Touareg 2003-07 Engine Repairs

Volkswagen Touareg 2003->
(7L)
Technical data
Engine identification
Engine data
00-1, Engine identification
00-1, Engine specifications
Engine identification
The engine number ( "engine code" and "serial number" )

is located on cylinder block, below the cylinder head of
cylinder bank 2.
The engine number consists of up to nine characters
(alphanumeric). The first part (maximum 3 letters)
represents the "engine code" , the second (six digit) is the
"serial number" . If more than 999,999 engines with the
same engine code are produced, the first of the six
characters is replaced with a letter.
In addition, a sticker with "engine code" and "serial
number" is affixed to acoustic cover of cylinder head at
cylinder bank 1.
The engine code is also included on the vehicle data plate.
Numbering of cylinders begins on right side - A - as seen

in direction of travel (cylinder bank 1) opposite the power
Volkswagen Technical Site: http://volkswagen.msk.ru http://vwts.info http://vwts.ru

Volkswagen, Skoda, Seat, Audi
transfer side - C - . Cylinders are counted on each side in

sequence.
Engine specifications
Engine code
BKW
12.03
Production
02.06
Tier 1
Emission values in accordance with

Displacement
10.04
BWF
ltr.
4.9
4.9
Output
kW at 1/rpm
230/3750
230/3750
Torque
Nm at rpm
750/2000
750/2000
Dia. mm
81.0
81.0
mm
95.5
95.5
18.5
18.5
51
51
Bore
Stroke
Compression ratio
CN
Ignition sequence
min.
1-6-5-10-2-7-3-8-4-9 1-6-5-10-2-7-3-8-4-9
Catalytic converter
yes
yes
Particle filter
no
yes
Exhaust gas recirculation
yes
yes
Charging
yes
yes
Charge air cooler
yes
yes
Engine, removing and installing
Page 1 / 21
10 - 1

Engine, removing
10-1, Engine, removing
Removing engine from Scissor Lift Table VAS 6131

10-1, Removing engine from Scissor Lift Table VAS 6131
Notes on installing
10-1, Notes on installation
Engine, removing
Special tools, testers and auxiliary items

required
Scissor lift table VAS 6131
Drip tray V.A.G 1306
Frame support T10191
Spring-type clip pliers VAS 5024

A
Torque wrench (40 to 200 Nm)

V.A.G 1332
Tensioner Hooks (2) VW 552
Not illustrated:
Standard set for Touareg VAS 6131/6
Support F/Vas6131 For V6/V10/V8 VAS6131/8
Container for removed components V.A.G 1698
Engine bung set VAS 6122
Cable tie
The engine with transmission is removed downward.

- Before removing engine, check DTC memories of all
control modules Vehicle Diagnosis, Testing and
Information System VAS 5051 or VAS 5052 "Guided
functions"
Note:
To allow free rotation of the driveshaft, move the

selector lever to the "N" position.
Leave the key in the ignition lock to prevent the

steering wheel lock from engaging.
It is advisable to remove the front wheels before the

disassembly. The vehicle can be lowered on the
hoist until the cover plates of the brake discs are just
above the floor. This ensures the greatest ability to
perform work at body-level regarding accessibility of
components in the engine compartment.
Page 2 / 21
When the engine is installed in the engine

compartment some components cannot be removed
or can only be removed with great difficulty.
Determine which components are faulty before
removing engine.
To prevent damage to removed components, use

the container for removed components V.A.G 1698
for storage.
All cable ties which are opened or cut open when

removing engine, must be replaced in the same
position when installing engine.
Caution!
Always observe the exact procedure for disconnecting
the battery!
- Switch off ignition and all electrical consumers.
- First, disconnect batter under drivers seat.
- Then disconnect the auxiliary battery, in luggage
compartment in spare wheel well.
Repair Manual, Electrical Equipment, Repair Group 27,

Battery, disconnecting and connecting
- Remove left and right windshield wiper arms

Windshield wiper system
- Remove engine compartment cover seal off bulkhead.
Page 3 / 21
- Remove covers - A - , - B - (if equipped) and - C - in

engine compartment and - D - for plenum chamber.
- Disconnect smaller connector - A - from Engine Control

Modules (ECM) and remove Ground (GND) connection arrow - for wiring harness.
- Open fuse box cover on left in plenum chamber and

disconnect connectors - A - , - B - and - C - .
- Remove wiring harness from plenum chamber and place
it on engine.
- Remove intake line on both sides between air filter and
intake manifold.
Note:
With connector couplings, follow the installation

instructions closely 21-1, Hose connections with
connector couplings, installing .
Vehicles with engine code BKW
Page 4 / 21
- Disconnect vacuum lines - arrows - for Exhaust Gas

Recirculation (EGR) valve and brake booster as well as
harness connector - A - for Heated Oxygen Sensor
(HO2S) G39 of cylinder bank 1.
- Disconnect vacuum line - arrow - for Exhaust Gas

Recirculation (EGR) valve as well as harness connector A - for Heated Oxygen Sensor (HO2S) 2 G108 of cylinder
bank 2.
Vehicles with engine code BWF
- Disconnect vacuum lines - 1 - for the bypass flap

vacuum actuators (mark lines before separating) and brake
booster - 2 - .
Page 5 / 21
- Disconnect the following connections and free up wiring

harness to components:
1 - 6-pin harness connector, black: For Heated Oxygen
Sensor (HO2S) G39
2 - 6-pin harness connector, brown: For Heated Oxygen
Sensor (HO2S) 2 G108
3 - 2-pin harness connector, black: For Turbocharger
intake temperature sensor G507
4 - 2-pin harness connector, brown: For Turbocharger
intake temperature sensor 2 G499
Continuation for all vehicles
- Disconnect harness connectors - arrows - for glow

plugs in cylinder bank 1 and cylinder bank 2.
Page 6 / 21
- Secure suspension struts using spring compressor VW

552. as shown.
- Remove upper suspension struts
Repair Manual, Suspension, Wheels, Steering, Repair

Group 40, II - Assembly overview: Front suspension
.
- Remove noise insulation
Repair Manual, Body Exterior, Repair Group 50, Noise

insulation
.
- Extract refrigerant from air conditioning system
Repair Manual, Heating Air Conditioning, Repair Group

87,
- Drain coolant
filling .
19-1, Cooling system, draining and
Page 7 / 21
- Disconnect line - arrow - from transmission oil cooler

below on right. Catch fluid which runs out.
- Disconnect line - A - from servo oil cooler at lower left.

