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Workshop Manual
Touareg 2003 ➤
8-cylinder injection engine
Engine ID AXQ BHX
Edition 11.2011
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List of Workshop Manual Repair GroupsList of Workshop Manual
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Repair GroupsList of Workshop Manual Repair Groups
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Repair Group
00 - Technical data
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10 - Removing and installing engine
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13 - Crankshaft group
15 - Cylinder head, valve gear
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17 - Lubrication
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19 - Cooling
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20 - Fuel supply system
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24 - Mixture preparation - injection
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26 - Exhaust system
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28 - Ignition system
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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 road-worthiness and
safety. In addition, the normal basic safety precautions for working on motor vehicles must, as a
matter of course, be observed.
Contents
00 - Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1 Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.1 Engine data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
13 - Crankshaft group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
1 Dismantling and assembling engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
1.1 Assembly overview - part I, toothed belt drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
1.2 Assembly overview - part II, cylinder block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
1.3 Removing and installing poly V-belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
1.4 Checking alignment of poly V-belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
2 Removing and installing sealing flange and drive plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
2.1 Assembly overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
2.2 Removing and installing drive plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
2.3 Removing and installing sealing flange at drive plate end . . . . . . . . . . . . . . . . . . . . . . . . . . 24
2.4 Renewing crankshaft oil seal, vibration damper end . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
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2.4 Removing and installing camshafts and variable camshaft timing adjusters . . . . . . . . . . . . 56
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17 - Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
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19 - Cooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
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1.1 Assembly overview - radiator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
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1.2 Assembly overview - radiator fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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1.3 Removing and installing fan support with fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
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1.4 Assembly overview - parts of cooling system, engine side, front . . . . . . . . . . . . . . . . . . . . 81
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Contents i
Touareg 2003 ➤
8-cylinder injection engine - Edition 11.2011
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1.8 Removing and installing fuel delivery unit, fuel gauge sender and suction-jet pumps . . . . 102
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1.9 Removing and installing fuel tank with attached components . . . . . . . . . . . . . . . . . . . . . . 104
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1.10 Checking fuel pumps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
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1.12 Checking non-return valve of right pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
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1.13 Checking non-return valve of left pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
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2 Electronic power control (EPC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
3 Activated charcoal filter system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117
3.1 Assembly overview - activated charcoal filter system . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118
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3.2 Checking fuel system for leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118
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4 Activated charcoal filter system (vehicles for USA and Canada) . . . . . . . . . . . . . . . . . . . . 122
4.1 Assembly overview - activated charcoal filter system . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123
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4.2 Checking fuel system for leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124
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1.3 Assembly overview - air filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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1.4 Assembly overview - vacuum hose assembly on intake manifold . . . . . . . . . . . . . . . . . . . . 136
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1.5 Safety precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137
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1.6 Rules for cleanliness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137
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ii Contents
Touareg 2003 ➤
8-cylinder injection engine - Edition 11.2011
2.1 Assembly overview - removing and installing parts of secondary air system . . . . . . . . . . . . 155
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Contents
Touareg 2003 ➤
8-cylinder injection engine
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iv Contents
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Technical data
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Engine number
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The engine number („engine code“ and „serial number“) is stam‐
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1.1 Engine data
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Issued 11.2011; Version 6.0
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1. Technical data 1
Touareg 2003 ➤
8-cylinder injection engine - Edition 11.2011
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♦ It is advisable to remove the front wheels before beginning
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the brake disc splash plates are just above the floor. This pro‐
vides the most ergonomic working position regarding acces‐
sibility of engine compartment components.
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♦ Some components cannot be removed, or removed only with
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– Switch off ignition and all electrical consumers.
– First disconnect battery under driver seat ⇒ Electrical system;
Rep. gr. 27 ; Disconnecting and reconnecting batteries .
Procedure
– Remove left and right wiper arms: ⇒ Electrical system; Rep.
gr. 29 ; Removing and installing wiper system .
– Pull engine compartment seal off bulkhead.
– Remove covers -A-, -B- and -C- from engine compartment.
WARNING
Fuel supply lines 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.
– Wrap a cloth around the joint to catch fuel which flows out.
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– Disconnect breather line -arrow- to solenoid valve in engine
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– Disconnect small connector -A- from engine control unit -1-
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– Separate connectors -1- to -4- for Lambda probes and lay
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connectors on engine.
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Connector for cylinder bank 1 = black, connector for cylinder bank
2 = brown
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off upper part of air filter and remove upper part of air filter.
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– Remove bracket for engine cover on right ⇒ page 134 . cop Vo
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– Pull lower part of air filter from air duct ⇒ Item 10 (page 134)
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– Remove heat shield -A- from steering box and separate uni‐
versal joint -B-. ⇒ Running gear, axles, steering; Rep. gr. 48 ;
Repairing steering, power-assisted steering
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cooling system.
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– Disconnect upper coolant hose from radiator and lower cool‐
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– Secure subframe to body ⇒ Running ed by gear, axles, steering; ara
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Rep. gr. 40 ; l - Assembly overview
thor - subframe, lower sus‐ eo
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– Then proceed with other securing bolt -3- in the same way.
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– At the same time, guide right and left mountings for gearbox
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ports are in the receptacle holes without pressure:
– Screw the two rotating plates of running gear supports under
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the suspension links applying a small amount of pre-tension.
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Continuation for all vehicles
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– Bolt shackles -10 - 222 A /12- to each lifting eye of engine.
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– Lift engine using workshop crane -VAS 6100- until the centre
of the flywheel is at the same height as the assembly plate of
the engine and gearbox support -VAS 6095- . Then bolt sup‐
port to cylinder block as shown in the illustration using univer‐
sal fastening elements.
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system; Rep. gr. 87 ; Repairing components of refrigerant cir‐ ility
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– Connect battery.
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Engine bracket to engine M10 75 Nm
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Engine mounting to en‐ M10 60 Nm
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Engine carrier to body M12 100 Nm + 1/2 turn (180°).
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Drive shafts to gearbox ⇒ Running gear, axles, steer‐
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13 – Crankshaft group
1 Dismantling and assembling engine
Assembly overview
Part I: toothed belt drive ⇒ page 15
Part II: cylinder block ⇒ page 17
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Caution
Note
♦ Secure engine to engine and gearbox support -VAS 6095- to carry out repairs.
♦ Engine must not be set down on oil sump, as this will damage the liquid gasket between the upper and lower
sump.
♦ Finding metal shavings or a large quantity of small metal particles during engine repair could indicate that
the crankshaft bearings or conrod bearings are damaged. To prevent this from causing further damage,
perform the following repairs:
♦ Thoroughly clean oil passages,
♦ Renew oil return valve,
♦ Renew oil spray jets,
♦ Renew oil cooler,
♦ Renew oil filter.
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1 - 10 Nm
2 - Bearing sleeve
3 - 20 Nm + 1/4 turn (90°) fur‐
ther
❑ Renew.
4 - Washer
❑ For tensioning roller.
5 - 40 Nm
6 - Tensioning roller
7 - Tensioning lever
8 - 22 Nm
9 - 55 Nm
❑ Renew.
❑ Oil threads and bolt
head contact surface.
10 - Securing plate
❑ Renew.
❑ Observe installation po‐
sition: side with lettering
faces to rear.
11 - Right camshaft pulley
❑ Pull off camshaft with
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12 - 10 Nm
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14 - Idler roller
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15 - Pin, 6 Nm
16 - 15 Nm
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17 - Coolant pump
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❑ Renew.
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es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
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rp
cu
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t.
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Cop py
t. rig
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Vo
co lksw
by
cted agen
Prote AG.
1 - 10 Nm
2 - Cover
❑ With connection for
crankcase breather
3 - Connecting hose
❑ For crankcase ventila‐
tion.
4 - Clip
5 - Baffle plate
❑ With seal.
AG. Volkswagen AG d
❑ Renew. lksw
agen oes
not
Vo gu
by
6 - Oil return supply valve rised ara
nte
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❑ For cylinder head, right aut
h
ra
ss c
7 - O-ring
ce
le
un
pt
an
❑ Renew.
d
itte
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rm
ab
8 - 20 Nm
pe
ility
ot
wit
, is n
h re
fluences the function of
hole
spec
es, in part or in w
t to the co
10 - Knock sensor 2 (G66)
rrectness of i
11 - Plug, 35 Nm
l purpos
12 - Seal
❑ Renew.
nform
ercia
13 - Engine bracket
m
a
❑ Engine bracket and
com
tio
specified torques
n in
r
te o
⇒ page 18
thi
s
iva
do
14 - 40 Nm + 1/4 turn (90°) fur‐
r
rp
cum
fo
ther
en
ng
t.
yi Co
op
❑ Renew. C py
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15 - Banjo bolt, 30 Nm op Vo
by c lksw
cted agen
Prote
16 - 10 Nm
AG.
pt
an
d
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erm
ab
ility
ot p
wit
Note
is n
h re
ole,
spec
secured tightly.
♦ Check that idler roller turns easily.
rrectne
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
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pyri by
Vo
co lksw
by
cted agen
Prote AG.
Note
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
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aut ra
ss c
ce
le
un
pt
an
d
itte
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rm
ab
pe
ility
♦ Torque wrench (5…50 Nm) -V.A.G 1331-
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tion in
Procedure
r
te o
thi
s
do
r
rp
cum
fo
t.
yi Co
Cop py
t. rig
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pyri by
Vo
o
by c lksw
cted agen
Prote AG.
Note
The air conditioning system compressor pulley must align with the
power-assisted steering vane pump pulley.
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
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au ra
ss c
ce
e
nl
pt
du
an
itte
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erm
ab
ility
ot p
wit
, is n
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hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
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t.
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Cop py
t. rig
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pyri by
Vo
co lksw
by
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Prote AG.
Note
olksw
Secure engine to engine and gearbox supportsw-VAS
agen 6095- to car‐AG does
AG. V agen
ry out repairs. by
Volk not
gu
a
ed ran
oris tee
h
Assembly overview ⇒ page 21 . aut or
ac
ss
Removing and installing drive plate ⇒ page 22 .
ce
e
nl
pt
du
an
itte
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erm
ab
⇒ page 24
ility
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⇒ page 26
hole
spec
2.1 Assembly overview
es, in part or in w
t to the co
1 - Gasket
rrectness of i
❑ Renew.
l purpos
2 - Sealing flange
❑ With seal.
nform
ercia
at
om
io
⇒ page 70 .
n
c
in t
or
his
ate
sleeves.
do
priv
cum
or
en
ng
ing lip.
❑ Use support sleeve sup‐
plied when installing.
❑ Only remove supporting
sleeve after sealing
flange has been slid on‐
to crankshaft journal.
❑ If the sealing flange has
not been renewed use
fitting tool -T10122- for
installing ⇒ page 26 ,
Removing and installing
sealing flange at drive
plate end.
❑ Removing and installing
⇒ page 24 .
3 - Shim
❑ 2 mm thick
4 - Drive plate
❑ Use locking pin -3242- to loosen and tighten ⇒ page 22 ; Removing and installing drive plate.
5 - Washer
❑ 3.4 mm thick
ce
le
un
pt
an
d
8 - 15 Nm
itte
y li
erm
ab
9 - Cylinder block
ility
ot p
wit
is n
10 - Oil sump
h re
ole,
spec
urposes, in part or in wh
11 - Securing bolt
t to the co
❑ M7 = 15 Nm
❑ M8 = 22 Nm
rrectne
12 - Timing chain
s
❑ Mark with arrow pointing in direction of rotation before removing (e.g. using paint).
s o
cial p
f
❑ Do not mark with a centre punch mark, notch or anything similar!
inform
mer
13 - Chain sprocket
atio
m
❑ For crankshaft.
o
n
c
i
or
n thi
e
14 - Thrust washer
t
sd
iva
o
r
cum
r
fo
en
ng
15 - Gasket
t.
yi Co
op py
❑ Renew.
. C rig
ht ht
rig by
opy Vo
16 - Sealing flange at belt pulley end by c lksw
cted agen
Prote AG.
