder head bolt Renew Refer to assembly instructions and sequence when loosening and tightening page 52 Removing and installing cylinder head 32 Cylinder head cover gasket Renew if damaged or leaking Note installation position Checking cylinder head for distortion Special tools and workshop equipment requi...

Page 58: ...nch 5 50 Nm V A G 1331 Torque wrench 40 200 Nm V A G 1332 Spring type clip pliers VAS 5024A Lifting tackle 3033 Sealant AMV 174 004 01 Sealant D 176 501 Removing Prerequisites Engine has been removed page 3 The engine must be no more than warm to touch Coolant has been drained page 115 Caution When doing any repair work especially in the engine compart ment pay attention to the following due to th...

Page 59: ... vibration damper securing bolt in direction of engine rotation The camshaft bar T10068 A must engage in both shaft grooves to allow the TDC position to be checked If not turn crankshaft another 360 in engine direction of ro tation to TDC of cyl 1 After checking remove camshaft bar Unbolt exhaust manifold from cylinder head page 169 Re moving and installing parts of exhaust system Remove chain ten...

Page 60: ... V o l k s w a g e n A G Mark timing chain before removing e g with paint arrow pointing in direction of rotation Note Do not mark chain by way of centre punch notch or the like First remove camshaft adjuster of exhaust camshaft To do this counterhold the relevant camshaft using an open end spanner on the hexagon drive arrows Now remove the camshaft adjuster together with the camshaft roller chain...

Page 61: ...tting into coolant Now carefully clean sealing surfaces of cylinder head and cyl inder block Ensure that the surface is not scored or scratched in the process If using abrasive paper do not use a grade less than 100 Installing Carefully remove metal particles emery residue and cloths If the piston for No 1 cylinder is not at TDC Turn crankshaft on the vibration damper securing bolt in di rection o...

Page 62: ...ence shown working from inside to outside Pre tighten all bolts to 30 Nm Then tighten all bolts to 50 Nm Then tighten all bolts 1 4 turn 90 further using a rigid wrench Finally tighten all bolts another 1 4 turn 90 further Further assembly is basically the reverse of the dismantling se quence Installing timing chains for intermediate shaft drive and camshaft drive page 58 Note Ensure that the O ri...

Page 63: ...h t b y V o l k s w a g e n A G Camshaft bar T10068 A Test procedure Remove intake manifold and cylinder head cover page 68 Removing and installing cylinder head cover Remove front noise insulation General body repairs exte rior Rep gr 50 Body front Assembly overview noise insulation Set crankshaft to TDC No 1 cylinder marking arrow by turn ing crankshaft on the vibration damper securing bolt in d...

Page 64: ...n valve timing housing C Markings on valve timing housing page 58 The distance between tooth 1 and tooth 2 of the camshaft adjuster must be exactly 16 rollers of the camshaft roller chain Note Figure shows view with cover removed Depending on version there may also be markings for FSI engines on the control housing Observe only markings for MPI engines page 58 If the markings do not align Adjust v...

Page 65: ... D 176 501 A1 Procedure Caution When doing any repair work especially in the engine compart ment pay attention to the following due to the cramped condi tions Route all the various lines e g for fuel hydraulics acti vated charcoal filter system coolant refrigerant brake fluid and vacuum and electrical wiring in their original po sitions To avoid damage to lines wiring ensure sufficient clear ance ...

Page 66: ...rail and place on crankshaft Insert large sprocket into timing chain so that lug on sprocket aligns with marking behind on cylinder block arrow B Fit sprocket onto intermediate shaft When installing ensure that timing chain runs completely straight in guide rail from crankshaft to intermediate shaft Ground tooth of drive sprocket must align with main bearing joint arrow A Lug on sprocket of interm...

Page 67: ... C o p y r i g h t b y V o l k s w a g e n A G Install chain tensioner in this position and tighten to 8 Nm arrows Installing timing chain for camshaft drive Prerequisite The camshaft adjusters are installed Cams A of cylinder 1 must face each other Crankshaft is positioned at TDC Insert camshaft bar T10068 A in both shaft grooves Remove small sprocket on intermediate shaft The large sprocket must...

Page 68: ...nks 4 align with markings on the camshaft adjuster 3 and with markings on control housing 5 Markings on valve timing housing page 58 Fit small sprocket of intermediate shaft into timing chain Mark ing 2 must align with middle copper coloured chain link 1 Fit small sprocket with timing chain attached onto intermediate shaft Installation is only possible in one position Lock vibration damper using c...

Page 69: ...of intermediate shaft must align with marking behind arrow C 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 Apply sealant D 176 501 A1 onto clean sealing surface of sealing flange as shown Note Observe dowel pins in cylinder block Immediately install sealing ...

Page 70: ... head gasket with sealant D 176 501 A1 Coat sealing surfaces of cover with sealant D 176 501 A1 and install cover without delay First insert all securing bolts arrows and tighten lightly Then tighten M8 securing bolts to 23 Nm and then tighten M6 securing bolts to 8 Nm Install chain tensioner for camshaft roller chain arrow and tighten to 40 Nm Turn crankshaft two full turns in direction of engine...

Page 71: ...i g h t b y V o l k s w a g e n A G Set crankshaft to TDC No 1 cylinder marking arrow by turn ing crankshaft on the vibration damper securing bolt in direc tion of engine rotation Cams A of cylinder 1 must face each other Insert camshaft bar T10068 A in both shaft grooves If nec essary move the camshafts back and forth slightly with an open end spanner Note Both camshaft adjusters marking 24E on i...

Page 72: ...shaft turn ad juster with sprocket to left accordingly and then fit camshaft roller chain Ensure the camshaft roller chain is tight against guide rail 1 and does not slag It must be possible to easily position adjuster and tighten it hand tight with camshaft roller chain positioned tautly on inlet cam shaft Arrow 1 on the camshaft adjuster of the inlet camshaft must align with the left notch 2 on ...

Page 73: ...osition of both camshaft adjusters again to ensure the setting is correct Remove camshaft bar T10068 A Note So that the camshaft roller chain does not jump a tooth when the crankshaft is turned the tensioning rail must be pressed against the camshaft roller chain by hand in place of the chain tensioner Turn crankshaft two full turns in direction of engine rotation and check valve timing page 56 If...

Page 74: ... in cylinder head gasket with sealant D 176 501 A1 Coat sealing surfaces of cover with sealant D 176 501 A1 and install cover without delay First insert all securing bolts arrows and tighten lightly Then tighten M8 securing bolts to 23 Nm and then tighten M6 securing bolts to 8 Nm Install chain tensioner for camshaft roller chain and tighten to 40 Nm Turn crankshaft two full turns in direction of ...