Catch fluid which runs out.
- Remove charge air connecting pipe - B - for cylinder
bank 1 and cylinder bank 2.
- Loosen clamp - arrow - from connecting pipe to air filter

for cylinder bank 1 and cylinder bank 2 and remove it.
Page 8 / 21
- Disconnect coolant hoses - arrows - and place them so

that they cannot be pinched when removing and installing
engine.
- Disconnect starter wire - A - and generator wire - B and place them on engine.
- Unclip transmission ventilation line - arrows - .
Page 9 / 21
- Disconnect connector from Intake Air Temperature (IAT)

sensor G42 - A - and from Mass Air Flow (MAF) sensor
G70 - B - for cylinder bank 1.
- Disconnect connector from Mass Air Flow (MAF) sensor

2 G246 - A - and from Intake Air Temperature (IAT)
sensor 2 G299 - B - for cylinder bank 2.
- Remove wire connection - arrow - of air suspension

compressor on air filter housing 23-1, Line connection to
compressor for air suspension
- Remove both top sections of air filter upward.
Page 10 / 21
- Open clamp and pull off servo-line - A - . Catch fluid

which runs out. Remove A/C lines - B - from A/C
compressor.
- Disconnect fuel lines - arrows - from fuel filter.

- Separate connection of catalytic converter/center muffler
and remove exhaust system 26-1, Muffler with
mountings (vehicles with engine code BKW), assembly
overview .
- Disconnect fuel lines - arrows - from fuel filter.
Page 11 / 21
- Separate connection of particle filter/exhaust pipe and

remove exhaust system 26-1, Muffler with mountings
(vehicles with engine code BWF), assembly overview .
- Remove heat shield on steering box and loosen universal
joint

Group 48, Steering column
.
- Disconnect connectors on transmission as well as
transfer case and loosen selector lever cable
Repair Manual, 6 Spd. Automatic Transmission 09D All

Wheel Drive, Repair Group 37, Shift mechanism, servicing
- Remove rear driveshaft
Repair Manual, Rear Final Drive, Repair Group 39,

Driveshafts, removing and installing
- Remove transmission transverse support - A - .
Page 12 / 21
- Disconnect brake lines at points indicated - arrow - .

Catch escaping brake fluid.
- Disconnect all harness connectors between chassis and
front axle in wheel housings.
Preparing Scissor lift table VAS 6131 for further
steps:
Note:
The basic set for Touareg VAS 6131/6 consists of

supports supports VAS 6131/6-1 to VAS 6131/6-7 .
To describe the following work sequence more
clearly, they are called support 1 (for VAS 6131/6-1)
to support 7 (for VAS 6131/6-7).
- Install support - 1 - on left and support - 2 - on right

(arrows point in direction of travel) on the Scissor lift table
VAS 6131 and secure bolts at the following positions:
Left support - 1 - : A5, B4 and B5
Page 13 / 21
Right support - 2 - : G4, H4 and H5
- Tighten support 3 and support 4 on Scissor lift table VAS

6131 in the following positions:
Left support - 3 - : A6 and C6
Right support - 4 - : F6 and H6
- Screw down turntables of supports - 3 - and - 4 - .

- Place supports - 5 - for subframe and - 6 - for
transmission console in corresponding positions on lift
table.
Engine and transmission are separated after removal:
- Remove insulation mat under lower section of oil pan.
- Loosen clamp for starter cable.
- Loosen and remove transmission bolts - A - .

- Remove six bolts for torque converter through hole in
upper section of oil pan - arrow - . To do so, rotate engine
at vibration damper using Counterhold Tool Touareg V10
T10172 and associated pin T10172/2 .
Page 14 / 21
- Install support - 7 - for transmission support in

corresponding positions on Scissor lift table VAS 6131 and
tighten down turntables completely.
- Before moving up Scissor lift table VAS 6131 , always

engage Support F/Vas6131 For V6/V10/V8 VAS6131/8 ,
which was completely tightened down earlier, into hole of
transmission flange - arrow - as shown.
Continued:
Page 15 / 21
- Position horizontally adjusted Scissor lift table VAS

6131 under engine/transmission assembly. The supports 1 - and - 2 - must be guided into corresponding mount arrows - at right and left.
- At the same time, guide support - 6 - for transmission

cross bar into corresponding holes - arrows - at right and
left.
When all four supports are in the appropriate receptacle
holes without pressure:
- If installed, check support height of support for V10, V8
and V6 assembly, Touareg VAS 6131/8 at knurled nut and
secure support in position D7 on Scissor lift table VAS
6131 .
Page 16 / 21
- Using light pressure beneath control arm, screw both

turning knobs of supports 3 and 4 until securing device can
be removed using Tensioner Hooks (2) VW 552 .
- Guide support - 5 - into corresponding mount in

subframe, if necessary check support height on knurled
nut.
- Locate subframe to body

Group 40, I - Assembly overview: Subframe, stabilizer bar,
lower control arms
- Loosen subframe bolts - 2 - and - 3 - , as well as

transmission transverse support - 4 - .
If subframe was not located:
- Loosen subframe bolts - 1 - .
Page 17 / 21
Note:
If the subframe was not located, it is necessary to

perform a vehicle alignment

Group 44, Vehicle alignment
.
- Slowly lower assembly, constantly observing clearances.
Removing engine from Scissor Lift Table VAS 6131
Special tools, testers and auxiliary items required
Shop crane VAS 6100
Transportation plate T10126
Transportation plate T10126/1
Frame support T10191
Work procedure
- Disconnect transmission from engine

Wheel Drive, Repair Group 37, Transmission, removing
and installing
- Loosen threaded connection - A - of engine mount on
Page 18 / 21
both sides of engine.