❑ Remove sump in order to remove and install ⇒ page 70 .
❑ Must seat on dowel sleeves.
❑ Before installing, remove oil residue from crankshaft journal using a clean cloth.
17 - O-ring
❑ Renew.
18 - Spray nozzle valve, 35 Nm
19 - Seal
❑ Renew. ⇒ page 26 .
20 - Crankshaft toothed belt pulley
❑ Fitting possible in one position only.
❑ For removal lock crankshaft using locking pin -3242- ⇒ page 22 ; Removing and installing drive plate.
21 - 200 Nm + 1/2 turn (180°) further
❑ Renew.
❑ Do not oil.
❑ Turning further can be done in several stages.
22 - Vibration damper/belt pulley
❑ For poly V-belt.
❑ For removal lock crankshaft using locking pin -3242- ⇒ page 22 ; Removing and installing drive plate.
23 - 22 Nm
24 - 25 Nm
25 - Cover
Removing
– Remove engine ⇒ page 3 .
– Separate engine from gearbox.
– Set engine to TDC. For this, notches -A- and -B- must align.
AG. Volkswagen AG d
Note lksw
agen oes
not
Vo gu
d by ara
♦ The engine is cranked by turning crankshaft icentre bolt.
se nte
or eo
h
aut ra
♦ The engine must only be cranked in clockwise
ss direction. c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
t to the co
Note
rrectness of i
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted
23
agen
Prote AG.
2. Removing and installing sealing flange and drive plate
Touareg 2003 ➤
8-cylinder injection engine - Edition 11.2011
ce
e
pt
du
an
note the following:
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
– Fit shim -1- of „2.0 mm thickness“ onto crankshaft journal.
– Then, install drive plate and washer -2- of „3.4 mm thickness“.
rrectness of i
– Insert new securing bolts and tighten by hand.
l purpos
nform
ercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
g
t.
yi Co
op py
at drive plate end
t. C rig
gh ht
pyri by
Vo
co lksw
Removing ⇒ page 25 .
by
cted agen
Prote AG.
Installing ⇒ page 25 .
Special tools and workshop equipment required
♦ Fitting tool -T10122-
2.3.1 Removing
– Remove engine ⇒ page 3 .
– Separate engine from gearbox.
– Remove drive plate ⇒ page 22 .
– Remove sump ⇒ page 70 .
– Remove sealing flange -arrow- from cylinder block.
– Remove existing gasket.
AG. Volkswagen AG d
agen oes
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2.3.2 Installing d b ara
rise nte
tho eo
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ce
e
Note
nl
pt
du
an
itte
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erm
ab
ility
sealing flange.
ot p
wit
, is n
t to the co
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
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Cop py
t. rig
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pyri by
Vo
co lksw
by
cted agen
Prote AG.
– Pull oil seal with sealing flange -A- by the outside over sleeve
-T10122/1- onto pulling sleeve -T10122/2- .
– Separate the two fitting sleeves.
– Then set pulling sleeve -T10122/2- with dry seal and sealing
flange onto crankshaft journal. gen AG
. Volkswagen AG
a does
lksw not
– Bolt sealing flange to cylinder block. Specified torque:
db
yV
o
10 Nm gu
ara
e nte
ris
– Install sump ⇒ page 70 . utho eo
ra
a c
ss
– Install drive plate ⇒ page 22 .
ce
le
un
pt
– Install engine ⇒ page 3 .
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
2.4 Renewing crankshaft oil seal, vibration
l purpos
damper end
Special tools and workshop equipment required
nform
ercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
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pyri by
Vo
co lksw
by
cted agen
Prote AG.
Removing
– Remove noise insulation tray.
– Remove toothed belt ⇒ page 34 .
– Unscrew centre bolt -2- from crankshaft toothed belt pulley
-1- and remove crankshaft toothed belt pulley from crankshaft
journal.
– Then remove seal using extractor hook -T20143/1- .
ce
e
nl
Installing
pt
du
an
itte
y li
– Remove oil residue from crankshaft journal and thrust washer
erm
ab
using a clean cloth.
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
– Press new seal in to stop using thrust piece -T40007- .
l purpos
nf
ercia
orm
– Install crankshaft toothed belt pulley using a new centre bolt.
m
atio
m
n in
or c
thi
e
sd
iva
o
r
rp
cu
– Install poly V-belt ⇒ page 18 .
o
m
f
en
ng
t.
yi
– Install noise insulation tray.
Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
Note
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
1 - Cap
❑ Renew seal if damaged.
2 - Boot
❑ Renew if damaged.
3 - Oil filler neck
❑ Renew seal if damaged.
4 - Connecting hose
❑ For crankcase ventila‐
tion.
5 - Cylinder head cover
❑ Removing and installing
left cylinder head cover n AG. Volkswagen AG do
⇒ page 32 . lkswage es n
o ot g
yV ua
❑ Removing and installing ir se
d b ran
right cylinder head cov‐ utho tee
or
er ⇒ page 30 . ss
a ac
❑ Renew if damaged.
ce
le
un
pt
an
d
itte
6 - Gasket
y li
erm
ab
❑ Note installation posi‐
ility
ot p
tion.
wit
is n
h re
❑ Renew if damaged or
ole,
spec
leaking.
urposes, in part or in wh
t to the co
7 - 10 Nm
❑ Observe tightening se‐
quence.
rrectne
❑ Removing and installing
left cylinder head cover
ss
⇒ page 32 .
o
cial p
f i
❑ Removing and installing
right cylinder head cov‐ nform
mer
er ⇒ page 30 .
atio
om
n
c
n thi
te
sd
o
pr
en
ng
t.
❑ Note installation position.
yi Co
Cop py
❑ Removing and installing left cylinder head cover ⇒ page 32 .
t. rig
gh ht
pyri by
❑ Removing and installing right cylinder head cover ⇒ page 30 .
co Vo
by lksw
cted agen
Prote AG.
9 - Baffle plate
10 - 5 Nm
11 - Coolant pipe
12 - Gasket
❑ Renew.
13 - Sealing grommet
❑ Insert in cylinder head cover.
❑ Renew if damaged or leaking.
14 - Cylinder head bolt
❑ Renew.
❑ Follow installation instructions and sequence when loosening and tightening.
1. Cylinder head 29
olkswagen AG
Touareg 2003 ➤ wage
n AG. V does
olks not
8-cylinder injection engine - Edition 11.2011 d by V gu
ara
e nte
ris
❑ Removing and installing right cylinder head
aut ⇒ page 44 .
ho eo
ra
ss ⇒ page 40 . c
❑ Removing and installing left cylinder head
ce
e
nl
pt
du
15 - Cylinder head
an
itte
y li
❑ Check for distortion ⇒ page 30 .
erm
ab
ility
ot p
❑ Removing and installing right cylinder head ⇒ page 44 .
wit
, is n
❑ Removing and installing left cylinder head ⇒ page 40 .
h re
hole
spec
❑ After renewing, renew entire coolant.
es, in part or in w
t to the co
16 - Cylinder head gasket
❑ Metal gasket.
❑ Renew.
rrectness of i
❑ Must seat on dowel pins.
l purpos
nform
ercia
17 - 10 Nm
m
18 - Combination valve
at
om
ion
❑ For secondary air system
c
in t
or
his
te
19 - Coolant pipe
a
do
priv
cum
or
20 - O-ring
f
en
ng
t.
yi
❑ Renew.
Co
Cop py
t. rig
gh
21 - 20 Nm
ht
pyri by
Vo
co lksw
by
22 - Lifting eye
cted agen
Prote AG.
23 - Seal
❑ Renew if damaged or leaking.
♦ Not illustrated:
♦ Cable ties
♦ Sealant -D 454 300 A2-
Removing
Caution
pt
y li
is installed.
rm
ab
pe
ility
– Remove intake hose between air filter and throttle valve con‐
ot
wit
, is n
trol module.
h re
hole
t to the co
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
1. Cylinder head 31
Touareg 2003 ➤
8-cylinder injection engine - Edition 11.2011
Note
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
1.3 Removing and installing left cylinder
head cover
Special tools and workshop equipment required
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
♦ Not illustrated:
es, in part or in w
t to the co
♦ Cable ties
♦ Sealant -D 454 300 A2-
rrectness of i
Removing
l purpos
Caution
nform
ercia
a
ment, pay attention to the following due to the cramped condi‐
com
tion in
tions:
r
te o
thi
♦ Route all the various lines (e.g. for fuel, hydraulics, acti‐
s
iva
do
r
cum
fo
t.
yi
sitions.
Co
Cop py
t. rig
♦ To avoid damage to lines, ensure sufficient clearance to
gh ht
pyri by
all moving or hot components.
co Vo
by lksw
cted agen
Prote AG.
– All cable ties which are opened or cut open when engine is
removed must be replaced in the same position when engine
is installed.
– Remove intake hose between air filter and throttle valve con‐
trol module.
– Remove bracket -3-.
– Disconnect connectors -4- from ignition coils.
– Remove ignition coils ⇒ page 158 .
– Disconnect crankcase breather hoses -1- and -2-.
1. Cylinder head 33
Touareg 2003 ➤
8-cylinder injection engine - Edition 11.2011
Note
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
tho eo
– Tighten securing bolts in the sequence -1- to -12-. Specified
s au ra
c
torque: 10 Nm s
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
Removing ⇒ page 35 .
m
a
com
tio
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
1.4.1 Removing
es, in part or in w
t to the co
Caution
rrectness of i
♦ Route all the various lines (e.g. for fuel, hydraulics, acti‐
rm
m
n in
c
sitions.
or
thi
te
sd
iva
cu
m
f
en
ng
t.
yi Co
Cop py
t. rig
gh
– Remove insulation tray ⇒ General body repairs, exterior; Rep.
ht
pyri by
Vo
gr. 50 ; Noise insulation
o
by c lksw
cted agen
Prote AG.
– Remove radiator fans with radiator fan support ⇒ page 79 .
– Bring lock carrier into service position ⇒ General body repairs,
exterior; Rep. gr. 50 ; Body - front; Lock carrier service posi‐
tion .
1. Cylinder head 35
Touareg 2003 ➤
8-cylinder injection engine - Edition 11.2011
Note
If the larger holes in the securing plates are positioned to the out‐
side of the camshaft sprockets, the crankshaft must be turned one
revolution further in direction of engine rotation.
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
tho eo
– Remove sealing plug s au-arrow- from left side of cylinder block. ra
c
The TDC drilling insthe crankshaft must be visible (or able to
ce
le
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
tion in
r
te o
thi
s
iva
Note
do
r
rp
cum
fo
en
g
t.
yi Co
op
bolts. C py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
– First unscrew bolt -1- from oil filter housing. Then unscrew
bolts -2- from cover for toothed belt tensioning element.
– Remove cover.
Note
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
1. Cylinder head 37
Touareg 2003 ➤
8-cylinder injection engine - Edition 11.2011
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
– Loosen tensioning roller -arrow- and remove toothed belt.
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
ion
c
in t
or
cum
or
– First, fit toothed belt to crankshaft toothed belt pulley -1-, then
f
en
ng
t.
yi
to idler roller of toothed belt tensioner -2- and then to tension‐
Co
op py
ing roller -3-. After that, fit toothed belt to camshaft sprockets t. C rig
gh ht
and coolant pump pulley as shown in the illustration. pyri by
Vo
o
by c lksw
cted agen
Prote AG.
Note
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
– Turn tensioning lever of toothed belt tensioning roller -1- in
ility
ot p
spec
– Tighten camshaft sprockets to 55 Nm.
es, in part or in w
t to the co
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
1. Cylinder head 39
Touareg 2003 ➤
8-cylinder injection engine - Edition 11.2011
ce
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Removing ⇒ page 41 .
Installing ⇒ page 43 .
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♦ Cable ties
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♦ 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, ensure sufficient clearance to
all moving or hot components.
1. Cylinder head 41
Touareg 2003 ➤
8-cylinder injection engine - Edition 11.2011
– All cable ties which are opened or cut open when engine is
removed must be replaced in the same position when engine
is installed.