Page 75: ...f o r m a t i o n i n t h i s d o c u m e n t C o p y r i g h t b y V o l k s w a g e n A G Special tools and workshop equipment required Spring type clip pliers VAS 5024 A Torque wrench V A G 1331 Assembly tool T10118 Puller T10095 A Removing All cable ties which are opened or cut open when engine is re moved must be replaced in the same position when engine is installed Remove engine covers Remo...

Page 76: ...on coil with output stage cyl 1 6 Remove intake hose between air mass meter G70 and throttle valve module J338 Pull 6 pin connector off throttle valve module J338 as well as 2 pin connector off activated charcoal filter system solenoid valve 1 N80 and crankcase breather valve Now pull activated charcoal filter system solenoid valve 1 N80 with bracket off intake manifold support Pull all vacuum con...

Page 77: ...Note Seal intake ports in intake manifold and in cylinder head with a clean cloth Unbolt retainer on front of cylinder head cover for wiring to knock sender and oil level temperature sender Remove cylinder head cover Installing Installation is carried out in the reverse order When installing note the following Note Bolt intake manifold first to cylinder head Then tighten the two bolts for the heat...

Page 78: ...ection 4 Supply line connection 5 8 Nm 6 Hall sender 2 G163 For exhaust camshaft Before removing mark connector belonging to component 7 Chain tensioner 40 Nm For camshaft timing chain Item 9 page 49 Only rotate engine when chain tensioner is instal led 8 Seal Renew if damaged or leaking 9 8 Nm 10 Seal Renew if damaged or leaking Installing page 73 11 Retainer For wiring harness and earth connecti...

Page 79: ...ant hose schematic diagram page 114 1 7 1 Installing cover seals Special tools and workshop equipment required Fitting sleeve 3378 Assembly tool 3253 Prerequisites Engine has been removed page 3 Coolant has been drained page 115 Removing Remove thermostat housing page 113 Parts of cooling sys tem engine side Now remove cover page 71 Installing seals Do not lubricate seals Install oil seal with fit...

Page 80: ... mm holes in cylinder head gasket arrows with sealant D 176 501 and coat sealing surface on cover part and seal ing flange with sealant D 176 501 Install cover immediately First insert all securing bolts and tighten lightly Then tighten M8 securing bolts Item 15 page 72 to 23 Nm and M6 securing bolts to 8 Nm Install chain tensioner for camshaft roller chain Item 7 page 72 and tighten to 40 Nm 1 8 ...

Page 81: ...spark plug socket and extension 3122 B Check compression using compression tester V A G 1763 Note Using compression tester operating instructions Have a second mechanic fully depress accelerator and crank engine Operate starter until tester shows no further pressure in crease Compression pressures New 10 13 bar wear limit 7 5 bar Maximum permissible difference between all cylinders 3 bar Insert sp...

Page 82: ...equence page 82 Removing and installing camshaft 3 Seal Renew if leaking When installing valve timing housing lightly lubricate contact surfa ces of seal When replacing seals do not spread too wide ly 4 Exhaust camshaft Check radial clearance with Plastigage wear limit 0 1 mm Runout max 0 01 mm Checking axial clear ance page 90 Identification and valve timing page 91 Removing and installing page 8...

Page 83: ...height Minimum height a 139 9 mm 11 Valves Do not rework only lapping in is permitted Valve dimensions page 94 12 Cylinder head Check for distortion page 51 Removing and installing page 52 Reworking valve seats page 91 After renewing renew entire coolant 13 Support element Before installing check camshaft axial clearance page 90 Do not interchange With hydraulic valve clearance compensation 14 Val...

Page 84: ...n A G Runout max 0 01 mm Checking axial clearance page 90 Identification and valve timing page 91 Removing and installing page 82 Dismantling and assembling valve timing housing 1 Guide rail clipped into timing housing 2 Valve timing housing 3 Removing and installing inlet camshaft control valve 1 N205 page 79 4 Removing and installing exhaust camshaft control valve 1 N318 page 79 5 8 Nm renew bol...

Page 85: ... a g e n A G 2 2 Removing and installing camshaft control valves Special tools and workshop equipment required Torque wrench V A G 1783 Torx bit set V A G 1766 1 4 drive ratchet VAS 6234 Special wrench long reach T10072 Not illustrated Sealant AMV 174 004 01 Sealant AMV 176 501 Removing Prerequisites The engine must be removed Remove cylinder head cover page 68 Note Before removing connectors mark...

Page 86: ...sender 2 G163 Move wiring harness clear Now remove thermostat housing page 113 Parts of cooling system engine side Note The cover has a hidden bolt This cannot be removed until ther mostat housing has been removed Remove chain tensioner for camshaft roller chain arrow Remove securing bolts arrows from cover Cover can be prised off carefully when all securing bolts have been removed Caution Cover l...

Page 87: ...oiling 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 seals with clean engine oil Carefully insert camshaft control valve into housing and push vertically to valve ...

Page 88: ... Nm and M6 securing bolts Item 17 page 50 to 8 Nm Install chain tensioner for camshaft roller chain Item 13 page 49 and tighten to 40 Nm Install cylinder head cover page 68 and intake manifold Further assembly is basically the reverse of the dismantling se quence 2 3 Removing and installing camshafts Special tools and workshop equipment required Camshaft bar T10068 A Torque wrench 5 50 Nm V A G 13...

Page 89: ...owing due to the cramped condi tions Route all the various lines e g for fuel hydraulics acti vated charcoal filter system coolant refrigerant brake fluid and vacuum and electrical wiring in their original po sitions Ensure that there is sufficient clearance to all moving or hot components All cable ties which are opened or cut open when engine is removed must be replaced in the same position when...

Page 90: ...ing components of cov er Camshaft control valve 1 N205 Exhaust camshaft control valve 1 N318 Hall sender G40 Hall sender 2 G163 Move wiring harness clear Now remove thermostat housing page 113 Parts of cooling system engine side Remove cover page 71 Mark timing chain before removing e g with paint arrow pointing in direction of rotation Note Do not mark chain by way of centre punch notch or the li...

Page 91: ...ately and diagonally Removing exhaust camshaft B 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 Carefully remove camshafts and lay aside on clean surface Remove roller rocker fingers together with support elements and lay aside on a clean surface Ensure that roller rocker fingers and support elements are ...