- Loosen support for V10, V8 and V6 assembly, Touareg
VAS 6131/8 from scissor lift platform and remove it.
- Install transportation plates T10126 and transportation

plates T10126/1 on cylinder heads as shown - arrows - .
- Hook lifting tackle 3033 into workshop crane VAS 6100
and into transportation plate .
- Lift engine from Scissor Lift Table VAS 6131 .
- Set engine in frame support T10191 .
Notes on installation
Caution!
When doing any repair work, especially in the engine
compartment, pay attention to the following due to
clearance issues:
Route lines of all types (e.g. for fuel, hydraulic,

additive, coolant and refrigerant, brake fluid,
vacuum) and electrical wiring so that the original
path is followed.
To prevent damages to the lines, make sure

there is sufficient clearance to all moving or hot
components.
Installation is performed in reverse order. When doing

this note the following:
Page 19 / 21
Page 20 / 21
- Make sure centering sleeves for engine to transmission

are installed in cylinder block. Install if necessary.
- Reconnect all lines, hoses and connections that were
disconnected for removal sequence.
- Electrical connections and routing Electrical Wiring
Diagrams, Troubleshooting and Component Locations
binder .
- Connect air conditioning lines
Repair Manual, Heating Air Conditioning, Repair Group

87,
.
- Top off oil level for power steering system
Repair Manual, Maintenance
.
- Fill with coolant
filling .
- Check headlight adjustment, correct if necessary

:
- Perform test drive and check all DTC memories Vehicle
Diagnosis, Testing and Information System VAS 5051 or
VAS 5052 "Guided Fault Finding" .
Torque specifications
Bolted connections
Engine to transmission
M10
45 Nm
(except starter)
M12
80 Nm
Engine support to cylinder block
50 Nm
Engine support to engine mount
75 Nm
Engine mount to engine carrier

Engine carrier to body
Transmission carrier to body
Subframe to body
60 Nm
100 Nm plus an additional 1 / 2 turn (180
50 Nm plus an additional 1 / 4 turn (90
Page 21 / 21
Repair Manual, Suspension, Wheels, Steering, Repair Group 40, I - Assembly overview:
Subframe, stabilizer bar, lower control arms
Engine, disassembling and assembling
Page 1 / 17
13 - 1

Caution!
Upper section of bearing bracket is bolted to the

cylinder with two multi-point socket bolts M8,
which are found in the valley between the
cylinder heads. These bolts must not be
loosened under any circumstances, because it
causes a deformation of the cylinder block which
is no longer reparable.
Crankshaft, piston, and connecting rods must

not be replaced! Only removal and installation of
these components is permitted.
Note:
If large quantities of metal particles or other deposits

(caused, for example, by partial seizure of the
crankshaft or connecting rod damage) are found in
the engine oil, the oil passages must be cleaned
thoroughly and the oil cooler replaced in order to
prevent further damage from re-occurring.
The engine must not be set down on the oil pan

otherwise the liquid gasket between the upper and
lower oil pan will be damaged. To set down the
engine, use frame T10191 .
Secure engine using engine and transmission holder

VAS 6095 when working on the engine.
Components in engine valley, assembly overview

13-1, Components in engine valley, assembly overview
Engine timing module, assembly overview
13-1,
Engine timing module (wheel cassette), removing and

installing 13-1, Engine timing module (wheel cassette),
removing and installing
Engine mounts and engine supports (right and left),
removing and installing 13-1, Engine mounts and
engine supports (right and left), removing and installing
Drive plate, removing and installing
13-1, Drive plate,
Page 2 / 17


Components in engine valley, assembly overview
Input hub
8 Nm
Clutch
Phased in introduction of a
torsion elastic clutch
Repair Manual, Electrical Equipment,

Repair Group 27, Generator
50 Nm plus an additional 1 / 4
turn (90
Replace
20 Nm
Generator
Removing and installing
Repair Manual, Electrical Equipment,

Repair Group 27, Generator
Oil filter housing, upper section
Coolant connection
With Engine Coolant

Temperature (ECT) Sensor
G62

19-1, Coolant connection,
Gasket
Seal
Replace
Replace
turn (90
Replace
Oil filter housing, lower section
Oil filter housing, assembly

overview 17-3, Oil filter
housing, assembly
overview
With coolant thermostat

housing: Assembly overview
19-1, Coolant thermostat
housing, assembly
Page 3 / 17
overview
Cover
Noise insulation
Installation not necessary
Bypass flap with cooler for

Exhaust Gas Recirculation
(EGR)
On vehicles with engine

code BWF
Assembly overview 26-2,

Bypass flap with cooler for
(EGR) (vehicles with engine
code BWF), assembly
overview
Fuel filter
For vehicles with engine

code BKW

Fuel filter (vehicles with
engine code BKW),
assembly overview
Alignment bushing
Secure with commercially

available grease, if
necessary, before
installation
Page 4 / 17
Sleeve
For linkage mounting

components
Replace with compensation

linkage in case of noticeable
formation of deposits
Compensation linkage
Camshaft gear
For cylinder bank 1: with

sensor wheel for camshaft
position

15-1, Camshaft
compensation wheel and
input gear, removing and
installing
Page 5 / 17
Compensation wheel

15-1, Camshaft
compensation wheel and
input gear, removing and
installing

turn (90
Full-floating axle
Compensating piston
20 Nm
Observe tightening
sequence 13-5,
Tightening sequence of bolts
for control housing
Seal
Do not oil or grease sealing

lip of sealing ring
Before installing, remove oil

residue from crankshaft
journal with a clean cloth
Replace 13-4, Crankshaft

seal (engine timing side),
replacing
Control housing
Replace

Control housing, assembly
overview
Cylinder bolt
Tighten to 60 Nm, then to

150 Nm plus an additional 1 /
4
turn (90
Page 6 / 17
Oil pan, upper section

Oil pan (upper section),
assembly overview
Hex bolt
Tighten to 60 Nm, then to

150 Nm plus an additional 1 /
4
turn (90
Engine timing module

13-1, Engine timing module
(wheel cassette), removing
and installing
Engine timing module (wheel cassette), removing and

installing
Page 7 / 17

required
Engine and transmission holder

VAS 6095
Guide pins T10200
Assembly tool T10208/3
Not illustrated:
Torque wrench (40 to 200 Nm) V.A.G 1332
Requirements:
Engine and transmission removed
Page 8 / 17
Page 9 / 17
Engine secured to engine and transmission holder

VAS 6095
Removing
- Drain engine oil

.
- Set crankshaft to TDC Cylinder 1
checking , check valve timing.
- Remove cylinder heads
15-1, Valve timing,
15-1, Cylinder head .
- Disconnect transmission from engine

Wheel Drive, Repair Group 37, Transmission, removing
and installing
.
- Remove all required hoses, lines and pipes from the
engine management side.
- Remove lower and upper sections of oil pan
pan, assembly overview .
17-2, Oil
- Loosen bolts for engine timing module.