– Remove front exhaust pipe from exhaust manifold
⇒ page 148 .
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– Unbolt guide tube for oil dipstick -arrow- from cylinder head.y Volks ot g
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– Disconnect connectors -2- and -3-.
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– Remove toothed belt ⇒ page 34 .
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– Loosen securing bolts -1- and -2- and remove rear toothed belt
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– Also prevent dirt and emery cloth particles from getting into
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1.5.2 Installing
– Carefully remove metal particles, emery residue and cloths.
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♦ Do not remove new cylinder head gasket from its packing until
form
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1. Cylinder head 43
Touareg 2003 ➤
8-cylinder injection engine - Edition 11.2011
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Removing ⇒ page 45 .
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Installing ⇒ page 47 .
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Caution
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agen 1. Cylinder head
Touareg 2003 ➤
8-cylinder injection engine - Edition 11.2011
– All cable ties which are opened or cut open when engine is
removed must be replaced in the same position when engine
is installed.
– Remove front exhaust pipe from exhaust manifold
⇒ page 148 .
– Disconnect connectors -1-, -2- and -3-.
– Remove toothed belt ⇒ page 34 .
– Remove camshaft pulley ⇒ page 34 , Removing, installing and
tensioning toothed belt.
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– Remove bolts securing coolant pipe -arrow-. byV
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– Remove intake manifold ⇒ page 132 .
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– Remove cylinder head cover ⇒ page 30 . cop Vo
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1.6.2 Installing
– Carefully remove metal particles, emery residue and cloths.
Note
♦ Do not remove new cylinder head gasket from its packing until
immediately before installing.
♦ Handle new gasket with extreme care. Damage will cause
leakage.
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1. Cylinder head 47
Touareg 2003 ➤
8-cylinder injection engine - Edition 11.2011
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Adjusting valve timing ⇒ page 34 .
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– Installing cylinder head cover ⇒ page 30 .
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– Install intake manifold ⇒ page 132 .
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It is not necessary to retighten cylinder head bolts after repairs.
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tension -3122 B-
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♦ Compression tester -
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V.A.G 1763-
Test prerequisites
• Engine oil temperature must be at least 30°C.
• The battery voltage must be at least 11.5 V.
• All electrical consumers, e.g. lights and rear window heating,
must be switched off.
• If the vehicle is equipped with an air conditioner, it must be
switched off.
• The selector lever of the must be in „P“or „N“ position.
Test procedure
– Remove ignition coils with output stages ⇒ page 158 .
– Disconnect all connectors from injectors.
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– Remove spark plugssusing
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– Check compression
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Using compression tester ⇒ operating instructions .
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– Have a second mechanic fully depress accelerator and crank
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– Carry out vehicle system test ⇒ Vehicle diagnostic tester „Gui‐
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– Finish the vehicle system test so that any fault entries stored
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1. Cylinder head 49
Touareg 2003 ➤
8-cylinder injection engine - Edition 11.2011
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⇒ page 61 .
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❑ Renew.
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❑ Do not interchange.
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❑ Removing and installing
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5 - Inlet camshaft bearing cap
❑ Removing and installing
⇒ page 56 , Removing
and installing camshafts
and variable camshaft
timing adjuster.
6 - Exhaust camshaft bearing
cap
❑ Removing and installing ⇒ page 56 , Removing and installing camshafts and variable camshaft timing
adjuster.
7 - 5 Nm + 1/4 turn (90°) further
❑ Renew.
8 - Double bearing cap
9 - Cap
❑ Renew.
❑ Punch through using a screwdriver and lever out for removal.
❑ Install using tool 3202.
10 - Bearing cap
When installing, seal parting surfaces of outer bearing caps with sealant -AMV 188 001 02- ⇒ page 61 .
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❑ Renew.
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16 - Camshaft adjuster
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adjuster.
17 - Gasket
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18 - Valve cotters
19 - Valve spring plate
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20 - Valve spring
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23 - Cylinder head
❑ Check for distortion ⇒ page 30 .
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❑ Removing and installing ⇒ page 34 Removing, installing and tensioning toothed belt.
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39 - O-ring
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Valve dimensions
Note
Valve dimensions
Dimension Inlet valve Exhaust valve
-∅ a- mm 26.8...27.0 29.8...30.0
-∅ b- mm 5.96...5.97 5.94...5.95
-c- mm 104.84...105.34 103.64...104.14
-α- ∠° 45 45
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fingers removed.
– Insert camshaft and secure with bearing caps -3-, -5- and
-7-.
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– Fit seal and press it in to stop using pressure sleeve -3241/1-
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and bolt -3241/6- .
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– Install toothed belt and camshaft sprockets ⇒ page 34 .
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Continuation for both cylinder heads
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– Screw in pin -2085/1- as shown in the illustration.
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– Unscrew inner part of oil seal extractor -2085- several turns
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– Lubricate threaded head of oil seal extractor, place it in posi‐ Prote AG.
tion and, exerting firm pressure, screw it into oil seal as far as
possible.
– Loosen knurled screw and turn inner part against pin -2085/1-
until seal is pulled out.
– Clamp flats of oil seal extractor in vice. Remove oil seal with
pliers.
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2.4.1 Removing
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– Set engine to TDC ⇒ page 34 .
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– Remove toothed belt and camshaft sprocket ⇒ page 34 ; Re‐
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– Remove cylinder head cover ⇒ page 32 .
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– Loosen securing bolts -1- and -2- and remove rear toothed belt
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– Mark installation position of all bearing caps (e.g. using a wa‐
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tion regardless of the existing markings on the bearing caps.
– Unscrew securing bolts for camshaft adjuster.
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– Remove bearing cap -1-.
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– Remove bearing caps -2-, -4-, -6-, -8- and -9- and place them
on a clean surface in sequence given.
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– Loosen bearing caps -3-, -5- and -7- alternately and diagonally
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– Carefully remove camshafts with camshaft adjusters and
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2.4.2 Installing
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– Renew half-round sealing plug.
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– Renew gasket for camshaft adjuster.
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– Coat hatched area lightly with sealant -AMV 188 001 02- .
– Fit camshaft timing chain onto camshaft drive gears as de‐
scribed below.
When reusing existing camshaft timing chain
The distance between tooth -A- and tooth -B- of the camshaft ad‐
juster must be exactly 16 rollers of the camshaft roller chain. The
illustration shows the exact positions of the -1st- and -16th- Arollers
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camshaft adjuster in cylinder head.
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Dowel sleeves for bearing caps and camshaft adjuster must be
fitted in cylinder head.
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– Install bearing caps -3-, -5- and -7- to locations as marked and
tighten new bolts alternately and diagonally. Specified torque:
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Note
– Lightly coat double bearing cap -6- and bearing cap -1- with
sealant -AMV 188 001 02- ⇒ page 61 and install bearing
caps. Specified torque: 5 Nm + 1/4 turn (90°) further.
– Install remaining bearing caps. Specified torque: 5 Nm + 1/4
turn (90°) further. wage
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– Renew camshaft seals ⇒ page 54 . ed by ara
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– Renew Hall sender seals ⇒ page 55 . utho eo
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– Carefully drive in cap ⇒ Item 9 (page 50) using thrust piece of
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fitting sleeves -3202- .
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♦ After installing camshafts wait for approx. 30 minutes before
starting engine. Hydraulic compensating elements must settle.
(Valves will otherwise contact piston).
♦ After working on valve mechanism, carefully turn engine by rrectne
hand to ensure that no valve strikes piston when engine is
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started.
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Lightly coat parting surfaces of front and rear bearing caps with
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2.5 Removing and installing roller rocker fin‐
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♦ Torque wrench (5…50 Nm) -V.A.G 1331-
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Procedure
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– Remove camshafts with camshaft adjuster ⇒ page 56 . yri
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– Mark allocation of roller rocker fingers and roller rocker finger
agen
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shafts in order to ensure correct reinstallation.
– Remove securing bolts -arrows-.
– Then, screw in M6 bolts into shaft holes and pull shafts out of
cylinder head.
– Remove roller rocker fingers.
Note
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5161/6- and push assembly cartridge down.
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– At the same time, turn knurled screw of assembly cartridge
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– Move knurled screw back and forth lightly to press apart valve
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– Release pressure fork and remove assembly cartridge from
guide plate.
– Remove guide plate from cylinder head.
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Note
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The compressed air line remains connected.
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– Pull off valve stem seals using valve stem seal puller -3364- . thi
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2.6.2 Installing
– To prevent damage to new valve stem seals, place plastic
sleeve -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.
– Remove plastic sleeve -A-.
If the valve cotters have been removed from the assembly item
then they must be inserted into the insertion device -VAS
5161/18- .
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– Press pressure fork down and pull knurled screw upwards.
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es, in part or in w
t to the co
– Install camshafts with camshaft adjuster ⇒ page 56 .
Adjusting valve timing ⇒ page 34 .
rrectness of i
l purpos
Note
nform
ercia
tion in
r
thi
s
do
r
started.
rp
cum
fo
en
ng
t.
yi Co
Cop py
2.7 Checking valve guides
t. rig
gh ht
pyri by
Vo
co lksw
by
Special tools and workshop equipment required cted agen
Prote AG.
♦ Dial gauge
Test procedure
– Insert new valve into guide. The end of the valve stem must
be flush with the guide. On account of differing stem diame‐
ters, only use inlet valve in inlet guide and exhaust valve in
exhaust guide.
– Determine rock. Wear limit: 0.8 mm
If rock tolerance is exceeded: AG. Volkswagen AG d
agen oes
lksw not
– Renew cylinder head. d byV
o gu
ara
ise nte
or eo
h
aut ra
ss c
ce
le
un
pt
an
d
itte
y li
rm
ab
ility
ot
wit
, is n
spec
♦ Depth gauge
es, in part or in w
t to the co
Note
tio
wear ⇒ page 65 .
n in
r
te o
thi
do
cum
en
g
t.
yi Co
op
draulic valve clearance compensation can no longer be C py
ht. rig
guaranteed and the cylinder head must be renewed. rig ht
py by
co Vo
by lksw
cted agen
Prote
– Remove camshafts ⇒ page 56 .
AG.
Note
ce
le
pt
an
d
itte
y li
Measured distance -a- minus minimum dimension = maximum
rm
ab
pe
ility
permissible reworking dimension.
ot
wit
, is n
Example:
h re
hole
spec
Measured distance 34.4 mm
es, in part or in w
t to the co
— Minimum dimension 34.0 mm
= Max. permissible reworking dimension 0.4 mm
rrectness of i
l purpos
Note
mm, repeat measurement using new valves. If the result does not
m
tion in
r
te o
thi
s
do
r
rp
cum
fo
t.
yi Co
a - = ∅ 26.2 mm Cop py
t. rig
gh ht
yri
b - = 1.5…1.8 mm p by
co Vo
by lksw
cted agen
Z - = bottom surface of cylinder head Prote AG.
17 – Lubrication
1 Removing and installing parts of lu‐
brication system
Dismantling and assembling oil filter housing ⇒ page 69
Removing and installing sump ⇒ page 70 .
Removing and installing oil pump ⇒ page 71 .
Removing and installing drive chain for oil pump ⇒ page 74
Checking oil pressure and oil pressure switch ⇒ page 75
Note
an
itte
y li
erm
ab
wit
h re
„504 00“.
hole
spec
es, in part or in w
t to the co
Note
service intervals.
l purpos
atio
Booklet 17.1
om
n in
c
thi
e
sd
iva
o
r
rp
cu
m
f
en
ng
ce
le
un
pt
an
d
y li
engine oil!
erm
ab
ility
ot p
b - Engine oil level within hatched zone: Engine oil can be topped-
wit
is n
up.
h re
ole,
spec
c - Area from min. mark up to hatched field: Must be topped up,
urposes, in part or in wh
t to the co
rrectne
1.3 Dismantling and assembling oil filter
housing
ss o
Assembly overview
cial p
f inform
mer
atio
m
Note
o
n
c
i
or
n thi
e
The oil filter housing can be removed or installed only with the
t
sd
va
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
. rig
1 - Dowel sleeve
ht ht
rig by
copy Vo
2 - Gasket
by lksw
cted agen
Prote AG.