Page 92: ...n page 91 Note Observe fitting position of bearing caps Point of bearing cap arrow A of inlet and outlet camshafts face outwards Installing inlet camshaft A Tighten bearing caps 5 and 9 alternately and diagonally to 5 Nm 1 8 turn 45 Install bearing caps 1 and 13 and tighten to 5 Nm 1 8 turn 45 Install bearing cap 7 and tighten to 5 Nm and turn 1 8 45 further Install bearing caps 3 and 11 and also ...

Page 93: ... of camshaft seals and slowly push valve timing housing over camshaft seals Install control housing arrows and tighten to 8 Nm Now install camshaft roller chain with camshaft adjusters page 64 Remove old sealant from 3 mm holes in cylinder head gasket arrows Fill 3 mm holes in cylinder head gasket with sealant D 176 501 Note Sealant D 176 501 hardens quickly Lubricate O ring for oil channel seal a...

Page 94: ...i t y w i t h r e s p e c t t o t h e c o r r e c t n e s s o f i n f o r m a t i o n i n t h i s d o c u m e n t C o p y r i g h t b y V o l k s w a g e n A G Special tools and workshop equipment required Valve lever VW 541 1 A Valve assembly device 2036 Spark plug socket and ex tension 3122 B Valve stem seal puller 3364 Valve stem seal fitting tool 3365 Adapter T40012 1 Phaeton 2003 6 cylinder i...

Page 95: ...ts and lay aside on a clean surface Ensure that roller rocker fingers and support elements are not interchanged Remove spark plugs using spark plug socket and extension 3122 B Set piston of respective cylinder to bottom dead centre Set up valve assembly device 2036 with adapter plates 2036 1 and adjust mounting Screw adapter T40012 1 into spark plug thread connect to compressed air line with comme...

Page 96: ...eeve A on valve stem Lubricate sealing lip of valve stem seal B place it in the valve stem oil seal fitting tool 3365 and push carefully onto valve guide Install camshafts page 82 2 4 1 Camshafts checking axial clearance Special tools and workshop equipment required Universal dial gauge bracket VW 387 Dial gauge Perform measurements only with support elements and roller rocker fingers removed Midd...

Page 97: ...t 022 101 Index B Inlet camshaft 022 102 Index Valve timing at 1 mm valve lift Inlet valve Exhaust valve Opens BTDC 211 5 Closes BTDC 6 5 Opens ATDC 18 50 Closes ATDC 223 5 2 5 Checking valve guides Special tools and workshop equipment required Universal dial gauge bracket VW 387 Dial gauge Test procedure Insert new valve into guide The end of the valve stem must be flush with the guide Due to sli...

Page 98: ...working dimension is exceeded hydraulic valve compensation can no longer be guaranteed and the cylinder head should be renewed Remove camshafts page 82 The max permissible reworking dimension is calculated as fol lows Insert valve and press firmly against seat Note If the valve is to be renewed as part of a repair use a new valve for the calculation Measure distance a between end of valve stem and...

Page 99: ... inlet valve seat a 32 8 mm b Max permissible re working dimension6 c 0 9 1 5 mm d max 38 0 mm r2 radius 2 0 mm Z Lower edge of cylin der head α 45 valve seat angle β 30 upper correction angle g 60 lower correction angle 2 6 2 Reworking exhaust valve seat a 29 8 mm b Max permissible re working dimension6 c 1 2 1 7 mm d max 35 0 mm r2 radius 2 0 mm Z Lower edge of cylin der head α 45 valve seat ang...

Page 100: ... f i n f o r m a t i o n i n t h i s d o c u m e n t C o p y r i g h t b y V o l k s w a g e n A G 2 6 3 Valve dimensions Note Valves must not be reworked Only lapping in is permitted 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 Exhaust valves Dimension Short exhaust valve Long exhaust valve a mm 30 20 30 20 b mm 5 97 5 ...

Page 101: ...t be above the max mark danger of damage to catalytic converter Engine oil oil capacities and engine oil specification page 95 Assembly overview page 95 Markings on oil dipstick page 98 Checking oil pressure and oil pressure switch page 104 Renew oil non return valve page 98 Removing and installing oil spray jet page 97 Removing and installing sump page 101 1 1 Engine oil Oil capacities With oil f...

Page 102: ...ylinder block Removing and installing sealing flange and dual mass flywheel page 30 Removing and installing crankshaft page 44 Dismantling and assem bling pistons and con rods page 40 5 Oil non return valve Note installation posi tion Removing and installing page 98 Renew if badly soiled See note page 95 6 8 Nm 7 Oil pump drive cover 8 O ring Renew Lubricate before installing 9 Oil pump drive 10 I...

Page 103: ...temperature sender G266 20 12 Nm 21 Baffle plate 22 8 Nm Apply locking fluid D 000 600 A2 when installing 23 Seal Renew Lubricate before installing 24 Oil filter housing left engine bracket Dismantling and assembling page 98 Coolant hose schematic diagram page 114 Right engine bracket and specified torque page 25 25 23 Nm 1 2 1 Removing and installing oil spray jet Special tools and workshop equip...

Page 104: ...and installing oil non return valve Removing Screw commercially available M8x1 5 bolt about 4 full turns into valve arrow and withdraw it from bore Installing Before installing moisten O ring with oil Press valve into oil channel by hand 1 2 3 Markings on oil dipstick 1 Max mark 2 Min mark a Area above hatched field up to max mark do not add engine oil b Oil level within hatched zone engine oil ca...

Page 105: ...fore instal ling 4 Oil cooler Ensure clearance to ad jacent components See note page 95 Coolant hose schematic diagram page 114 5 Securing ring 6 Seal Renew Lubricate before instal ling 7 Oil cooler cover 25 Nm 8 Oil pressure switch F1 20 Nm Black If seal is leaking nip open and renew Checking page 104 9 Oil filter element Observe change inter vals See note page 95 10 Oil filter lower part 25 Nm B...

Page 106: ... pump Note When installing oil pump note the following First tighten all se curing bolts by hand Then tighten oil pressure pipe Item 7 page 100 to cylinder block and then to oil pump Item 2 page 100 Finally tighten oil pump with securing bolts Item 3 page 100 1 Drive shaft For oil pump drive 2 Oil pump housing 3 23 Nm 4 Gears Checking backlash page 101 Checking axial clear ance page 101 5 Oil pump...

Page 107: ...i g h t b y V o l k s w a g e n A G Checking oil pump backlash Special tools and workshop equipment required Feeler gauges Wear limit 0 20 mm Checking oil pump axial clearance Special tools and workshop equipment required Straight edge Feeler gauges Wear limit 0 10 mm 1 5 Removing and installing sump Special tools and workshop equipment required Engine and gearbox jack V A G 1383 A Torque wrench 5...