Caution!
Make sure that the input shafts for oil- and coolant
pumps do not fall off cylinder block.
- Carefully pull engine timing module off inclined splines.
Installing
- Screw guide pins T10200 into threaded holes of upper

section of bearing bracket as shown.
- Place engine timing module on guide pins.
Note:
Observe the following adjustment marks and

requirements and note the inclined splines while
doing so (wheels turn slightly when sliding on the
module):
Page 10 / 17
- Holes on splines of crankshaft gear and input gear for oil

pump must align as shown.
- Input shaft fits only in one position. Rotate shaft so that

the wide cut-out in the hole aligns to the broad tooth on the
pin.
- The hole on the drive wheel of cylinder bank 1 must align

with cast tab on inside of engine timing module as shown.
- Carefully slide engine timing module on guide pins in its
seat, note the mentioned adjustment markings while doing
so.
Page 11 / 17
- Center engine timing module by placing pressure piece

of assembly tool T10208/3 on generator shaft end - A - .
Pressure piece must be able to be set into countersink
without force.
- Replace individual guide pins with bolts and tighten bolts
to 60 Nm.
- Tighten bolts to 150 Nm plus an additional 1 / 4 turn. (90
) turn.
Engine mounts and engine supports (right and left),
Page 12 / 17
Engine/transmission jack V.A.G 1383 A
Assembly support T10296
Removing
- Remove front sound insulation
Repair Manual, Body Exterior, Repair Group 50, Sound

insulation
- Remove front wheelhousing liners
Repair Manual, Body Exterior, Repair Group 66,

Wheelhousing liners
- Remove lower part of air filter for cylinder bank 1 and 2
23-1, Air filter, assembly overview , Air filter - Assembly
overview.
- Remove nut - 2 - on engine mount at left and right

engine supports.
Page 13 / 17
- Align mounting pins of assembly support T10296

centrally at the mountings of the cylinder block - arrows to assembly support . Tighten mounting pins.
- Insert assembly support T10296 into
engine/transmission jack V.A.G 1383 A and support
assembly (engine and transmission) at mountings of
cylinder block - arrows - with slight pretension.
- Remove right and left bolts - 1 - for engine mount.
- Carefully lift assembly with assembly support T10296

and remove engine mount.
Caution!
Page 14 / 17
Page 15 / 17
Be aware of the available clearance between the

cylinder heads and the bulkhead.
- If necessary, unfasten engine supports at cylinder block
and remove engine mounts together with engine supports.
Installing
- Make sure the alignment pin of engine mount is correctly
positioned in engine carrier.
- Start all bolts and nuts by hand and then tighten to torque
specification.
Bolted connections
Engine support to cylinder block
50 Nm
Engine mount to engine carrier - 1 -
60 Nm
Engine support to engine mount - 2 -
75 Nm
The rest of assembly is basically a reverse of the

disassembling sequence.
Drive plate, removing and installing
Flywheel lock adapter VW 558
Not illustrated:
Caliper gauge
Hex bolt M850 and three M12-hex nuts
Drive plate, loosening and tightening
- Secure flywheel lock adapter VW 558 with hex bolt
Page 16 / 17
Page 17 / 17
M8x50 to drive plate. Insert three M12 hex nuts between

flywheel lock adapter and drive plate. Installed location of
flywheel retainer: - A - to loosen; - B - to tighten
Installing drive plate.
- Install drive plate using a washer
Item - 8 - .
- Install new bolts and tighten to 30 Nm.
- Using caliper gauge, check distance between drive plate

and cylinder block. Specified dimension - a - : 19.0 to 20.6
mm.
If specification is not obtained:
- Remove drive plate again and insert shim between
crankshaft and drive plate. Tighten bolts again to 30 Nm.
- Tighten bolts to 50 Nm and turn an additional 1 / 4 turn
(90
), (additional rotation may occur in several stages).
Differential shaft
Page 1 / 2
13 - 2
Differential shaft
Note:
Secure engine in engine and transmission holder

VAS 6095 when working on engine.
Balance shaft, assembly overview

shaft, assembly overview
13-2, Balance
Balance shaft, assembly overview
Note:
It is only possible to remove the balancing shaft

when the engine timing module has been removed
beforehand 13-1, Engine timing module (wheel
cassette), removing and installing .
Differential shaft
Thrust washer
Main bearing bolt
Page 2 / 2
Note tightening sequence

and torque Topic 13-3 ,
Main bearing bolts,
tightening.
Bearing cap bolt
For differential shaft bearing

Main bearing bolts,
tightening.
Bearing cap
With eye for securing oil

pump
Bearing shell
Balancing shaft
Positioning
Bearing shell
Thrust washer
Bearing cap
Topic 13-1
Bearing cap with grooves for

thrust washers
Crankshaft
Page 1 / 6
13 - 3
Crankshaft
Caution!
Upper section of bearing bracket is bolted to

cylinder with two multi-point socket bolts M8,
which are found in the valley between the
cylinder heads. These bolts must not be
loosened under any circumstances, because it
causes a deformation of the cylinder block which
is no longer reparable.
Crankshaft, piston, and connecting rods must

not be replaced! Only removal and installation of
these components is permitted.
Note:
Secure engine on engine and transmission holder

Crankshaft, assembly overview

assembly overview
13-3, Crankshaft,
Bearing bracket for crankshaft, removing and

installing 13-3, Bearing bracket for crankshaft,
Crankshaft dimensions
13-3, Crankshaft dimensions
Crankshaft, assembly overview
Crankshaft
Page 2 / 6

Bearing bracket
Installed in tensioned state

13-3, Bearing bracket for
crankshaft, removing and
installing
Thrust washer
For lower section of bearing

bracket
Main bearing bolt

Main bearing bolts,
tightening.
Crankshaft
Page 3 / 6
Bearing shell
Crankshaft
Axial play new: 0.07 to 00.17

mm, Wear limit: 0.37 mm
Check radial clearance with

Plastigage 0.03 to 00.08
mm, Wear limit: 0.17 mm
Do not turn crankshaft when

measuring radial play
13-3, Crankshaft
dimensions
8 Nm
Oil spray jet
For piston cooling
Bearing shell
Cylinder block
With upper section of

bearing bracket
Cylinder bore, checking

13-6, Checking cylinder
bores
Piston and cylinder

dimensions 13-6, Piston
and cylinder dimensions
Engine Speed (RPM) Sensor

G28
10 Nm
Thrust washer
For upper section of bearing

bracket
Bearing bracket for crankshaft, removing and installing
Crankshaft
Page 4 / 6
Caution!
Upper section of bearing bracket is bolted to cylinder
with two multi-point socket bolts M8, which are found
in valley between the cylinder heads. These bolts must
not be loosened under any circumstances, because it
causes a deformation of the cylinder block which is no
longer reparable.
Note:

Tensioning element T10201
Not illustrated:
Removing
Crankshaft
Page 5 / 6
- Remove bolts for lower section of bearing bracket.
- Install engine support bridge T10201 on lower section of

bearing bracket as shown.
- Tighten bolts of tensioning device T10201 to 20 Nm.
- Remove lower section of bearing bracket.
Installing
- Place tensioning device T10201 on lower section of
bearing bracket and tighten bolts to 20 Nm.
- Check whether all bearing shells are lying properly in
bearing supports Item - 4 - . Pay attention to thrust
washers Item - 2 - .
- Carefully place lower section of bearing bracket into
cylinder block.
Tightening main bearing bolts
Topic 13-3 .
Tightening main bearing bolts
- Tighten main bearing bolts in three stages in the

tightening sequence shown as follows ( - arrow - points in
driving direction).
Tighten using torque wrench:
Crankshaft
Page 6 / 6
Step I = 35 Nm
Step II = 65 Nm
Tighten further using a solid wrench:

Stage III = 1 / 2 additional turn (180
(Dimensions in mm)
Reconditioning
dimension, dimensions in mm
Crankshaft bearing
pins-diameter
-0.032
Basic dimension
Connecting rod bearing

pins-diameter
-0.022
58.00
65.00
-0.047
-0.042
-0.032
-0.022
1st oversize
57.75
64.75
-0.047
-0.042
-0.032
-0.022
2nd oversize
57.50
64.50
-0.047
-0.042
Sealing flanges, seals and vibration damper
Page 1 / 11
13 - 4

Note:

Front sealing flange and vibration damper, assembly

overview 13-4, Front sealing flange and vibration
damper, assembly overview
Sealing ring for crankshaft, vibration damper side,
replacing 13-4, Crankshaft seal (vibration damper side),
replacing
Crankshaft seal (engine timing side), replacing
Generator shaft seal, replacing
seal, replacing
13-4,
13-4, Generator shaft
Front sealing flange and vibration damper, assembly

overview
Sealing flange, front
Must be located on dowel

sleeves
8 Nm
Observe tightening
sequence 13-4,
for front sealing flange and
coolant pump cover
Coolant pump cover
Vibration damper
turn (90
Page 2 / 11
Washer
Seal
Do not additionally oil or

grease sealing lip of sealing
ring

remains from crankshaft

seal (vibration damper side),
replacing
13 Nm
Tightening sequence of bolts for front sealing flange and

coolant pump cover
- Tighten bolts in the shown tightening sequence to 8 Nm.

Crankshaft seal (vibration damper side), replacing
Page 3 / 11
Counter-holder tool T10172
Extractor hook T20143/2
Not illustrated:
Assembly tool T10196
Work procedure
- Bring lock carrier into service position
Repair Manual, Body Exterior, Repair Group 50, Lock

carrier
.
- Remove vibration damper
Item - 4 - .
Note:
Be careful not to damage sealing surface when

removing sealing ring.
Page 4 / 11
- Carefully remove old sealing ring from its seat using hook
T20143/2 .
- Before installing, remove oil remains from end of
crankshaft with a clean cloth.
Note:
Only remove protective ring from seal immediately

prior to assembly.
- Join assembly sleeve T10196/1 and assembly sleeve

T10196/2 . Slide sealing ring - A - to stop on assembly
sleeve T10196/2 .
- Separate both assembly sleeves.
Page 5 / 11
- Place assembly sleeve T10196/2 together with sealing

ring on crankshaft flange and tighten knurled bolts - A hand-tight.
- Press in seal up to stop using pressure sleeve
T1096/3 .
The rest of the assembly is a reverse of the disassembling
sequence.
Pulling hook T20143/2
Not illustrated:
Requirement:
Page 6 / 11
Engine removed
Transmission separated from engine
Work procedure
Note:
Make sure the sealing surface is not damaged when

removing the seal.
T20143/2 .
- Before installing, remove oil remains from end of
crankshaft with a clean cloth.
- Join assembly sleeve T10207/1 and assembly sleeve

T10207/2 . Slide sealing ring - A - to stop on assembly
sleeve T10207/2 .
Page 7 / 11
- Separate both assembly sleeves.
- Place assembly sleeve T10207/2 together with sealing

ring on crankshaft flange and tighten knurled bolts - A hand-tight.
- Press in seal up to stop using pressure sleeve
T1207/3 .
The rest of the installation follows the reverse of the
removal procedures.
Generator shaft seal, replacing
Pulling hook T20143/1
Not illustrated:
Page 8 / 11
Work procedure
- Remove fuel filter 20-1, Fuel filter (vehicles with engine
code BKW), removing and installing .
Vehicles with engine codes BWF
- Remove bypass flap with cooler for Exhaust Gas
Recirculation (EGR) 26-2, Bypass flap with cooler for
Exhaust Gas Recirculation (EGR) (vehicles with engine
code BWF), assembly overview .
- Remove generator

Generator
.
Note:
Make sure the sealing surface is not damaged when

removing the seal.
T20143/1 .
- Remove oil residue on input shaft for generator using a
clean cloth.
Page 9 / 11
- Press inner part of sealing ring toward outside as shown.
- Screw guide sleeve T10208/1 hand-tight onto input shaft

for generator and carefully slide sealing ring - A - on up to
stop.
Page 10 / 11
- Position pressure piece T10208/2 and press in inner part

of sealing ring up to stop.
- Position pressure piece T10208/3 and press in outer part
of sealing ring up to stop.
The rest of the assembly is basically a reverse of the
disassembling sequence.
Page 11 / 11
Control housing
Page 1 / 3
13 - 5
Control housing
Note:

Control housing, assembly overview

housing, assembly overview
Control housing, assembly overview
Engine timing module

13-1, Engine timing module
(wheel cassette), removing
and installing
13-5, Control
Control housing
Control housing
Insert with silicone sealant D