❑ For oil passage
❑ Renew.
3 - 10 Nm
4 - Oil cooler seal
❑ For oil passage
5 - 20 Nm
❑ Renew.
6 - Oil cooler
7 - Oil filter element
❑ Observe change inter‐
vals ⇒ Maintenance ;
Booklet 17.1
8 - Oil filter lower part, 25 Nm
9 - Oil drain plug, 10 Nm
10 - Seal
11 - Oil cooler seal
❑ For coolant passage
12 - Oil filter housing
13 - 25 Nm
14 - Coolant drain plug, 10 Nm
15 - Coolant pipe
16 - 1.4 bar oil pressure switch
-F1- , 20 Nm
❑ Checking ⇒ page 75 .
ce
le
un
pt
an
d
itte
y li
rm
ab
Note
pe
ility
ot
wit
, is n
h re
only with the oil filter housing removed ⇒ page 69 .
hole
spec
es, in part or in w
t to the co
1 - Oil pump
❑ Removing and installing
rrectness of i
⇒ page 71
l purpos
2 - Pipe connection
3 - 10 Nm
nform
ercia
4 - Chain tensioner
m
a
com
tio
❑ Secure with locking pin -
n in
r
thi
s
al.
iva
do
r
rp
cum
5 - 10 Nm
fo
en
ng
t.
yi Co
6 - Chain sprocket Cop py
t. rig
gh
❑ Note installation posi‐
ht
pyri by
Vo
o
tion ⇒ page 71 . by c lksw
cted agen
Prote AG.
7 - 34 Nm
8 - Drive chain
❑ For oil pump.
❑ Removing drive chain
⇒ page 74 .
9 - 30 Nm
10 - Sump, upper part
11 - Sump, lower part
12 - 10 Nm
13 - Oil level and oil tempera‐
ture sender -G266-
14 - 10 Nm
15 - Oil drain plug, 50 Nm
❑ For sump, lower part
16 - Seal
❑ Renew.
17 - 15 Nm
18 - Oil drain plug, 50 Nm
❑ For sump, upper part
19 - 22 Nm
20 - Seal
❑ Renew.
ce
le
un
pt
an
22 - 25 Nm
d
itte
y li
erm
ab
23 - Oil suction pipe
ility
ot p
wit
is n
h re
ole,
spec
urposes, in part or in wh
t to the co
– Fit chain sprocket onto oil pump shaft. The flattened side
-arrow- faces oil pump shaft and the inscription on the chain
rrectne
sprocket faces towards front.
ss o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
. rig
Special tools and workshop equipment required
ht ht
rig by
copy Vo
♦ Engine and gearbox support -VAS 6095-
by lksw
cted agen
Prote AG.
♦ Locking pin -T40011-
♦ Silicone sealant D176 501A1
♦ Eye protection
Prerequisites
• Engine removed
• Engine is secured on engine and gearbox support -VAS
6095- .
Removing
– Drain engine oil from lower part and upper part of sump.
Note
ce
le
un
pt
sump. If necessary, slightly loosen banjo bolt -1-.
an
d
itte
y li
rm
– Now unscrew lower part and upper part of sump.
ab
pe
ility
ot
– Loosen sump with light blows of a rubber headed hammer or
wit
, is n
light leverage with a lever, if necessary.
h re
hole
spec
– Press chain tensioner together -in direction of arrow- and se‐
es, in part or in w
cure it with pin -T40011- -1-.
t to the co
rrectness of i
l purpos
– Now unscrew chain sprocket -2- from oil pump.
nform
ercia
– Unscrew the three oil pump securing bolts m
⇒ Item 9 (page 70) and the oil suction pipe securing bolts
a
com
tio
⇒ Item 22 (page 71) .
n in
r
te o
thi
– Now oil pump can be removed.
s
iva
do
r
rp
c
– Remove sealant residue from cylinder block.
um
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
Note
Note
olkswagen AG
en AG. V
The sealant bead must not be thicker, otherwise olkexcess
swa
g
sealing does
not
compound will enter the oil sump and mayeblock
d by V the oil suction gu
ara
line strainer. tho
ris nte
eo
au ra
c
ss
– Fit upper part of sump immediately and lightly tighten all sump
ce
le
un
pt
bolts „diagonally“.
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
– Then „diagonally“ tighten sump bolts -1- to 15 Nm and bolts
l purpos
-2- to 22 Nm.
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
Note
ce
e
nl
oil pump
pt
du
an
itte
y li
erm
ab
♦ Engine removed
ility
ot p
wit
, is n
h re
6095- .
hole
spec
– Remove toothed belt ⇒ page 34 .
es, in part or in w
t to the co
– Drain engine oil from lower part and upper part of sump.
Note rrectness of i
l purpos
or
atio
m
n in
or c
thi
e
sd
iva
cu
o
m
f
t.
yi Co
op py
– Remove thrust washer from crankshaft journal. t. C rig
gh ht
pyri by
– Mark direction of rotation of drive chain using a coloured felt-
co Vo
by lksw
cted
tip marker.
agen
Prote AG.
ce
le
un
pt
♦ Adapter -V.A.G 1342/14-
an
d
itte
y li
♦ Voltage tester -V.A.G
rm
ab
pe
ility
1527B-
ot
wit
, is n
h re
hole
V.A.G 1594C-
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
Test prerequisites
• Engine oil level OK.
• Oil pressure warning lamp -K3- must light up for approx. 3
seconds when ignition is switched on
• Engine oil temperature at least 80 °C (radiator fan must have
run once)
Checking oil pressure
– Check oil pressure at different revolutions: 2000 rpm: 3.0…5.5
bar, above 2000 rpm: maximal 7.0 bar.
If the specifications are not obtained
– Rectify mechanical damage, e.g. bearing damage.
At higher engine speeds, the oil pressure must not exceed 7.0
bar.
If the specification is exceeded:
– Renew oil pump, if necessary ⇒ page 71 .
ce
le
V.A.G 1342/14- into oil filter housing in place of oil pressure
un
pt
an
d
switch. ⇒ Item 16 (page 69) .
itte
y li
rm
ab
pe
ility
ot
wit
Note
, is n
h re
hole
spec
Observe installation position of adapter: the conical connecting
es, in part or in w
piece of adapter must be screwed into pressure hose of tester.
t to the co
– Connect brown wire of tester to earth (-).
rrectness of i
– Connect voltage tester -V.A.G 1527B- using test cables from
l purpos
-V.A.G 1594 C- to battery positive (+) and oil pressure switch.
LED must not light up.
nform
ercia
a
com
tion in
If LED does not light up:
r
te o
thi
s
iva
– Start engine and run at idling speed. At 1.2…1.6 bar the LED
do
r
rp
c
must light up, otherwise renew oil pressure switch -F1- .
um
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
19 – Cooling
1 Removing and installing parts of cool‐
ing system
Caution
Note
ce
e
pt
du
an
itte
y li
erm
ab
Test for leaks in cooling system using cooling system tester -
ility
ot p
V.A.G 1274- and adapter for cooling system tester -V.A.G 1274/8-
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
Assembly overview - radiator fan ⇒ page 79 .
Removing and installing fan support with fan ⇒ page 79 .
rrectness of i
Assembly overview - parts of cooling system, engine side, front
⇒ page 81 .
l purpos
orm
atio
m
⇒ page 83 .
o
n in
or c
sd
iva
cu
o
m
f
en
ng
1 - Coolant pipe
❑ Secured to fan support
AG. Volkswagen AG d
with spacers. ksw
agen oes
n ol ot g
yV ua
2 - To expansionisetank
db ran
r tee
ho
3 - Coolant shose
au
t or
ac
s
❑ Secured to top of front
ce
le
un
pt
end with retaining clips.
an
d
itte
y li
4 - Upper coolant hose
erm
ab
ility
ot p
wit
is n
quick-release coupling.
h re
ole,
spec
urposes, in part or in wh
ing.
t to the co
❑ With junction for coolant
hose leading to expan‐
sion tank.
rrectne
5 - Radiator/cooler
s
❑ Removing and installing
s o
⇒ page 88
cial p
f inform
❑ After renewing, renew
mer
entire coolant.
atio
om
6 - Condenser
c
i
or
n thi
te
sd
7 - Oil cooler
iva
o
pr
en
ng
t.
yi
8 - Oil cooler
Co
Cop py
ht. rig
❑ For power-assisted rig ht
py by
steering co Vo
by lksw
cted agen
Prote AG.
9 - Lock carrier
10 - 10 Nm
11 - Low-temperature cooler
❑ For fuel cooling
❑ Only with certain equipment
12 - 10 Nm
13 - Rubber bush
❑ For lock carrier
14 - Retaining clip
❑ Check for secure seating.
15 - Rubber bush
16 - Lower coolant hose
❑ Secured to radiator with quick-release coupling.
❑ Check for secure seating.
17 - To coolant pump -V36-
18 - Coolant outlet temperature sender -G83-
19 - To coolant pump.
20 - To coolant pipe on top/side.
❑ Bolted to cylinder head bank 1.
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
1.3 Removing and installing fan support
cted agen
Prote AG.
with fan
Special tools and workshop equipment required
♦ Spring-type clip pliers -VAS 5024A-
Removing
WARNING
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
urposes, in part or in wh
t to the co
– Pull retaining ring -1- of rubber mounting on left and right in
direction of arrow off brake vacuum pump -V192- and lay
pump to side.
rrectne
– Then release locking mechanisms on left and right of radiator
s
using a screwdriver -arrows- and lift out complete fan support
s o
upwards.
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
ce
e
nl
pt
du
an
ment.
itte
y li
erm
ab
❑ Removing and installing
ility
ot p
⇒ page 89
wit
, is n
h re
3 - Upper coolant hose
hole
spec
4 - To radiator
es, in part or in w
t to the co
5 - Lower coolant hose
6 - Radiator outlet coolant tem‐
rrectness of i
perature sender -G83-
l purpos
nf
ercia
or
7 - Retaining clip
m
m
atio
m
n in
c
ing.
or
thi
te
sd
iva
8 - O-ring
o
r
rp
cu
o
❑ Renew if damaged. m
f
en
ng
t.
yi Co
op
9 - To bottom of radiator C py
t. rig
gh ht
yri
10 - Connection
p by
o Vo
by c lksw
cted
❑ Secured to radiator with
agen
Prote AG.
quick-release coupling.
❑ Check for secure seat‐
ing.
11 - Coolant pump -V36-
❑ Checking ⇒ page 85 .
❑ Fitting location of pump:
bolted to longitudinal
member on right.
12 - Bracket
13 - 23 Nm
14 - Non-return valve
❑ Note installation position.
❑ Arrow points towards engine.
15 - Coolant hose
16 - Coolant pipe
17 - Coolant pipe
18 - Coolant pipe, on side
19 - 10 Nm
1 - Coolant pipe
❑ Between left and right
cylinder head
❑ With junction to heat ex‐
changer for heating, ex‐
pansion tank and upper
coolant hose.
2 - O-ring
❑ Renew.
3 - Coolant temperature send‐
er -G62-
❑ With coolant tempera‐
ture display sender -
G2- .
❑ For engine control unit.
❑ Before removing, re‐
lease pressure in cool‐
ing system if necessary.
4 - Coolant pipe
5 - To thermostat.
AG. Volkswagen AG d
6 - 20 Nm lksw
agen oes
not
o
yV gu
7 - Gasket rised b ara
nte
ho eo
8 - Coolant pipe aut ra
ss c
❑ From cylinder head
ce
e
nl
pt
bank 1
du
an
itte
y li
erm
9 - Coolant pipe
ab
ility
ot p
wit
, is n
h re
10 - To expansion tank
hole
spec
11 - To expansion tank
es, in part or in w
t to the co
12 - Coolant pipe
13 - 10 Nm
rrectness of i
14 - To upper coolant hose
l purpos
15 - 10 Nm
nform
ercia
ion
c
17 - Coolant hose
in t
or
his
ate
cum
or
en
ng
t.
yi Co
op
20 - Coolant pipe C py
ht. rig
rig ht
21 - 10 Nm
py by
co Vo
by lksw
cted agen
22 - Retaining clip
Prote AG.