Page 108: ...isposal Pull 3 pin connector off oil level and oil temperature sender G266 Now unbolt retainer for cable guide Fit support T10151 in place of retainer arrows Remove anti roll bar Running gear axles steering front and four wheel drive Rep gr 40 Removing and installing subframe lower suspension links and anti roll bar On right side of engine carrier now unscrew bracket for 4 pin connector and signal...

Page 109: ...from cylinder block with a flat scraper WARNING When removing sealant residue wear eye protection to pre vent eye injuries Remove sealant residue on sump with a rotating brush e g a hand drill with a plastic brush Clean sealing surfaces They must be free of oil and grease Installing Prerequisite Intermediate plate must be bolted firmly to cylinder block Item 10 page 31 Note Observe expiry date of ...

Page 110: ...n A G Apply silicone sealing compound bead as shown to the clean sealing surface of the sump Install sump immediately and tighten all sump bolts lightly Tighten oil sump bolts to 12 Nm Tighten sump intermediate plate securing bolt arrow to 45 Nm Note Let sealing compound dry for approx 30 minutes after installing sump Only then fill with engine oil Further assembly is basically the reverse of the ...

Page 111: ... pressure warning indicator When not under pressure the oil pressure switch is open and will close when the operating pressure is attained The oil pressure warning will be activated approx 10 seconds after switching the ignition on Switch in delay of oil pressure warning approx 3 seconds Switch off delay of oil pressure warning approx 5 seconds Note Functional check and repair of the optical and a...

Page 112: ... is running the oil pressure warning will be activated immediately and will not be cancelled even below 1500 rpm The oil pressure warning will be cancelled when the oil pressure switch is closed for longer than 5 seconds at an engine speed above 1500 rpm or when the ignition is switched off Test prerequisites Engine oil level OK checking page 98 Oil pressure warning lamp K3 must light up for appro...

Page 113: ...g oil pressure Check oil pressure at different revolutions 1 500 rpm at least 1 7 bar 2000 rpm 3 0 5 5 bar Over 2000 rpm maximum 7 0 bar If the specifications are not attained Check strainer in suction line for dirt Check pressure pipe between oil pump and cylinder block for leaks Rectify mechanical damage e g bearing damage At higher engine speeds the oil pressure must not exceed 7 0 bar If the s...

Page 114: ...nsure that there is sufficient clearance to all moving or hot components Note When the engine is warm the cooling system is under pres sure If necessary release pressure before beginning repair work Hoses are secured with spring type clips In case of repair only use spring type clips Spring type clip pliers VAS 5024A are recommended for in stallation of spring type clips When installing coolant ho...

Page 115: ...5 To oil cooler For gear oil 6 Radiator outlet coolant tem perature sender G83 Before removing re lease pressure in cool ing system if necessary 7 Retaining clip Check for secure seat ing 8 O ring Renew 9 Lower coolant hose Secured to radiator and thermostat housing with a retaining clip Ensure secure seating 10 Front coolant pipe bottom With coolant pipe for gear oil cooler 11 Rubber mounting 12 ...

Page 116: ...l i a b i l i t y w i t h r e s p e c t t o t h e c o r r e c t n e s s o f i n f o r m a t i o n i n t h i s d o c u m e n t C o p y r i g h t b y V o l k s w a g e n A G 1 2 Assembly overview removing and installing fan 1 Fan support 2 10 Nm 3 Radiator fan control unit J293 4 10 Nm 5 Radiator fan V7 6 10 Nm 7 Radiator fan control unit 2 J671 8 Radiator fan 2 V177 9 Bracket Phaeton 2003 6 cylinde...

Page 117: ...h cooling system tester V A G 1274 and adapt er V A G 1274 7 Depending on equip ment connection may be sealed with a blank ing plug 2 Cap Check using cooling system tester V A G 1274 and adapt er V A G 1274 1A Test pressure 1 4 1 6 bar 3 10 Nm 4 Plug 5 Coolant hose 6 Cable guide For coolant hose and wiring harness 7 Y piece Note installation posi tion 8 To heat exchanger for heat er unit 9 To heat...

Page 118: ...g of coolant hoses on thermostat housing page 113 parts of cooling system engine side 1 O ring Renew if damaged 2 Retaining clip Check for secure seat ing 3 Thermostat housing 4 8 Nm 5 Thermostat Note installation posi tion Checking heat thermo stat in water Begins to open at ap prox 80 C Ends at approx 105 C Opening lift at least 7 mm 6 Connection 7 Seal Renew 8 Coolant temperature send er G62 Wi...

Page 119: ...g Ensure secure seating Coolant hose schematic diagram page 114 4 Lower coolant hose 5 Coolant pipe Between coolant pump and thermostat housing 6 Thermostat housing 7 To cylinder block 8 Connection Item 4 page 99 9 To heat exchanger for heat er unit 10 Bracket 11 Y piece 12 From continued coolant circulation pump V51 Installation location of pump page 114 13 To continued coolant cir culation pump ...

Page 120: ...ant circulation pump V51 Continued coolant circulation pump V51 is located on left in engine bay next to longitudinal member 1 Hose pump outlet to cylinder block Item 12 page 113 2 Non return valve observe arrow for direction of flow 3 Hose pump inlet from lower coolant hose Item 13 page 113 1 6 Coolant hose schematic diagram 1 Radiator 2 Oil cooler For gear oil 3 Cylinder head 4 Expansion tank 5 ...

Page 121: ...ining and filling coolant Special tools and workshop equipment required Refractometer T10007 A Drip tray VAS 6208 Torque wrench V A G 1331 Hose clip pliers VAS 6499 Adapter V A G 1274 7 Cooling system charge unit VAS 6096 Draining WARNING Steam may escape when expansion tank is opened Wear eye protection and protective clothing to avoid eye injuries and scalding Cover cap with cloth and open caref...

Page 122: ...w i t h r e s p e c t t o t h e c o r r e c t n e s s o f i n f o r m a t i o n i n t h i s d o c u m e n t C o p y r i g h t b y V o l k s w a g e n A G Unscrew plug arrow from coolant pipe Item 16 page 113 Note Follow disposal regulations for coolant To drain coolant from engine also remove coolant hose from oil cooler arrow Then pull off hose from lower coolant pipe Item 10 page 109 Filling Pha...