176 501 A1
13-5, Sealant
bead on control housing
20 Nm
Observe tightening
sequence 13-5,
for control housing
20 Nm
Seal
Do not additionally oil or

grease sealing lip of sealing
ring

remains from crankshaft

seal (engine timing side),
replacing
Drive plate
Page 2 / 3

13-1, Drive plate, removing
and installing
turn (90
Replace
Washer
13 Nm
Control housing
Sealant bead on control housing
- Apply sealant bead onto clean sealing surface of the

control housing as shown.
Tightening sequence of bolts for control housing
- Tighten bolts in the illustrated tightening sequence to 20

Nm.
Page 3 / 3
Piston and connecting rod
Page 1 / 7
13 - 6

Caution!
Crankshaft, piston, and connecting rods must not be
replaced! Only removal and installation of these
components is permitted.
Note:

Piston and connecting rod, assembly overview

Checking piston position at TDC
at TDC, checking
Piston and cylinder dimensions
cylinder dimensions
13-6,
13-6, Piston position

13-6, Piston and
Piston rings, cylinder bores and piston positioning

13-6, Piston rings, cylinder bores and piston positioning
Connecting rod bolt, 30 Nm plus

an additional 1 / 4 turn (90 )
Replace
Lubricate threads and

contact surface
Use old bolt to measure

radial play
Connecting rod bearing cap
Note installation position
Bearing shell
Note version: Upper bearing

shell (to piston) made of
Page 2 / 7
wear-resistant material,
identification: Black line on
contact surface in area of
separating point
Do not interchange used

bearing shells
Insert bearing shells in

center
Check for secure seating
Axial play wear limit: 0.37

mm
Measure radial clearance

with Plastigage: Wear limit:
0.08 mm. Do not turn
crankshaft when checking
radial clearance
Connecting rod
Mark matching cylinder arrow A -
Location: Markings - arrows

B - point to vibration damper
side
Circlip
Piston
With combustion chamber
Mark installed position and

cylinder allocation
Installed position and

allocation, piston/cylinder
Topic 13-6
Directional arrow on piston

head points to intake side
Install with piston ring

compressor
Checking piston position at

TDC 13-6, Piston position
at TDC, checking
Piston and cylinder
Page 3 / 7
dimensions 13-6, Piston

and cylinder dimensions
Cylinder bore, checking

13-6, Checking cylinder
bores
Piston pin
If difficult to move, heat

piston to 60 C

using a drift VW 222 A
Piston rings
Offset gaps by 120
Use piston ring pliers for

removal and installation
"TOP" faces toward piston

crown
Checking ring gap

13-6,
Checking piston ring gap
Check piston ring groove

clearance 13-6, Checking
ring to groove clearance
Piston position at TDC, checking
It is not possible to measure piston projection position

using workshop equipment. Due to the connecting rod
principle for cylinder head bolts in conjunction with the
aluminum cylinder block results in a compression of the
cylinder block which cannot be reproduced when cylinder
head is removed. For this reason, a new cylinder head
gasket with the same index number ( 15-1, Tightening
sequence of bolts for cylinder head cover ) must be
installed when replacing the cylinder head gasket.
Piston and cylinder dimensions
Note:
No repair sizes are provided!
Page 4 / 7
Page 5 / 7
Honing dimension
Basic dimension
mm
Piston diameter
Cylinder bore diameter
80.97
81.01
Piston rings, cylinder bores and piston positioning
Checking piston ring gap
Feeler gauge
Test sequence
- Push piston ring squarely from above down to approx. 15
mm from bottom end of cylinder.
Piston ring
dimensions in mm
New
Wear limit
1. Compression ring
0.20 to 0.40
1.0
2. Compression ring
0.30 to 0.50
1.0
Oil scraping ring
0.25 to 0.50
1.0
Checking ring to groove clearance
Page 6 / 7
Feeler gauge
Test sequence
- Clean ring groove before checking.
Piston ring
dimensions in mm
New
Wear limit
1. Compression ring
0.08 to 0.10
0.25
2. Compression ring
0.03 to 0.05
0.25
Oil scraping ring
0.02 to 0.05
0.15
Checking cylinder bores
Internal dial gauge 50 - 100 mm
Test sequence
- Measure bores at 3 locations in both directions - A across engine and - B - in line with crankshaft.
Deviations from nominal dimension: max. 0.05 mm.
Piston: Installed position and allocation,
piston/cylinder
Pistons are identified on piston head:
Pistons 1 through 5: for cylinder bank 1
Pistons 6 through 10: for cylinder bank 2
Positioning:
Directional arrow on piston head points to intake

side
Page 7 / 7
Cylinder head
Page 1 / 28
15 - 1
Cylinder head
Caution!
Because of the threaded connection of cylinder head
through the aluminum cylinder block into crankshaft
bearing bracket (connecting rod), both cylinder heads
must always be removed. If cylinder head bolts are
loosened or tightened on one side, cylinder block is
warped.
Note:

When installing a replacement cylinder head with

camshaft installed, the contact surfaces between the
lifters and cam lobes must be lubricated before
installing the cylinder head cover.
The plastic protectors installed to protect the open

valves must only be removed immediately before
fitting the cylinder head.
When cylinder heads are replaced, all coolant must

also be replaced.
Cylinder head, assembly overview

head, assembly overview
15-1, Cylinder
Removing input gear for camshaft 15-1, Camshaft

compensation wheel and input gear, removing and
installing
Valve timing, checking
15-1, Valve timing, checking
Valve timing, adjusting
15-1, Valve timing, adjusting
Cylinder heads, removing and installing

Checking compression pressure
pressures, checking
Cylinder head, assembly overview
Note:
15-1,
15-1, Compression
Cylinder head
Page 2 / 28

Components depicted here correspond to cylinder

bank 1. They are different only as a mirror image of
components for cylinder bank 2.
Connecting hose

code BWF
To crankcase ventilation
valve
Ensure seated tightly
Sealing sleeve

code BWF
Replace if damaged
Cylinder head
Bracket

code BWF
For intake hose between air

filter and intake manifold flap
Acoustic cover

code BWF
Cylinder head cover

code BWF
Always clean sealing

surfaces of cylinder head
cover with a clean cloth
before setting in place
Replace seal together with

cylinder head cover if
damaged or leaking
Observe tightening
sequence of bolts 15-1,
for cylinder head cover
Acoustic cover

code BKW
Cylinder head cover

code BKW
Always clean sealing

surfaces of cylinder head
cover with a clean cloth
before setting in place
Replace seal together with

cylinder head cover if
Page 3 / 28
Cylinder head
damaged or leaking
20 Nm
Between control housing and

cylinder head
Cylinder head gasket
Replace
Install new seal of the same

strength 15-1,
Identification of cylinder
head gasket
Imprint of replacement part

numbers - A - must be
readable
After replacing replace entire

amount of coolant
Cylinder head
Observe tightening
sequence of bolts 15-1,
for cylinder head cover