1 - Expansion tank
❑ Test cooling system for
leaks using cooling sys‐
tem tester -V.A.G 1274-
and adapter for cooling
system tester -V.A.G
1274/8- .
2 - Cap
❑ Check using cooling
system tester -V.A.G
1274- and adapter for
cooling system tester -
V.A.G 1274/9- .
❑ Test pressure: 1.4…1.6
bar.
3 - Connector
❑ For coolant shortage in‐
dicator
4 - Spring-type clip
❑ Check for secure seat‐
ing.
AG. Volkswagen AG d
5 - Coolant hose ksw
agen oes
not
Vol
y gu
6 - To connection ise
d b ara
nte
or eo
h
7 - To coolant pipe s aut ra
c
s
8 - Overflow hose
ce
le
un
pt
an
d
itte
9 - 10 Nm y li
erm
ab
10 - Coolant pipe ility
ot p
wit
is n
spec
12 - 8 Nm
urposes, in part or in wh
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
1 - Radiator/cooler
2 - Upper coolant hose
3 - Lower coolant hose
4 - Coolant pump -V36-
5 - Non-return valve
❑ Note installation posi‐
tion.
❑ Arrow points in direction
AG. Volkswagen AG d
of flow. ksw
agen oes
not
ol
yV gu
6 - Coolant pipe ised b ara
nte
or
❑ Secured to cylinder auth eo
ra
head bank 1. ss c
ce
e
nl
pt
7 - Alternator
du
an
itte
y li
8 - Oil cooler
erm
ab
ility
ot p
wit
, is n
h re
9 - Expansion tank
hole
spec
10 - Heat exchanger for heater
es, in part or in w
t to the co
unit
11 - Coolant pipe
rrectness of i
❑ Secured between cylin‐
der head bank 1 and cyl‐
l purpos
sender -G62-
orm
m
atio
13 - Cylinder bank 2.
om
n in
or c
14 - Cylinder bank 1.
thi
te
sd
iva
15 - Coolant pipe
o
r
rp
cu
o
❑ Connected to cylinder
f
en
ng
t.
yi
head bank 1.
Co
Cop py
ht. rig
16 - Coolant pipe rig ht
py by
co Vo
lksw
❑ To thermostat housing
by
cted agen
Prote AG.
17 - Coolant pump
18 - Thermostat housing
AG. Volkswagen AG d
agen oes
ksw not
♦ Current flow diagram by Vol
gu
ara
d
ise nte
Test prerequisite thor eo
au ra
s c
• Fuse -16- -arrow- must be OK. s ce
e
nl
pt
du
Test procedure
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
1.9 Draining and filling coolant
rrectness of i
Special tools and workshop
l purpos
equipment required
♦ Refractometer -T10007-
nform
ercia
a
com
t
♦ Spring-type clip pliers -VAS
ion in
5024A-
r
te o
thi
s
iva
do
r
rp
c
tester -V.A.G 1274/8-
um
fo
en
ng
t.
yi
♦ Torque wrench -V.A.G
Co
op py
1331- t. C rig
gh ht
pyri by
♦ Cooling system charge unit
co Vo
by lksw
cted agen
-VAS 6096- Prote AG.
Draining
WARNING
ce
e
nl
pt
du
an
itte
y li
erm
ab
Note
ility
ot p
wit
, is n
h re
hole
spec
Filling
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
AG. Volkswagen AG d
agen
Note olksw
oes
not
byV gu
ara
ed
is nte
♦ Use only coolant additive
ut
h G12 plus in accordance with
or eo
„TL VW 774 F“. Identification:
ss a purple colour. ra
c
ce
e
♦ G 12 plus and coolant additives marked „Conforming to
nl
pt
du
an
TL VW 774 F“ prevent frost and corrosion damage and scaling
itte
y li
and also raise boiling point of coolant. Therefore, the cooling
erm
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system must be filled all year round with frost and corrosion
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protection additives.
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♦ Because of its higher boiling point, the coolant improves en‐
hole
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gine reliability under heavy loads, particularly in countries with
es, in part or in w
tropical climates.
t to the co
♦ Frost protection is required down to about -25°C (in countries
with arctic climates: down to about -35°C).
rrectness of i
♦ The coolant concentration must not be reduced by adding wa‐
l purpos
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amount of G 12 can be increased, but only up to 60 % (frost
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Removing
– Drain coolant ⇒ page 86 .
nf
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– Pull out retaining clips from quick-release coupling for coolant
m
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hose at top and bottom and detach coolant hoses from radia‐
om
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tor.
or c
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gr. 63 ; Assembly overview - front bumper
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– Drain coolant ⇒ page 86 .
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♦ Adapter for cooling system tester -V.A.G 1274/9-
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– Operate pump on tester and build-up pressure of between 1.4
and 1.6 bar.
– Check cooling system tester for leaks.
– In addition, check sealing cap.
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92
Prote AG.
Rep. gr.19 - Cooling
Touareg 2003 ➤
8-cylinder injection engine - Edition 11.2011
Caution
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all moving or hot components.
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♦ Hose connections are secured with couplings or spring-type
es, in part or in w
or clamp-type clips.
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♦ Always renew clamp-type clips with spring-type clips.
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♦ Fuel hoses on engine must be secured with spring-type clips
only. The use of clamp or screw-type clips is not permissible.
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clips.
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Observe safety precautions ⇒ page 99 .
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Assembly overview - fuel tank with attachments ⇒ page 94 .
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Assembly overview - fuel filter ⇒ page 96 . . Cop py
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Renewing fuel filter ⇒ page 96
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Schematic diagram of fuel lines and components in fuel tank
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⇒ page 98 .
Draining fuel tank ⇒ page 100
Removing and installing fuel delivery unit, fuel gauge sender and
suction-jet pumps ⇒ page 102
Removing and installing fuel tank with attachments
⇒ page 104 .
Checking fuel pumps ⇒ page 107
pt
ting locations.
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8 - Suction-jet pump
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❑ Left side.
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9 - Protective cover
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12 - Protective cover
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13 - Suction-jet pump
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❑ Right side.
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❑ Checking fuel pump ⇒ page 107 .
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❑ Right side.
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20 - To pressure retention valve
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1 - Connection
❑ For breather line.
2 - Flange
❑ Left side.
❑ With fuel filter housing
❑ Note installation posi‐
tion on fuel tank
⇒ page 99 .
3 - Filter element
4 - Seal
❑ Renew.
5 - Earth wire
6 - 10 Nm
7 - Supply line
❑ To fuel pressure regula‐
tor.
8 - Connection
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9 - Connection aut
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❑ Filter feed from right fuel s
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10 - Earth connection
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12 - Locating pin
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Note
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The fuel filter is located in the left opening of fuel tank, as seen
or
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Prerequisites
• Fuel tank must be emptied ⇒ page 100 , Emptying fuel tank.
• Fuses -13- and -14- -arrow- must be removed from their sock‐
ets.
Procedure
WARNING
Fuel supply lines 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.
ce
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nl
pt
du
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itte
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erm
ab
ility
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wit
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es, in part or in w
t to the co
– Remove nuts -1- from cover. If necessary, unscrew backrest
rrectness of i
mounting -2- or support mounting ⇒ General body repairs,
interior; Rep. gr. 72 ; Rear seats .
l purpos
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ion
c
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or
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ate
do
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for
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t. rig
– Mark installation position of filter cover -2- using coloured felt
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pyri by
tip marker pen.
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Prote AG.
– Pull off earth wire -1- and unscrew filter cover -arrows- from
housing.
If filter element is changed, ensure that earth connection contacts
are not bent and have sufficient preloading.
1 - Gravity valve
❑ Left side.
2 - Flange
❑ Left side.
3 - Fuel filter
4 - Gravity valve
❑ Right side.
5 - Supply line
❑ To fuel rail. AG. Volkswagen AG d
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6 - Supply line for auxiliary d byV gu
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❑ Right side.
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12 - Suction-jet pump
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❑ Right side.
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13 - Delivery line
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Insert left or right flange with marking -arrow- in direction of travel.
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urposes, in part or in wh
t to the co
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Caution
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When doing any repair work, especially in the engine compart‐
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ment, pay attention to the following due to the cramped condi‐
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♦ Route all the various lines (e.g. for fuel, hydraulics, acti‐
agen
Prote AG.
vated charcoal filter system, coolant, refrigerant, brake
fluid and vacuum) and electrical wiring in their original po‐
sitions.
♦ To avoid damage to lines, ensure sufficient clearance to
all moving or hot components.
♦ For safety reasons, fuse nos. -13- and -14- -arrows- must be
removed from the fuse holder before opening the fuel system.
Otherwise, the fuel pump could be activated by the driver's
door contact switch.
♦ Fuse nos. 13 and 14 are located in the E-box fuse holder in
the left plenum chamber.
When removing and installing fuel gauge sender or fuel pump
(fuel delivery unit) from a full or partly full fuel tank, observe the
following:
♦ Even before work commences, the extraction hose of an ac‐
tivated fume extraction system has to be placed in the vicinity
of the assembly opening of the fuel tank to trap any escaping
fumes. If no exhaust gas extraction system is available, a ra‐
dial fan with a displacement greater than 15 m3/h can be used
providing that motor is not in air flow.
♦ Prevent skin contact with fuel! Wear fuel-resistant gloves!
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es, in part or in w
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♦ Special wrench -T10202-
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do
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WARNING
c by lksw
cted agen
Prote AG.
Fuel supply lines 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.
Procedure
– Note safety precautions before beginning work ⇒ page 99 .
– Open fuel tank filler flap.
Note
– Cut carpet open from point -A- to point -B- in the pre-cut area
-arrows-.
AG. Volkswagen AG d
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– Remove nuts -1- from cover. If necessary, unscrew
ut
ho backrest eo
ra
mounting -2- or support mounting ⇒ Generalss a body repairs, c
interior; Rep. gr. 72 ; Rear seats .
ce
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nl
pt
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– Hold a cloth on connections for fuel supply line and auxiliary
itte
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ility
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Note
hole
spec
es, in part or in w
t to the co
– Disconnect connector for fuel pump and fuel tank sender.
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– Now remove locking ring from flange using fuel tank sender
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possible into right and then left side of fuel tank and extract
ion
c
fuel.
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or
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Prote AG.
Note
AG. Volkswagen AG d
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1.8 Removing and installing fuel delivery
d b ara
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or eo
unit, fuel gauge sender and suction-jet
h
aut ra
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pumps
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spec
urposes, in part or in wh
t to the co
rrectne
Test prerequisites
cial p
f inform
mer
• Fuses -13- and -14- -arrow- must be removed from their sock‐
o
n
c
ets.
or
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sd
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• Connectors and wires for left and right flanges have been re‐
i
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pr
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moved.
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• Locking rings for left and right flanges have been unscrewed.
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Procedure
rig by
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cted
– Note safety precautions before beginning work ⇒ page 99 .
agen
Prote AG.
– Pull off connectors -1- and -2- as well as hose couplings -3-
and -4- below right flange.
– Remove flange with pressure regulator.
– Unclip black filler hose -arrow- from fuel delivery unit housing
on left and right sides of fuel tank.
AG. Volkswagen AG d
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– Detach fuel supply line to suction-jet pumps from fuel delivery
ce
le
un
pt
unit -arrow- on left and right sides of fuel tank.
an
d
itte
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– Unscrew fuel delivery unit in bottom of fuel tank by turning
rm
ab
pe
ility
about 90° to left.