Page 123: ...m must be filled all year round with coolant additive Because of its higher boiling point the coolant improves en gine reliability under heavy loads particularly in countries with tropical climates ONLY refractometer T10007A may be used for determining current anti freeze value The normal frost protection must be for 25 C in countries with arctic conditions to 36 C When climatic conditions require...

Page 124: ...1 5 50 Nm Removing Drain coolant page 115 Pull off upper coolant hose retaining clip and remove coolant hose from radiator Pull off lower coolant hose on radiator Remove front bumper General body repairs exterior Rep gr 63 Assembly overview front bumper Bring lock carrier into service position General body repairs exterior Rep gr 50 Lock carrier service position Remove radiator fan with radiator f...

Page 125: ...ial tools and workshop equipment required Drip tray V A G 1306 Torque wrench V A G 1331 5 50 Nm Removing Remove front bumper General body repairs exterior Rep gr 63 Assembly overview front bumper Bring lock carrier into service position General body repairs exterior Rep gr 50 Lock carrier service position Remove poly V belt page 28 Drain coolant page 115 Unscrew coolant pump securing bolts and rem...

Page 126: ...1 are recommended for installation of spring type clips Observe safety precautions page 128 Observe rules for cleanliness page 128 Assembly overview fuel tank with attachments and fuel filter page 120 Removing and installing fuel tank with its attachments and fuel filter page 137 Assembly overview fuel delivery unit fuel gauge sender and suction jet pump on right page 122 Removing and installing f...

Page 127: ...port using engine and gearbox jack V A G 1383 A Removing and installing page 137 7 Connecting hose From filler neck 8 Aperture for left sender Removing and installing page 134 9 Aperture for right sender Removing and installing page 131 10 Sender aperture for supply and return flange 11 Heat shield For fuel tank 12 20 Nm 1 4 turn 90 fur ther 13 Securing strap Note installation position 14 Cross me...

Page 128: ... b y V o l k s w a g e n A G 24 To connection on supply and return flange Item 6 page 123 25 Expansion tank 26 Breather valve 27 8 Nm 1 4 turn 90 further 28 Pressure retention valve Checking page 126 29 Breather line Ensure secure seating 30 To activated charcoal filter 31 Breather line 32 8 Nm 1 4 turn 90 further 1 2 Dismantling and assembling right side fuel delivery unit fuel gauge sender and s...

Page 129: ... suction jet pumps 4 Connector Coded connector to flange Item 25 page 124 5 Fuel gauge sender 3 G237 Lever type sender Clipped onto support for fuel delivery unit Checking Current flow diagrams Fault finding program Check ing fuel gauge sender 6 Connection Fuel supply line Item 24 page 122 Arrow points away from connection 7 Seal Renew 8 Connection For fuel return line Item 23 page 121 Arrow point...

Page 130: ...line 20 Supply line 21 Non return valve 22 To return line of fuel delivery unit left side Item 20 page 126 23 From supply line of fuel delivery unit left side Item 19 page 126 24 Locking ring 110 Nm Ensure secure seating Remove and install using wrench 3087 25 Flange Note installation position on fuel tank page 126 26 Seal Renew 27 To fuel delivery unit on left side Clipped onto right of fuel deli...

Page 131: ... line For auxiliary heater 6 Flange Note installation posi tion on fuel tank page 126 7 Fuel gauge sender 2 G169 Plunger type sender Checking Vehicle di agnostic tester 8 Locking lug Clipped onto left of fuel delivery unit 9 Connector Coded connector to flange Item 6 page 125 10 To supply line for suction jet pump right side Item 28 page 124 11 From supply line for suction jet pump on fuel deliver...

Page 132: ...24 20 From return line Item 22 page 124 21 Return line 22 Supply line Installation position of fuel delivery unit flange Insert sender flange with marking arrow in direction of travel Checking pressure retention valve on expansion tank The pressure retention valve is open from breather valve on ex pansion tank for flow in both directions arrow 1 side to expan sion tank On the other side flow is po...

Page 133: ...k s w a g e n A G 1 Supply and return flange With connections for quick release couplings 2 Supply line 3 Return line 4 Suction jet pump Right side 5 Fuel delivery unit Right side 6 Connecting hose From filler neck 7 Y piece 8 Non return valve 9 Y piece 10 Supply line for auxiliary heater 11 Flange Left side 12 Fuel delivery unit Left side 13 Suction jet pump Left side 14 Supply line To fuel deliv...

Page 134: ...uel pump can be activated when the driver door is opened When removing and installing fuel gauge sender or fuel pump fuel delivery unit from a full or partly full fuel tank observe the following Before beginning work place an extraction hose close to sender opening in fuel tank to extract escaping fuel fumes and switch on exhaust extraction system If no exhaust gas ex traction system is available ...

Page 135: ...h 3087 WARNING Fuel system is under pressure Wear eye protection and pro tective clothing to avoid possible injury and skin contact Before loosening hose connections wrap a cloth around the connec tion Then release pressure by carefully pulling hose off con nection Procedure Note safety precautions before beginning work page 128 Open fuel tank filler flap Push suction hose arrow of fuel extractor ...

Page 136: ...r flange and pull off fuel hose Now remove locking ring from flange using wrench 3087 Carefully lever out flange and raise it slightly Insert suction hose of fuel extractor VAS 5190 as deeply as possible into right and then left side of fuel tank and extract fuel For work on left side of fuel tank proceed as described above When breather lines are pulled off buttons of hose couplings sometimes can...

Page 137: ... left and right to specified torque 1 8 Removing and installing fuel delivery unit fuel gauge sender and suction jet pump right side Special tools and workshop equipment required Wrench 3087 Test prerequisites Fuel tank must be drained page 128 Draining fuel tank Connectors and wires for left and right hand sender flanges have been removed Locking rings for left and right sender flanges have been ...

Page 138: ... r i g h t b y V o l k s w a g e n A G Pull off three connectors arrows underneath right sender flange On right side B unclip plunger type sender 3 from fuel de livery unit 1 arrows and carefully pull it out Now pull black filler hose out of hole 4 in fuel delivery unit housing 1 On right side B unclip return hose of left hand suction jet pump 2 out of fuel delivery unit 1 arrows Pull off return l...

Page 139: ...i n t h i s d o c u m e n t C o p y r i g h t b y V o l k s w a g e n A G Pull supply hose 1 on left side off Y piece 2 and pull it out of right sender hole Push both retaining clips 1 from right fuel delivery unit B to side slightly and carefully remove fuel delivery unit Note The fuel delivery unit housing is filled with fuel Fuel may run out if housing is tipped or canted Now unclip black retur...