15-1, Cylinder heads,
Cylinder head bolt
Replace
Observe sequence for

loosening and tightening
removing and installing ,
Cylinder head, removing and
installing
Sealing sleeve

code BKW
Replace if damaged
Page 4 / 28
Cylinder head
Connection piece

code BKW
To crankcase ventilation
valve
Tightening sequence of bolts for cylinder head cover
- Tighten bolts in the shown tightening sequence to 10

Nm.
Identification of cylinder head gasket
Number of holes (specifies thickness of gasket) )
Page 5 / 28
Cylinder head
Control code (disregard)

Replacement part number
) Cylinder
head gasket is available in three different

strengths, whereby the number of holes indicates the
corresponding strength ETKA (Electronic Parts
Catalog) Always install a new gasket of the same strength
when replacing.
Camshaft compensation wheel and input gear, removing
and installing
Note:
After each separation of the gear drive, the position

of the pump pistons in the pump injector units must
be checked after completing assembly and adjusted
if necessary 23-1, Position of pump pistons in
pump injector units, checking and adjusting
Page 6 / 28
Cylinder head
Page 7 / 28
required
Torque wrench (5 to 50 Nm) V.A.G

1331

V.A.G 1332
Puller T10055
Multi-point socket T10198
Clamping device T10199
Wrench T10211
Note:
Work sequence described and components depicted

here apply to cylinder bank 1. The difference for
cylinder bank 2 is minimal and is not described
separately for this reason.
Removing
- Remove engine and transmission
removing and installing .
10-1, Engine,
- Remove intake manifold flap and crankcase ventilation

line from respective cylinder.
- Remove acoustic cover and cylinder head cover of the
applicable cylinder head.
- Check rocker arm shaft running surfaces for wear.
- Remove coolant pipe below tandem and fuel pump.
- Remove vibration damper Item - 4 - . For this, use
counterholder T10172 with threading pins T10172/1 .
Cylinder head
- Screw crankshaft locator bar T10195 onto crankshaft

stub. Observe alignment pin while doing so.
- Now carefully rotate crankshaft until the pin of crankshaft
locator bar T10195 inserts into alignment bore.
- Remove corresponding pump 20-1, Tandem pump
and Fuel Pump (FP), removing and installing , Tandem
and fuel pump, removing and installing.
Cylinder bank 1: Tandem pump
Cylinder bank 2: Fuel Pump (FP)
- Remove oil supply line to exhaust turbocharger.
- Position Wrench T10211 as shown and loosen adapter

ring on pump injection unit central connector.
Page 8 / 28
Cylinder head
- Remove Camshaft Position (CMP) Sensor G40 - C (only on cylinder bank 1).
- Remove outer bearing cap - A - , place clamping device
T10199 on camshaft gear and tighten its bolt to 40 Nm.
- Loosen mounting bolt - B - for camshaft gear using
socket insert T10198 and remove together with tandem
pump drive.
- Loosen bolts on Clamping Device T10199 and remove
it.
- Remove compensating piston - B - for full-floating axle

of compensation linkage.
- Unscrew pull-off head for pump-injector unit from puller
T10055 .
Page 9 / 28
Cylinder head
- Screw puller T10055 into full-floating axle as shown and

pull full-floating axle out of its seat in direction of - arrow , using careful knocking motions.
- Pull out the outer compensation linkage on transmission

side, including its sleeve. If necessary, loosen by hitting
lightly with a plastic hammer.
- Remove camshaft gear.
- Now remove compensation wheel and inner
compensation linkage on engine side.
- Remove diamond disc from camshaft stub.

Installing
Page 10 / 28
Cylinder head
- Clean bearing cap contact surfaces of any sealant

residue.
- Oil compensation linkage sleeve guide surfaces.
Note:
If there is marked crimping or deposits on

compensation linkage sleeve guide surfaces, these
must be replaced.
- First engage inner, engine-side compensation linkage A - at bottom (if necessary, guide through compensating
piston hole with finger) and then slide top onto sleeve.
- Place a new diamond disc on camshaft stub.
- Bring lower, transmission-side compensation linkage into

position 15-1, Compensation linkage position and insert
compensation wheel with phase - arrow - in direction of
transmission.
Page 11 / 28
Cylinder head
- When inserting, turn the camshaft gear so marking arrow - on sensor wheel aligns with upper edge of sealing
surface.
- Secure construction by carefully sliding full-floating axle
on by hand with force as even as possible.
Caution!
There is the risk that a linkage may pivot to the side
out of the wheel cassette and will not engage when
full-floating axle is inserted, or it may be distorted
when inserting the full-floating axle.
- Insert guide sleeve in transmission-side compensation
linkage.
- Carefully pull full-floating axle back out of its seat. When
doing so, ensure compensation linkages which have
already been positioned remain in correct location.
- Install transmission-side compensation linkage with
writing toward transmission. When doing so, support if
necessary with light tapping on guide sleeve with a plastic
hammer.
- Control correct seating of compensation linkage with
finger through compensating piston hole.
- Compensation wheel must be aligned so that the holes in
the four linkages and in sprocket are positioned flush
behind one another 15-1, Compensation linkage
position .
Page 12 / 28
Cylinder head
Page 13 / 28
Compensation linkage position
- Lubricate free-floating axle with oil, then carefully slide in

by hand and with as even a force as possible. Correct seat
of full-floating axle faces toward a clear gap to cylinder
head bore - arrow - .
- Before fastening, turn the camshaft gear so that the