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wit
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hole
spec
Note
es, in part or in w
t to the co
The fuel delivery unit housing is filled with fuel. Fuel may run out
if housing is tipped or canted.
rrectness of i
– Now unclip fuel gauge senders on each side of fuel tank and
l purpos
– Pull out hose ends through left and right sender openings.
com
tion in
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AG. Volkswagen AG d
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ab
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Prerequisites
wit
is n
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spec
urposes, in part or in wh
• Fuses -13- and -14- -arrow- must be removed from their sock‐
t to the co
ets.
Removing
rrectne
WARNING
o
cial p
f inform
mer
Fuel supply lines are under pressure! Wear eye protection and
atio
i
or
sd
iva
o
pr
cum
r
fo
en
ng
ce
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nl
Once the fuel pressure has been reduced:
pt
du
an
itte
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– Remove silencers and mountings .
erm
ab
ility
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hole
spec
– Remove rear axle ⇒ Running gear, axles, steering; Rep. gr.
es, in part or in w
t to the co
– Open fuel flap and remove fuel tank cap.
– Pull rubber gasket off filler neck.
rrectness of i
l purpos
– Remove securing bolts -1- on filler neck and pull off earth wire
-2-.
nform
ercia
at
om
io
housing liner .
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c
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or
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ate
do
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for
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t.
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Cop py
t. rig
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by c lksw
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Prote AG.
– Remove securing bolts for filler neck -1- and activated char‐
coal filter -2- in wheel housing.
AG. Volkswagen AG d
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olksw not
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– Now bend filler neck
s au slightly downwards and pull off breather ra
c
line connections to activated charcoal filter. s
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un
pt
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d
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rm
Note
ab
pe
ility
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wit
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hole
spec
– Pull off earth wire clipped to activated charcoal filter and re‐
es, in part or in w
t to the co
move activated charcoal filter.
rrectness of i
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fuel tank.
m
– Support fuel tank using engine and gearbox jack -V.A.G 1383
com
tion in
thi
do
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WARNING
n
t.
yi Co
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Fuel supply lines are under pressure! Wear eye protection and
rig ht
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gloves to avoid injuries and skin contact. Before loosening by c lksw
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hose connections, wrap a cloth around the connection. Then Prote AG.
– Reach through between fuel tank and vehicle floor and hold a
cloth above fuel supply hose. Now disconnect fuel supply line
and breather line from flange.
Note
ce
♦ Ensure that fuel hose connections are tight. le
un
pt
an
d
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♦ Ensure earth cable -2- is secured tight to body.
erm
ab
ility
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Note
h re
ole,
spec
urposes, in part or in wh
Before bolting on fuel tank, check that supply and breather lines
t to the co
are still clipped onto fuel tank.
rrectne
1.10 Checking fuel pumps
s
Checking delivery rate of pumps ⇒ page 108
s o
cial p
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Checking current draw of pumps ⇒ page 109 .
nform
mer
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c
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Special tools and workshop
um
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equipment required
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t.
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♦ Diesel extractor -VAS t. C rig
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5226- yri
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♦ Pressure gauge -V.A.G
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1318-
♦ Adapter -V.A.G 1318/9-
♦ Adapter -V.A.G 1318/10-
♦ Adapter -V.A.G 1318/24-
♦ Remote control for V.A.G
1348 -V.A.G 1348/3 A-
♦ Multimeter -V.A.G 1715- or
hand-held multimeter -
V.A.G 1526D- with pickup
clamp -V.A.G 1526B/2-
♦ Spring-type clip pliers -VAS
5024 A-
♦ Current flow diagram
♦ Measuring container
Test prerequisites
olkswagen AG
en AG. V
• Fuses -13- and -14- -arrow- must be removed
olks from their sock‐
wag does
not
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• Battery voltage at least 11.5 V autho eo
ra
ss c
• Fuel pump relays -1- for right fuel delivery unit and -2- for left
ce
le
un
pt
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d
itte
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Test procedure
rm
ab
pe
ility
– Note safety precautions before beginning work ⇒ page 99 .
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wit
, is n
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– Remove filler cap from fuel tank filler neck.
hole
spec
es, in part or in w
t to the co
WARNING rrectness of i
Fuel supply lines are under pressure! Wear eye protection and
l purpos
a
com
tion in
r
– Wrap a cloth around the joint to catch fuel which flows out and
te o
thi
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cum
en
ng
t.
yi
– Retighten threaded connection.
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rig ht
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Prote AG.
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nl
pt
du
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erm
ab
ility
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– Hold hose in measuring container -2- with minimum capacity
hole
spec
of 1000 cm3.
es, in part or in w
t to the co
– Empty measuring container before making measurement.
– Operate remote control for 15 seconds. At least 800 cm3 fuel
rrectness of i
per 15 seconds must be delivered.
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nform
mercia
at
om
ion
c
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ate
do
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cum
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t.
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Cop py
– Empty measuring container before making measurement.
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– Operate remote control 15 seconds again. At least 800 cm3 by c lksw
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Prote
fuel per 15 seconds must be delivered.
AG.
– Cut carpet open from point -A- to point -B- in the pre-cut area
-arrows-.
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ara
ed
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spec
urposes, in part or in wh
t to the co
rrectness o
cial p
f inform
mer
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om
n
c
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or
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en
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t.
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Cop py
ht. rig
rig ht
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co Vo
by lksw
cted agen
Prote AG.
Note
WARNING
Fuel supply lines 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.
Note
pt
an
• Fuel pump relays -1- for right fuel delivery unit and -2- for left
d
itte
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ab
ility
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wit
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h re
ole,
spec
urposes, in part or in wh
t to the co
rrectness o
cial p
f inform
mer
atio
om
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c
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Cop py
t. rig
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pyri by
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111
c by lksw
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Prote AG. 1. Parts of fuel supply system
AG. Volkswagen AG d
agen oes
Touareg 2003 ➤ Volksw not
gu
y
8-cylinder injection engine - Edition 11.2011 rise
d b ara
nte
tho eo
au ra
– Now unscrew locking ring from flange (fuel filter) using
ss wrench c
-T10202- .
ce
le
un
pt
an
d
itte
– Carefully lever flange and raise it slightly.
y li
erm
ab
– Disconnect connectors next to fuel filter.
ility
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is n
h re
ole,
spec
urposes, in part or in wh
t to the co
rrectnes
– Then detach fuel supply hose -2- leading from right fuel deliv‐
s o
ery unit from fuel filter -1-.
cial p
f inform
– Allow fuel from connection -1- to flow back into fuel tank.
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
Note
– Open lever of pressure tester and let fuel flow back to fuel tank
through hose -V.A.G 1318/13- . en AG. V
olkswagen AG
ag does
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th
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ss
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pt
du
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itte
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erm
ab
ility
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wit
, is n
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hole
spec
es, in part or in w
t to the co
1.13 Checking non-return valve of left pump
Test prerequisites
rrectness of i
• Remote control -V.A.G 1348/3 A- is still connected.
l purpos
Note
nform
mercia
At the same time, this test checks for leaks in the fuel supply line
at
om
io
connections from the fuel delivery units to the point at which the
n
c
in t
r
his
ate
do
priv
– Then detach fuel supply hose -2- leading from left fuel delivery
um
for
en
g
t.
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Cop py
t. rig
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pyri by
Vo
co lksw
by
cted agen
Prote AG.
ce
le
un
pt
– Close pressure gauge shut-off tap -arrow- (lever at right an‐
an
d
itte
gles to direction of flow).
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erm
ab
ility
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wit
is n
h re
ole,
spec
urposes, in part or in wh
t to the co
rrectness o
cial p
f in
– Connect pressure tester -V.A.G 1318- with adapter -
form
mer
atio
V.A.G 1318/24- as shown.
om
n
c
i
or
n thi
te
sd
a
Note
iv
o
pr
cum
r
fo
en
ng
– Open lever of pressure tester and let fuel flow back to fuel tank
through hose -V.A.G 1318/13- .
– Remove pressure tester -V.A.G 1318- with adapters.
ce
le
un
pt
an
d
itte
y li
1 - Bearing bracket
rm
ab
pe
ility
❑ Removing and instal‐
ot
wit
ling: ⇒ Brake systems;
, is n
h re
Rep. gr. 46 ; Assembly
hole
spec
es, in part or in w
(LHD) .
t to the co
2 - Connector
❑ Black, 6-pin.
rrectness of i
3 - 10 Nm
l purpos
nform
ercia
sender 2 -G185-
m
❑ Not adjustable.
a
com
tion in
❑ Remove footwell cover
r
te o
to remove sender.
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
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Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
ce
le
un
can open or close the throttle valve independently of the accel‐
pt
an
d
erator position sender.
itte
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rm
ab
pe
This means that the throttle valve can already be completely open
ility
ot
even though the accelerator is only depressed half way. This has
wit
, is n
the advantage of preventing throttling losses at the throttle valve.
h re
hole
spec
This also results in significantly improved consumption and ex‐
es, in part or in w
haust emission values under certain load conditions.
t to the co
The torque required by the engine can be produced by the engine
control unit by optimising the combination of throttle valve cross-
rrectness of i
section and charge pressure.
l purpos
After evaluating the torque requirements of various components
(e.g. air conditioning system, automatic gearbox, ABS/ESP and
so on), the engine control unit calculates the optimal throttle valve
nform
ercia
opening angle for the respective situation. m
a
com
t
Observe safety precautions.
ion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
pt
an
itte
ab
clips.
ility
ot p
wit
, is n
spec
t to the co
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
ce
e
nl
pt
du
an
itte
y li
1 - Expansion tank
erm
ab
ility
ot p
2 - Gravity valve
wit
, is n
h re
3 - To gravity valve
hole
spec
4 - Pressure retention valve
es, in part or in w
t to the co
❑ Function ⇒ page 118 .
5 - 9 Nm
rrectness of i
6 - Connecting hose l purpos
7 - Air filter
❑ Clean if soiled.
nform
ercia
8 - Connector
m
at
om
i
❑ For breather line.
on
c
in t
or
his
ate
do
riv
10 - 9 Nm
p
cum
for
en
ng
11 - Connector
t.
yi Co
Cop py
. rig
12 - Activated charcoal filter
t
gh ht
yri by
solenoid valve 1 -N80- cop Vo
by lksw
cted agen
Prote
13 - Rubber bracket
AG.
14 - To connection
❑ On intake manifold
15 - Breather line
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
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Procedure: s aut ra
c
s
– Remove rear right wheel and wheel housing liner.
ce
e
nl
pt
du
an
itte
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erm
ab
air filter using a hose clamp -3094- .
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
or
– Disconnect breather line -arrow- to solenoid valve in engine
m
m
atio
compartment.
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
Note
pt
an
d
itte
y li
erm
ab
ility
ot p
– When valve is open -A-, check the following lines and compo‐
wit
is n
1842- .
t to the co
If the pressure does not drop again, the leakage can be found on
fuel tank:
ss o
cial p
f inform
mer
atio
om
n
c
n thi
filter.
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
ce
e
nl
pt
du
an
– With valve -A- is open, check fuel tank for leaks by hearing,
itte
y li
erm
touching, with commercially available leak detector spray or
ab
ility
ultrasonic tester -V.A.G 1842- .
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wit
, is n
h re
hole
Caution
spec
es, in part or in w
t to the co
After completing work check tyre pressure!
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
pt
du
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the system.
erm
ab
ility
ot p
spec
memory.
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
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rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
ce
le
clamp-type clips.
un
pt
an
d
itte
y li
♦ Use spring-type clip pliers -VAS 6340- for installation of spring-
erm
ab
type clips
ility
ot p
wit
is n
♦ or space-saving hose clip pliers -VAS 6362- .
h re
ole,
spec
urposes, in part or in wh
Observe safety precautions ⇒ page 99 .
t to the co
Observe rules for cleanliness ⇒ page 99 .
rrectne
4.1 Assembly overview - activated charcoal filter system
ss o
1 - Expansion tank
cial p
f inform
❑ Right side.
mer
atio
2 - Gravity valve
om
n
c
i
or
n
3 - Fuel filler neck
thi
te
sd
va
4 - 5 Nm
i
o
pr
cum
r
fo
en
ng
5 - Bracket
t.
yi Co
op py
6 - Vacuum line
t. C rig
gh ht
yri by
❑ For vacuum supply of
op Vo
by c lksw
fuel system diagnostic
cted agen
Prote AG.
pump -V144-
❑ To vacuum connection
on intake manifold
❑ Check for secure seat‐
ing.