Page 140: ...f suction jet pump through right hand sender opening Now unclip suction jet pump 3 on right side B and remove by turning slightly Now unclip fuel gauge sender 2 and it pull out 1 9 Removing and installing fuel delivery unit fuel gauge sender and suction jet pump left side Special tools and workshop equipment required Wrench 3087 Test prerequisites Fuel tank must be drained page 128 Draining fuel t...

Page 141: ... b y V o l k s w a g e n A G Note The fuel hoses between the right and left side of fuel tank are secured with cable binder Procedure Note safety precautions before beginning work page 128 Pull off three connectors arrows underneath left sender flange On left side A unclip plunger type sender 3 from fuel de livery unit 1 arrows and carefully pull it out On left side A unclip return hose of right s...

Page 142: ... g e n A G Pull off return line 3 and supply line 4 on right side Pull both hose ends out through left sender hole Push both retaining clips 1 from right fuel delivery unit A to side slightly and carefully remove fuel delivery unit with sender flange attached Note The fuel delivery unit housing is filled with fuel Fuel may run out if housing is tipped or canted Now unclip black return hose 2 from ...

Page 143: ...t pump 3 on left side A and remove by turning slightly Now unclip fuel gauge sender 2 and it pull out Note Only two fuel lines supply Item 19 page 124 and return Item 20 page 124 can be seen through the right sender hole These can only be removed via the supply and return flange Item 9 page 123 with fuel tank removed 1 10 Removing and installing fuel tank with attachments and fuel filter Special t...

Page 144: ...irs exterior Rep gr 63 Removing and installing rear bumper Remove rear right wheel housing liner General body re pairs exterior Rep gr 66 Removing and installing wheel housing liner Remove centre and rear silencers page 172 Remove propshaft Transfer box and final drives Rep gr 39 Removing and installing propshaft Remove rear axle Running gear Rep gr 42 Removing and installing rear axle Open fuel t...

Page 145: ... loosen securing straps 2 Lower fuel tank Installing Installation is carried out in the reverse order When installing note the following Connections for breather and fuel lines must engage audibly when joined Do not interchange supply and return hose return hose blue or blue markings supply hose black Install breather and fuel hoses free of kinks Secure fuel hoses with spring type clips Ensure tha...

Page 146: ... h r e s p e c t t o t h e c o r r e c t n e s s o f i n f o r m a t i o n i n t h i s d o c u m e n t C o p y r i g h t b y V o l k s w a g e n A G Checking non return valve of left pump page 147 Special tools and workshop equipment required Pressure gauge V A G 1318 Adapter V A G 1318 11 Adapter V A G 1318 16 Adapter V A G 1318 17 Adapter V A G 1318 23 Spring type clip pliers VAS 5024A Phaeton 2...

Page 147: ...tage tester V A G 1527B Auxiliary measuring set V A G 1594C Multimeter V A G 1715 Measuring container Current flow diagram 1 11 1 Checking delivery rate of both fuel pumps Test prerequisites Voltage supply for both batteries OK Fuel pump relays 1 and 2 must be removed from their sockets Test procedure Remove filler cap from fuel tank filler neck Remove intake hose between air mass meter G70 and th...

Page 148: ... G 1318 11 of pressure gauge and hold hose in a measuring container Open pressure tester shut off tap The lever then points in the direction of flow Connect remote control V A G 1348 3 A using adapter V A G 1348 3 3 to connections of fuel pump relay 2 and 3 Connect positive terminal 1 of remote control to positive pole in engine compartment Operate remote control V A G 1348 3A Then slowly close sh...

Page 149: ...a minimum delivery rate of 1 200 cm3 30 s If delivery rate has been attained but nevertheless you suspect a fuel supply system fault e g intermittent failure of fuel supply system Check current draw of fuel pumps page 144 If the minimum delivery rate is not attained Check fuel lines for possible restrictions kinks or blockages Pull supply line 1 off inlet to fuel filter Note Press buttons on hose ...

Page 150: ...imum delivery rate is not reached page 144 1 11 3 Checking delivery quantity of left pump Reconnect remote control connector 2 Disable activation of right pump To do this pull connector 1 for remote control out of relay socket for right pump Empty measuring container Operate remote control for 30 seconds while measuring bat tery voltage Compare quantity of fuel delivered with specification 11 Deli...

Page 151: ...Repeat test on left fuel delivery unit Note The left fuel pump will be switched off at idle a few seconds after the engine has been started If current draw is exceeded Right fuel pump is defective Renew fuel delivery unit page 131 Left fuel pump defective renew fuel delivery unit page 134 Note If the fuel system malfunction is intermittent you can perform the check during a road test but a 2nd per...

Page 152: ...f approx 4 bar has built up If pressure builds up too high relieve excess pressure by carefully opening shut off tap WARNING Danger of spray when opening shut off tap Hold container over free connection of pressure tester Watch pressure drop on pressure gauge After 10 minutes pressure must not drop below 3 0 bar If the pressure drops further Check fuel lines and connections to fuel tank for leaks ...

Page 153: ...re drops further Right fuel pump is defective Renew fuel delivery unit page 131 If pressure drops further page 147 1 11 7 Checking non return valve of left pump Reconnect supply line on right side 2 On right side separate supply line 4 to left pump Connect pressure gauge V A G 1318 lever perpendicular to direction of flow with adapter V A G 1318 23 and V A G 1318 17 on hose 1 to pump Reconnect rem...

Page 154: ...ed charcoal filter system solenoid valve 1 N80 is activated pulsed by the engine control unit depending on load and engine speed The opening period depends on the input signals During the purging procedure regeneration of activated char coal the intake manifold vacuum draws fresh air through the vent of the activated charcoal filter The fuel vapours stored in the ac tivated charcoal and fresh air ...

Page 155: ...o c u m e n t C o p y r i g h t b y V o l k s w a g e n A G 1 Activated charcoal filter In spare wheel well on vehicle floor 2 9 Nm 3 Breather line 4 Activated charcoal filter sol enoid valve 1 N80 5 To connection On intake manifold 6 Connecting hose 7 Connector For breather line On front right wheel housing 8 Connector For breather line Next to fuel filter 9 Connector In area of rear axle 10 Brea...

Page 156: ... h e c o r r e c t n e s s o f i n f o r m a t i o n i n t h i s d o c u m e n t C o p y r i g h t b y V o l k s w a g e n A G 2 2 Checking activated charcoal filter system for leaks Special tools and workshop equipment required Vacuum tester V A G 1368 Hand vacuum pump V A G 1390 Adapter set V A G 1318 17 Test procedure Pull breather hose 1 to solenoid valve off breather line 2 from activated cha...

Page 157: ...al filter Connect adapter V A G 1318 17 to line leading to solenoid valve and seal it Operate hand vacuum pump V A G 1390 several times A vacuum must build up If vacuum does not build up Check breather lines and couplings for interruptions or sepa rated couplings page 148 If vacuum builds up the breather lines are OK If there is still rea son to believe that there is a fault in the activated charc...

Page 158: ... w a g e n A G Reconnect breather line 1 to solenoid valve in engine com partment on activated charcoal filter Separate breather line 2 to expansion tank in wheel hous ing at activated charcoal filter Connect adapter V A G 1318 17 to line from activated char coal filter and seal it Operate hand vacuum pump V A G 1390 several times Vacuum must not build up If vacuum builds up Check breather arrow o...

Page 159: ...a cable from the accelerator There is no mechanical connection between the accelerator and the throttle valve The position of the accelerator is transmitted to the engine control unit by two accelerator position senders variable resistors to gether in one housing connected to the accelerator The position of the accelerator driver s requirement is a main input value for the engine control unit The ...

Page 160: ...r This means that the throttle valve can already be completely open even though the accelerator is depressed half way This has the advantage of preventing throttling losses at the throttle valve This also results in significantly improved consumption and ex haust emission values under certain load conditions The torque required by the engine can be produced by the engine control unit by optimising...

Page 161: ...em page 128 Safety precautions page 158 Observe rules for cleanliness page 128 Technical data page 159 Assembly overview intake manifold page 155 Assembly overview dismantling and assembling fuel rail page 157 Assembly overview air filter page 158 1 1 General notes on injection Fuel hoses in engine compartment must be secured only with spring type clips The use of crimp type or screw type clips is...

Page 162: ...ew 6 25 Nm 7 Vacuum connection For brake servo or vac uum pump for brakes V192 for vehicles with automatic gearbox 8 Vacuum connection 9 Vacuum connection 10 25 Nm 11 Throttle valve module J338 Gold plated connector contacts If renewed adapt en gine control unit to throt tle valve module Ve hicle diagnostic tester Guided func tions 12 10 Nm 13 Vacuum actuator For intake manifold change over 14 To ...

Page 163: ...cylinder head cover 1 3 Assembly overview fuel rail 1 Wiring harness With connectors for in jectors Clipped into cable chan nel 2 10 Nm 3 Fuel rail 4 Injector N30 N33 N83 N84 Checking page 161 5 Seal Renew 6 Retaining clip Check for secure seat ing 7 Return line connection 8 Supply line connection 9 Fuel pressure regulator Checking page 163 checking fuel pressure regulator and holding pressure 10 ...

Page 164: ...onnector 5 Seal Renew if damaged 6 Upper part of air filter 7 6 Nm 8 8 Nm 9 Air duct Secured to lock carrier 10 Connecting piece For air filter lower part with air pipe 11 Heat shield For lower part of air filter 12 Lower part of air filter 13 10 Nm 14 Filter element 15 6 Nm 1 5 Safety precautions For safety reasons fuse No 28 must be removed from the fuse holder before opening the fuel system Oth...

Page 165: ...e airbag is triggered If the engine is to be turned at starter speed without starting Pull connectors off ignition coils 1 6 Assembly tool T10118 can be used to release locking mechanism Apply assembly tool T10118 to locking mechanism button arrow and carefully pull connector off 1 6 Rules for cleanliness When working on the fuel supply and injection system observe the following 5 rules for cleanl...

Page 166: ...u n l e ssauthorisedbyVolkswagenAG VolkswagenAGdoesnot guaranteeorac c e p t a n y l i a b i l i t y w i t h r e s p e c t t o t h e c o r r e c t n e s s o f i n f o r m a t i o n i n t h i s d o c u m e n t C o p y r i g h t b y V o l k s w a g e n A G 13 Not adjustable Phaeton 2003 6 cylinder injection engine Edition 02 2014 160 Rep gr 24 Mixture preparation injection ...

Page 167: ...t n e s s o f i n f o r m a t i o n i n t h i s d o c u m e n t C o p y r i g h t b y V o l k s w a g e n A G 2 Checking components Checking injectors page 161 Checking fuel pressure regulator and holding pressure page 163 2 1 Checking injectors Checking injectors for leaks and quantity injected page 162 Special tools and workshop equipment required Remote control V A G 1348 3 Adapter V A G 1348 3...

Page 168: ...ing for leaks Remove fuse holder cover Connect remote control of V A G 1348 V A G 1348 3A with Phaeton adapter cable V A G 1348 3 3 to connections 1 and 2 Operate remote control If fuel pump runs Check injectors for leaks visual check No more than 1 to 2 drops per minute must escape from each valve when fuel pump is running If the fuel loss is greater Renew defective injector Pay attention to the ...

Page 169: ...n engine com partment Operate remote control for V A G 1348 V A G 1348 3A for 30 seconds Repeat check on other injectors Use new measuring beakers After all injectors have been activated place measuring beak ers on a horizontal surface and compare the injected quantity Specification 128 140 ml per injector If the measured values of one or more injectors are above or be low the prescribed specifica...

Page 170: ...1318 Adapter V A G 1318 9 Adapter V A G 1318 17 Adapter V A G 1318 23 The fuel pressure regulator regulates the fuel pressure depending on intake manifold pressure The specification for the check is dependent upon the working pressure of the fuel pump This is approx 3 5 bar Test prerequisite Fuel pump delivery rate OK checking page 139 Test procedure WARNING Fuel supply lines are under pressure We...

Page 171: ...A G 1318 to adapter V A G 1318 9 and adapter V A G 1318 17 and connect this assembly to supply line 2 Open pressure tester shut off tap The handle points in direc tion of flow Start engine and run at idling speed Measure fuel pressure Specification approx 3 5 bar Pull vacuum hose off fuel pressure regulator arrow The fuel pressure must increase to approx 4 0 bar If the specification is not attaine...

Page 172: ... on gauge again If the pressure does not drop Check non return valves of fuel pumps page 145 If the pressure drops again Check pressure tester V A G 1318 for leaks Check line connections O rings on fuel rail and injectors for leaks If no leaks can be found Switch off ignition Renew fuel pressure regulator Item 9 page 157 WARNING Fuel supply lines are under pressure Wear eye protection and gloves t...

Page 173: ...ry out the guided function Renew control unit Removing Switch off ignition Remove windscreen wiper motor on right side Electrical system Rep gr 92 Removing and installing windscreen wiper system Release both connectors from control unit and pull off Control unit can now be removed Installing Place control unit into retaining frame Fit connector and lock in position Install windscreen wiper motor o...