7 - Fuel system diagnostic
pump -V144-
❑ Checking fuel system
for leaks ⇒ page 124 .
❑ Black connector, 3-pin
8 - Connecting hose
❑ Between air filter, fuel
system diagnostic pump
-V144- and activated
charcoal filter solenoid
valve 2 -N115-
❑ Check for secure seat‐
ing.
9 - 5 Nm
10 - Air filter
❑ Clean if soiled.
11 - Rubber bush
❑ Note installation position.
❑ Renew if damaged.
12 - Activated charcoal filter solenoid valve 2 -N115-
❑ Black connector, 2-pin
13 - Activated charcoal filter
❑ Location: in rear right wheel housing.
4. Activated charcoal filter system (vehicles for USA and Canada) 123
Touareg 2003 ➤
8-cylinder injection engine - Edition 11.2011
14 - Securing bolts
❑ Qty. 3
❑ 9 Nm
15 - Breather line
❑ To vacuum connection on intake manifold
❑ Check for secure seating.
16 - Connector
❑ Black, 2-pin.
17 - Activated charcoal filter solenoid valve 1 -N80-
❑ Note installation position.
18 - Rubber bracket
❑ Note installation position.
19 - Breather line
❑ Check for secure seating.
20 - Pressure retention valve
❑ Function ⇒ page 124 .
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
spec
t to the co
f inform
Test prerequisite:
mer
atio
m
n
c
-V144- .
i
or
n thi
te
sd
a
• Guided fault finding has been performed with the vehicle di‐
iv
o
pr
agnosis tester .
um
r
fo
en
ng
t.
yi
Preparation of fuel system tester -KLI 9210- :
Co
Cop py
t. rig
gh ht
pyri by
Vo
co
Note
by lksw
cted agen
Prote AG.
The fuel system tester -KLI 9210- may differ in appearance de‐
pending on the version.
ce
le
un
pt
an
d
y li
Check tester if pressure is not maintained.
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
– In engine compartment, disconnect breather line -arrow- to
activated charcoal filter solenoid valve 1 -N80- .
4. Activated charcoal filter system (vehicles for USA and Canada) 125
Touareg 2003 ➤
8-cylinder injection engine - Edition 11.2011
Note
♦ Once the diagnostic mode 8 „Tank leak test“ has been acti‐
vated, the leak diagnostic pump and the activated charcoal
filter solenoid valve 2 -N115- are closed for max. 1,000 sec‐ G. Volkswagen AG d
onds. The activated charcoal filter solenoid valve 1 -N80- lkisswagen A oes
not
not activated. Now the entire system is closed. by Vo gu
a d ran
ise
♦ If the engine control unit cancels the test, it is possible
ut
ho
r
to ini‐ tee
or
tiate it again by switching off and restarting the
ss engine.
a ac
ce
e
nl
pt
du
an
itte
– Set valve -D- to „Test“. The fuel system will now be filled with
y li
erm
ab
nitrogen.
ility
ot p
wit
– Observe pressure gauge -C- and flow meter -E-. When the
, is n
h re
throughput quantity decreases and the pressure increases to
hole
spec
es, in part or in w
t to the co
Note
rrectness of i
Depending on the filling level of the fuel tank, this process can
take up to 3 minutes.
l purpos
nf
ercia
orm
• After 5 minutes the pressure must not drop below 20 mbar
m
atio
m
(8 in. H2O).
o
n in
or c
If pressure does not drop, exit from diagnostic mode 8 and check
thi
te
sd
a
o
r
rp
cu
⇒ page 129 .
o
m
f
en
ng
t.
If no pressure builds up or the pressure is not held for at least 5
yi Co
op py
minutes, localise leak as follows: t. C rig
gh ht
pyri by
Leave engine running at idling speed for at least 8 minutes with
co Vo
by lksw
cted
activated diagnostic mode 8.
agen
Prote AG.
Note
If no fault is found:
– Remove rear right wheel housing liner.
If smoke escapes from air filter ⇒AItem
G. Vol7
ks(page
wagen 128) :
n AG do
wage es n
Volks ot g
– Clamp off hose between d by
activated charcoal filter solenoid
ua
ran
ir se
valve 2 -N115- tho and air filter -arrow-. Also refer to tee
or
⇒ Item B (page
au 128) . ac
ss
ce
le
pt
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ab
ility
ot p
wit
is n
h re
ole,
spec
urposes, in part or in wh
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
127
cted agen
Prote AG.
4. Activated charcoal filter system (vehicles for USA and Canada)
Touareg 2003 ➤
8-cylinder injection engine - Edition 11.2011
❑ To intake manifold.
un
pt
an
d
itte
y li
7 - Air filter
erm
ab
ility
wit
h re
ole,
pump -V144-
t to the co
9 - Fuel tank
10 - Cap
rrectne
n
c
system
i
or
n thi
te
sd
o
r
cum
r
fo
valve 1 -N80- .
en
ng
t.
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op
B - Clamp off in this area
C py
t. rig
gh ht
yri
❑ For leak detection in fuel system p by
co Vo
by lksw
cted
❑ For checking activated charcoal filter solenoid valve 2 -N115- .
agen
Prote AG.
pt
du
an
y li
erm
ab
h re
spec
t to the co
or
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted
129
agen
Prote AG.
4. Activated charcoal filter system (vehicles for USA and Canada)
Touareg 2003 ➤
8-cylinder injection engine - Edition 11.2011
AG. Volkswagen AG d
Note lksw
agen oes
not
o
byV gu
ara
d
Fitting location of fuel system diagnosis pump -V144- : in rear right
orise nte
eo
wheel housing under wheel housing liner. s aut
h
ra
c
s
ce
e
nl
pt
du
an
itte
y li
– Remove securing bolts ⇒ Item 14 (page 123) of activated
erm
ab
charcoal filter and lower filter to have better access to vacuum
ility
ot p
line.
wit
, is n
h re
hole
spec
Caution
es, in part or in w
t to the co
Support activated charcoal filter to prevent its hanging down
from hoses and lines. This prevents damages.
rrectness of i
l purpos
nf
ercia
o
– Connect turbocharger tester -V.A.G 1397A- with T-piece and
rm
hose ∅ 6mm, between vacuum line -1- and fuel system diag‐
m
atio
m
n in
or c
thi
– Switch on measuring range I (absolute pressure measure‐
te
sd
iva
ment).
o
r
rp
cu
o
m
f
t.
yi Co
op py
– On vehicle diagnosis tester, select operating mode Guided
. C rig
ht ht
rig
functions . py by
co Vo
by lksw
cted agen
– Select guided function „Checking tank ventilation system for Prote AG.
leaks“.
– Observe display on turbocharger tester -V.A.G 1397A- while
test is running.
• Pressure must pulsate and must not exceed 0.700 bar during
test.
– If pressure exceeds 0.7 bar during test, vacuum supply is too
low. Check vacuum line to intake manifold for possible kinks
or blockages.
ce
e
nl
pt
du
an
24 – itte
Mixture preparation - injection
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
General notes on injection
es, in part or in w
t to the co
♦ Fuel hoses in engine compartment must be secured only with
spring-type clips. The use of clamp or screw-type clips is not
permissible.
rrectness of i
♦ For trouble-free operation of electrical components, a voltage
l purpos
nform
ercia
at
om
io
Technical data ⇒ page 137 .
n
c
in t
or
his
e
do
priv
cum
Assembly overview - fuel rail ⇒ page 133
for
en
ng
t.
yi Co
Assembly overview - air filter ⇒ page 133 . . Cop py
rig
ht ht
rig
Assembly overview - vacuum hose assembly on intake manifold py by
o Vo
⇒ page 136 .
by c lksw
cted agen
Prote AG.
ce
e
pt
du
an
tion.
itte
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erm
ab
16 - Dowel cone
ility
ot p
wit
❑ Fit gasket before instal‐
, is n
h re
lation.
hole
t to the co
18 - 10 Nm
❑ To secure intake manifold.
rrectness of i
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
ce
e
nl
Nm
pt
du
an
itte
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❑ Counterhold when tight‐
erm
ab
ening.
ility
ot p
wit
❑ For fuel supply.
, is n
h re
hole
spec
es, in part or in w
t to the co
ing.
❑ Secure with spring-type
clip.
rrectness of i
3 - 10 Nm
l purpos
4 - Ball stud, 3 Nm
nform
ercia
5 - Fuel rail
at
om
ion
❑ With retaining tabs for
c
in t
or
his
ate
tors.
do
priv
cum
or
6 - Seal
f
en
ng
t.
yi Co
❑ Renew. Cop py
t. rig
gh
❑ Before installing, mois‐
ht
pyri by
Vo
o
ten lightly with clean en‐
c by lksw
cted agen
gine oil. Prote AG.
1 - Intake hose
2 - Spring-type clip
3 - Intake hose
4 - 6 Nm
5 - Air mass meter -G70- with
intake air temperature sender -
G42-
6 - Seal
❑ Renew if damaged.
7 - Air filter upper part
❑ On the right side with
connection to secon‐
dary air pump motor -
V101- .
8 - Filter element
9 - To secondary air pump mo‐
tor -V101-
10 - Air duct
❑ Secured to lock carrier.
11 - Rubber bush
❑ Clipped to longitudinal
member.
12 - Air filter lower part
❑ To remove lower part of
air filter on right, right
engine cover retainer n AG. Volkswagen AG do
must be removed olkswage es n
ot g
⇒ page 134 . d byV ua
ran
ir se tee
13 - 10 Nm utho
or
a ac
ss
14 - Connection from air sus‐
ce
le
un
pension compressor
pt
an
d
itte
y li
ab
pe
ility
ot
wit
, is n
h re
spec
t to the co
-direction of arrow-.
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
– Now pull loosened line -B- off connection -A- on air filter.
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
ce
e
nl
pt
du
dary air
an
itte
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erm
ab
2 - To secondary air pump mo‐
ility
ot p
tor -V101-
wit
, is n
h re
3 - Connecting hose
hole
spec
❑ Route without tension.
es, in part or in w
t to the co
4 - Vacuum connection
❑ For combination valve.
rrectness of i
5 - Secondary air inlet valve -
N112-
l purpos
nform
ercia
6 - Bracket
❑ Secured to fuel rail.
m
at
om
ion
7 - Variable intake manifold
c
in t
or
his
te
8 - To vacuum reservoir
a
do
priv
c
❑ ⇒ Item 10 (page 156)
um
for
en
ng
t.
yi
9 - Valve 2 for variable intake
Co
Cop py
manifold changeover. -N261-
t. rig
gh ht
pyri by
Vo
o
10 - Non-return valve by c lksw
cted agen
Prote AG.
❑ Black side of valve faces
intake manifold connec‐
tion
11 - Vacuum actuator
❑ For intake manifold
change-over.
12 - Variable intake manifold
changeover valve -N156-
13 - Vacuum actuator
❑ For intake manifold change-over.
14 - To cylinder block.
❑ ⇒ Item 3 (page 17)
15 - Crankcase breather valve
ce
e
nl
the left plenum chamber.
pt
du
an
itte
y li
erm
ab
WARNING
ility
ot p
wit
, is n
h re
Fuel supply lines are under pressure! Wear eye protection and
hole
spec
hose connections, wrap a cloth around the connection. Then
es, in part or in w
t to the co
release pressure by carefully pulling hose off connection.
rrectness of i
To prevent injuries to persons and/or damage to the injection and
ignition system, the following must be observed:
l purpos
nf
ercia
orm
♦ Switch off ignition before connecting or disconnecting injection
m
atio
m
n in
or c
thi
te
sd
a
o
r
rp
cu
o
m
♦ Test and measuring instruments must always be secured to
f
en
ng
t.
rear seat and operated by a second person from this location.
yi Co
Cop py
t. rig
If test and measuring instruments are operated from front pas‐
gh ht
pyri by
senger seat and the vehicle is involved in an accident, there is a
co Vo
by lksw
cted
possibility that the person sitting in this seat may receive serious
agen
Prote AG.
injuries when the airbag is triggered.
♦ If the engine is to be turned at starter speed without starting:
– Pull connectors off ignition coils with output stage (cylinders
1…8).
3) Not adjustable.
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2 Checking components
Checking injectors ⇒ page 139 .
Checking fuel pressure regulator and holding pressure
⇒ page 142 .
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Checking for leaks
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WARNING
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spec
Fuel supply lines are under pressure! Wear eye protection and
es, in part or in w
gloves to avoid injuries and skin contact. Before loosening
t to the co
hose connections, wrap a cloth around the connection. Then
release pressure by carefully pulling hose off connection.
rrectness of i
– Remove complete fuel rail (fuel supply line remains connec‐
l purpos
ted) ⇒ page 133 .
– Remove fuse holder cover.
nform
ercia
– Pull fuel pump relays -1- and -2- from their sockets.
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Pay attention to the following when installing the injectors:
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♦ Renew O-rings on all injectors and lightly moisten with clean
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engine oil.
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♦ Insert injectors vertically and in the correct position into the fuel
hole
spec
rail and secure with retaining clips.
es, in part or in w
t to the co
♦ Fit fuel rail with secured injectors onto intake manifold and
press in evenly.
rrectness of i
Checking quantity injected
l purpos
• Fuel pump relays and fuses 13 and 14 are fitted in their sock‐
ets.
nform
ercia
at
om
i
– Bridge test box sockets 1 and 65 using adapter cable from
on
c
in t
or
his
ate
do
priv
c
uring glass -V.A.G 1602- .
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Test procedure
The fuel pressure regulator maintains the fuel pressure at a con‐
stant 4.0 bar.
• Fuel pump delivery is OK.
WARNING
Fuel supply lines 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.
AG. Volkswagen AG d
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– Wrap a cloth around the threaded connection -arrow- d by and
V re‐ gu
ara
lease fuel pressure by quickly opening and closingorisconnection.
e nte
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– Loosen spring-type clip and disconnect fuelsshose
a
from con‐ c
nection on fuel rail ⇒ Item 14 (page 133) .
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shown in the illustration.
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tion of flow.
spec
es, in part or in w
t to the co
– Always secure both hose ends with clips -2-.
rrectness of i
– Start engine and run at idling speed.
l purpos
nform
ercia
a
– Check delivery rate of fuel pumps ⇒ page 107 .
com
tion in
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– Renew fuel pressure regulator -2-, if necessary. cop Vo
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If specification is attained:
AG.
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tem; Rep. gr. 92 ; Windscreen wiper system .
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– Install plenum chamber cover.
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fault memory
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Procedure
– Connect vehicle diagnosis, testing and information system -
VAS 5051- as follows:
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– Start engine and run at idling speed.
an
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Only when engine does not start:
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– Switch on ignition.
is n
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Selecting operating mode:
spec
urposes, in part or in wh
– Press button on display for „Vehicle self-diagnosis“.
t to the co
Selecting vehicle system:
rrectne
– Press „01 - Engine electronics“ button on display.
The control unit identification with code as well as chassis number
s
and immobilizer identification number will be indicated on the dis‐
s o
cial p
play.
f inform
mer
atio
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o
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Select diagnostic function:
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– Press „02 - Read fault memory“ button on display.
Prote AG.
26 – Exhaust system
1 Removing and installing parts of ex‐
haust system
Assembly overview - exhaust manifold with starter catalytic con‐
verters and attachments ⇒ page 148
Assembly overview - silencers with mountings ⇒ page 153
Note
After working on the exhaust system, ensure that the system has
sufficient clearance to the bodywork. If necessary, loosen flange
on catalytic converter and realign silencers and exhaust pipes
⇒ page 154 .
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1.1 Assembly overview - exhaust manifold with starter catalytic converters and
attachments
1 - Nut, 25 Nm
2 - Nut, 25 Nm
3 - Exhaust manifold
❑ For cylinder bank 1.
❑ Removal only possible
with engine removed.
4 - M8 25 Nm, M10 40 Nm
5 - Lambda probe -G39- 50 Nm
❑ Bank 1, probe 1.
❑ Installed in exhaust gas
stream of cylinders 1, 2,
3 and 4.
❑ Removing and installing
⇒ page 149
6 - Starter catalytic converter
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7 - Lambda probe after catalyt‐ ss
ic converter -G130- 50 Nm
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❑ Bank 1, probe 2.
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❑ Removing and installing
pe
ility
⇒ page 149
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8 - Catalytic converter
hole
spec
9 - Mounting
es, in part or in w
10 - 25 Nm
l purpos
11 - To centre silencer
12 - Mounting
nform
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13 - To centre silencer
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14 - Gasket
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❑ Renew.
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15 - M8 25 Nm, M10 40 Nm
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16 - Bracket
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❑ For supporting gearbox on right.
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17 - Lambda probe 2 after catalytic converter -G131- , 50 Nm cop Vo
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❑ Bank 2, probe 2. Prote AG.
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22 - Bracket
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❑ For supporting gearbox on left.
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23 - 25 Nm
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24 - Exhaust manifold
spec
es, in part or in w
❑ For cylinder bank 2.
t to the co
❑ Removal only possible with engine removed.
❑ Removing ⇒ page 149
rrectness of i
25 - Gasket l purpos
❑ Renew.
❑ Note installation position.
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removal of cylinder bank 2 exhaust manifold.
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Removing:
– Remove cover for engine and intake
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– Remove intake hoses by
Vo -1- and -2-. Loosen hose clip
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for
ua crank‐
case breatherorisvalve
ed -3- and pull crankcase breather valve
ran
tee off
hose connection.
auth or
a
ss c
– Remove intake air duct to throttle valve module -J338- .
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Connector for cylinder bank 1 = black, connector for cylinder bank C py
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2 = brown
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Lambda probe 2 after catalytic converter -G131- (bank 2, probe
om
n
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probe 2):
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Note
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Specified torques
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1 - Exhaust tailpipe
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2 - Rear silencer
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❑ Centre and rear silenc‐ hole
spec
ers are installed as a
es, in part or in w
t to the co
ing production. In case
of repair, the centre and
rear silencers are sup‐
rrectness of i
plied separately, with a
double repair clamp for
l purpos
connecting.
❑ In case of repair, align
nform
ercia
a
com
tion in
3 - Mounting
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❑ Installation position
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⇒ page 154 .
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❑ Renew if damaged.
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4 - 25 Nm
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5 - Exhaust tailpipe
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Prote AG.
6 - Separating point
❑ For repair cases
❑ Marked by impressions
on exhaust pipe.
❑ Centre and rear silenc‐
ers are installed as a
single component dur‐
ing production. In case
of repair, the centre and
rear silencers are sup‐
plied separately, with a
double repair clamp for
connecting.
❑ Cut through connecting
pipe at right angles at
separating point using e.g. pneumatic sabre saw -V.A.G 1523A- .
❑ The notches to the left and right of the separating points must be visible following the installation of the
double clamp.
7 - Mounting
❑ Installation position ⇒ page 154 .
❑ Renew if damaged.
8 - 25 Nm
9 - Mounting
❑ Installation position ⇒ page 154 .
10 - Double clamp
❑ Must be slid to its mid-point on forward exhaust pipe.
❑ Note installation position: Securing bolt ends must not project beyond lower edge of clamp.
11 - Mounting
❑ Installation position ⇒ page 154 .
12 - Double clamp, 40 Nm
❑ Must be slid to its mid-point on forward exhaust pipe.
ce
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nl
13 - To exhaust manifold
pt
du
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itte
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14 - Centre silencer
erm
ab
ility
❑ Centre and rear silencers are installed as a single component during production. In case of repair, the
ot p
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centre and rear silencers are supplied separately, with a double repair clamp for connecting.
, is n
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hole
15 - Double clamp
spec
es, in part or in w
t to the co
❑ Installation position ⇒ page 154 .
rrectness of i
Installation position, double repair clamp in direction of travel
l purpos
– The end of bolt -1- must not project beyond lower edge of
double clamp.
nf
ercia
orm
– The angle -2- must be 10° + 5°.
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Aligning exhaust system
AG.
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subsequent engine start (up to max. 80 C engine temperature),
un
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the secondary air system will, after a 20 second delay, switch in
d
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for 5 seconds during idling and will be checked by the self-diag‐
rm
ab
pe
nosis.
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air system ⇒ page 155
hole
spec
es, in part or in w
t to the co
stalling parts of secondary air system
rrectness of i
Note
l purpos
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tion in
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1 - Combination valve
❑ For cylinder bank 1.
2 - 10 Nm
3 - To secondary air inlet valve
-N112-
4 - Combination valve
❑ For cylinder bank 2.
5 - Gasket
6 - Connecting hose
❑ From cylinder bank 1 to
cylinder bank 2.
7 - Secondary air inlet valve - AG. Volkswagen AG d
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8 - 10 Nm rise
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9 - Bracket ss au ra
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10 - Vacuum reservoir
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11 - Hose coupling
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❑ Press together at front
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to release.
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12 - Pressure hose
spec
es, in part or in w
t to the co
ing.
❑ Press together at front
to release.
rrectness of i
13 - Secondary air pump motor
l purpos
-V101-
14 - From air filter.
nform
ercia
15 - Pressure pipe
m
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io
❑ Bolted to cylinder head
n
c
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cover.
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16 - 8 Nm
p
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17 - 10 Nm
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18 - To secondary air inlet valve -N112- t. C rig
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Secondary air pump relay -J299-
Note
28 – Ignition system
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1 Repairing ignition system
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General notes on ignition system ole,
spec
urposes, in part or in wh
t to the co
of at least 11.5 V is necessary.
♦ Certain tests may lead to a fault being detected by the control
unit and stored. Therefore after completing all checks and re‐
rrectne
pairs the fault memory must be read and if necessary cleared.
s
Assembly overview - parts of ignition system ⇒ page 157
s o
cial p
f i
Safety precautions ⇒ page 158 .
nform
mer
atio
om
n
c
i
or
n thi
⇒ page 158 .
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1.1 Assembly overview - parts of ignition system
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1 - Connector for knock sensor
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❑ Secured to fuel rail with
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retaining tab.
Prote AG.
10 - Spark plug, 30 Nm
❑ Remove and install with spark plug socket and extension 3122 B.
❑ Type and electrode gap ⇒ page 159 , test data, spark plugs
AG. Volkswagen
11 - Knock sensor 2 -G66- lkswagen AG do
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❑ Line to knock sensor
ed by secured to bracket ⇒ Item 12 (page
ua
ran 158) .
ris tee
12 - Bracket utho or
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ss
13 - 10 Nm
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❑ For inlet camshaft bank 1.
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spec
es, in part or in w
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To prevent injuries to persons and/or damage to the injection and
ignition system, the following must be observed:
rrectness of i
♦ Switch off ignition before connecting or disconnecting injection
l purpos
nform
mercia
ti
1…8).
on in
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rear seat and operated by a second person from this location.
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If test and measuring instruments are operated from front pas‐
ht
pyri by
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senger seat and the vehicle is involved in an accident, there is a
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possibility that the person sitting in this seat may receive serious Prote AG.
injuries when the airbag is triggered.
AG. Volkswagen AG d
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– Before disconnecting by V connectors of cylinders 5 to 8t gremove
ol no
ua
bracket -1- by riunscrewing
sed bolts -arrows-. ran
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– Fit puller -T40039- onto ignition coil with output stage and pull
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at
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1.4 Test data, spark plugs
copy Vo
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Prote AG.
Engine code AXQ / BHX
Firing order 1-5-4-8-6-3-7-2
Spark plugs
VW/Audi 101,905,615 A
Manufacturer's designation FGR 7 KQE 0
Electrode gap max. 1.1 mm
Specified torque 4). 30 Nm
4) Remove and install spark plugs with spark plug socket and extension 3122 B.