Page 174: ...n Selecting operating mode Press button on display for Vehicle self diagnosis Selecting vehicle system Press 01 Engine electronics button on display The control unit identification with code as well as chassis number and immobilizer identification number will be indicated on the dis play Note A print out can be made if required Press the Print button Press button Selecting diagnostic function Pres...

Page 175: ...lytic con verters and attachments page 170 Exhaust pipes with main catalytic converters and silencers with mountings page 172 Removing and installing exhaust manifolds and exhaust pipes with starter catalytic converters page 174 Note To support the exhaust system when removing use engine and gearbox jack V A G 1383 A After working on the exhaust system ensure that the system has sufficient clearan...

Page 176: ... pipes ensure that the flange connec tion after the catalytic converter seals tightly Leaks in this area cause pulsation in exhaust This allows ambient air to reach the Lambda probe after the catalytic converter thereby dis turbing Lambda regulation Renew self locking nuts 1 Cylinder head 2 Gasket Renew 3 M8 25 Nm M10 40 Nm 4 Exhaust manifold 5 Gasket Renew 6 Lambda probe G39 50 Nm Installed in ex...

Page 177: ...30 50 Nm Installed in exhaust gas stream of cylinders 1 2 and 3 Grease only the threads with G 052 112 A3 G 052 112 A3 must not get into the slots on the probe body Remove and install with Lambda probe open ring spanner set 3337 11 Lambda probe 2 after catalytic converter G131 50 Nm Installed in exhaust gas stream of cylinders 4 5 and 6 Grease only the threads with G 052 112 A3 G 052 112 A3 must n...

Page 178: ...and 3 9 Mounting Installation position page 174 Renew if damaged 10 25 Nm 11 Centre silencer 12 Separating point For repair cases Marked by impressions on exhaust pipe Centre and rear silenc ers are installed as a single component during production In repair cases the centre and rear silencers are supplied individ ually with a repair double clamp for connecting them Installing page 173 Cut through...

Page 179: ...er 3 Bracket 4 Spring 5 Spacer sleeve 6 Hexagon bolt 25 Nm Separating point between centre silencer and rear silencer Separate connecting pipe between centre silencer and rear silencer at the point marked with a groove Special tools and workshop equipment required Pneumatic sabre saw V A G 1523A Installation position of double clamp 1 From main catalytic converter 2 To centre silencer 3 Three mark...

Page 180: ...ure must be strictly followed Switch off ignition and all electrical consumers and remove key First disconnect drive battery on right in luggage compartment Then disconnect second battery on left in luggage compart ment Electrical system Rep gr 27 Disconnecting and reconnecting batteries Removing Pull all coolant hoses off intake manifold Remove air filter housing complete with intake hose page 15...

Page 181: ...mbda probe after catalytic converter using Lamb da probe open ring spanner set 3337 Remove catalytic converter for cylinders 4 5 and 6 and Lamb da probe after catalytic converter in the same way Now remove exhaust manifold Installing The assembly is basically a reverse of the dismantling sequence First install the catalytic converter for cylinders 4 5 and 6 to exhaust manifold with Lambda probe af...

Page 182: ...temperature This produces an oxygen rich exhaust gas causing afterburning and reducing the heat up phase of the catalytic con verter Actuation is performed by the engine control unit via the secondary air pump relay J299 to secondary air inlet valve N112 and combination valve Additionally after each subse quent engine start up to max 85 C engine temperature the secondary air system will after a 20...

Page 183: ...178 6 Gasket Renew 7 Air duct In cylinder head 8 10 Nm 9 Connection For combination valve 10 5 Nm 11 Pressure hose Ensure secure seating 12 O ring Renew if damaged 13 Connection 14 Secondary air pump motor V101 15 Rubber bush 16 Bracket For secondary air pump motor V101 17 Connector For secondary air pump motor V101 18 20 Nm 19 Retaining clamp 20 Air filter With non return valve Clean if soiled 21...

Page 184: ...secondary air pump is inserted in socket 7 If tools are necessary to pull relays or control units out of the relay plate first disconnect battery earth strap Electrical system Rep gr 27 Disconnecting and reconnecting batter ies 2 2 Checking combination valve Special tools and workshop equipment required Hand vacuum pump V A G 1390 Test prerequisites Vacuum pipes and hose connections free of leaks ...

Page 185: ...s s o f i n f o r m a t i o n i n t h i s d o c u m e n t C o p y r i g h t b y V o l k s w a g e n A G Connect hand vacuum pump V A G 1390 to vacuum con nection on combination valve arrow Detach pressure hose to combination valve at connection arrow and blow in softly Combination valve must be closed Operate hand vacuum pump V A G 1390 Combination valve must open If combination valve does not ope...

Page 186: ...pecifically relate to the ignition system are dealt with here For other components of the in jection and ignition system page 155 For trouble free operation of electrical components a voltage of at least 11 5 V is necessary During some checks it is possible that the control unit will de tect and store a fault Therefore after completing all checks and repairs the fault memory must be read and if ne...

Page 187: ... Gold plated contacts on sensor and connector 6 Knock sensor 1 G61 Gold plated contacts on sensor and connector Location cylinder block exhaust side 7 20 Nm The torque setting influ ences the function of the knock sensor 8 Exhaust camshaft adjuster With sender wheel for Hall sender 2 G163 Installing page 64 9 Cover Removing and installing page 71 10 Seal Renew 11 Hall sender 2 G163 For exhaust cam...

Page 188: ...fts 1 2 Safety precautions To prevent injuries to persons and or damage to the injection and ignition system the following must be observed Switch off ignition before connecting or disconnecting injection and ignition system wiring as well as test instrument cables If the engine is to be turned at starter speed without starting Observe following if test and measuring instruments are required durin...

Page 189: ...ply assembly tool T10118 to locking mechanism button arrow and carefully pull connector off each ignition coil with output stage Push puller T10095A on from flat side of connector in direction of arrow and pull out ignition coil with output stage Installing Note When fitting new spark plugs the ignition coil must be re greased using lubricating paste G 052 141 A2 This will stop the ignition coil s...

Page 190: ...the ignition coil sealing hose arrow The bead must be 1 2 mm thick To install insert ignition coil with output stage into respective spark plug recess so that the flat sides of connectors fit with each other arrows Push puller T10095A on from flat side of connector in direction of arrow and push ignition coil with output stage onto spark plug 1 4 Test data spark plugs Engine code AYT BKL BRK14 Fir...

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