marking - arrow - on the sensor wheel aligns with upper
edge of sealing surface.
- Remove tandem or fuel pump drive.
- Position bearing cap flush with cylinder head edge using
Sealant AMV 176 501 and tighten. Tightening torque
Topic 15-1 .
- Install new compensating pistons. Tightening torque
Topic 15-1 .
- Positing Clamping Device T10199 and tighten camshaft
gear bolt. Tightening torque Topic 15-1 .
Bolted connections
Bolts, nuts
Cylinder head
Page 14 / 28
M6
10 Nm
M8
20 Nm
M10
45 Nm
M12
60 Nm
Exceptions:
Compensating piston
Bolt for camshaft gear
110 Nm
1st oversize
60 Nm
2nd oversize
150 Nm
Stage III
Bolt for bearing cap
Valve timing, checking

required
/ 4 additional turn (90
8 Nm plus and additional 1 / 4 turn (90
Cylinder head
Camshaft locator bar T10193 for

cylinder bank 1

cylinder bank 2
Work procedure
- Remove noise insulation ( Item - 14 - ) and covers (
Item - 13 - ) from cylinder heads.
- Rotate crankshaft slowly in direction of engine rotation

using counterholder T10172 until camshaft locator bar
T10193 for camshaft for cylinder bank 1 and camshaft
locator bar T10194 for camshaft for cylinder bank 2 can be
inserted into fitting holes as shown.
- Raise vehicle on vehicle platform.
- Check whether marking - arrow A - on vibration damper

aligns with alignment pin - arrow B - .
If markings do not align:
Page 15 / 28
Cylinder head
- Adjust valve timing
Page 16 / 28
15-1, Valve timing, adjusting .
Valve timing, adjusting

required

cylinder bank 1

cylinder bank 2
Crankshaft anchor T10195
Cylinder head
Page 17 / 28
Work procedure
10-1, Engine,
- Remove tandem and fuel pumps from cylinder heads

20-1, Tandem pump and Fuel Pump (FP), removing and
installing .
- Remove noise insulation ( Item - 14 - ) and covers (
Item - 13 - ) from cylinder heads.
- Remove acoustic covers and cylinder head cover.
- Turn engine using counterholder T10172 until at least

one camshaft locator bar can be inserted.
- Place clamping device T10199 onto wheel of secured
camshaft and loosen camshaft wheel bolt. Wheel can now
be turned freely on camshaft.
If only one camshaft locator bar could be inserted:
- Turn engine using counterholder T10172 until camshaft
locator bar for other cylinder bank can be inserted.
- Place clamping device T10199 on camshaft gear and
loosen its bolt. Wheel can also now be turned freely on
camshaft.
- Remove vibration damper Item - 4 - . For this, use
counterholder T10172 with threading pins T10172/1 .
Cylinder head
- Screw crankshaft locator bar T10195 onto crankshaft

stub. While doing so, observe alignment pin.
- Carefully rotate crankshaft until pin of crankshaft locator
bar T10195 inserts into alignment bore.
- Place clamping device T10199/1 as shown and tighten

its clamping bolts to 70 Nm.
- Place a torque wrench (40 to 200 Nm) V.A.G 1332 into
square of clamping device and push with 80 Nm in
opposite direction of engine rotation direction to eliminate
play from gear drive.
Cylinder bank 1: in direction of - arrow -
Cylinder bank 2: against direction of - arrow -
- Maintain specified force and tighten mounting bolt of

camshaft gear to a tightening torque of 50 Nm using socket
T10198 .
- Remove clamping device T10199/1 .
Page 18 / 28
Cylinder head
- Place clamping device T10199 on camshaft gear.

Note:
Make sure that clamping device T10199 makes

contact flush on cylinder head.
- Tighten clamping device T10199 bolts to 40 Nm.

- Then tighten camshaft gear using socket T10198 .
Torque specification: 150 Nm plus an additional 1 / 4 turn
(90
).
- Remove clamping device T10199 .

- Remove anchors from camshafts and crankshaft.
- Continue turning crankshaft two rotations in direction of
engine rotation until the crankshaft is again at TDC for
cylinder 1.
- Check whether anchors for camshafts as well as for

crankshaft can be inserted simultaneously.
Caution!
Page 19 / 28
Cylinder head
Because of the threaded connection of cylinder head

through the aluminum cylinder block into crankshaft
bearing bracket (connecting rod), both cylinder heads
must always be removed. If cylinder head bolts are
loosened or tightened on one side, cylinder block is
warped.
Not illustrated:
Container for removed components V.A.G 1698
Engine bung set VAS 6122
Cable tie
Page 20 / 28
Cylinder head
Page 21 / 28
Removing
10-1, Engine,
- Remove acoustic covers as well as cylinder head covers

from cylinder heads.
- Remove tandem and fuel pumps from cylinder heads
20-1, Tandem pump and Fuel Pump (FP), removing and
installing .
15-1, Valve timing,
- Remove drive gears for camshafts 15-1, Camshaft

installing .
- Remove bolts ( Item - 8 - ) between control housing
and cylinder head of cylinder bank 1 and 2.
- Loosen and remove cylinder head bolts in specified

sequence ( - arrow - points in driving direction).
- Carefully remove cylinder heads with assistance of a
second technician.
Note:
The cylinder heads must be carefully guided to

prevent damages.
- Place clean rags into cylinders so that no dirt or emery

cloth particles can get in between cylinder wall and piston.
- Do not allow dirt or abrasive powder to get into coolant
either.
- Carefully clean cylinder head and cylinder block sealing
surfaces. Avoid introducing scratches or scoring (do not
use sandpaper with grit below 100).
Cylinder head
Installing
Note:
Always replace cylinder head bolts.
Only unpack new cylinder head gasket immediately

prior to installation.
Install cylinder head gasket with the same

"thickness" index as the one removed.
Handle gasket carefully. Damages to the silicone

layer and in areas of recesses may result in leaks.
- Before installing cylinder heads, position crankshaft to

TDC for cylinder 1.
- Turn back crankshaft in opposite direction of engine
rotation direction until all pistons stand almost evenly below
TDC.
- Set cylinder head gasket in place.
- Install cylinder head according to position of

compensation linkage - arrow - , insert cylinder head bolts
with associated washers and tighten hand-tight.
Caution!
All cylinder head bolts, except number - 1 - , - 2 - , 17 - and - 19 - in tightening sequence must be
installed with notched washers ETKA (Electronic
Parts Catalog)
Page 22 / 28
Cylinder head
Page 23 / 28
- Tighten cylinder heads in sequence indicated, in four

stages as follows ( - arrow - points in driving direction).
Tighten using torque wrench:

Step I = 30 Nm
Step II = 60 Nm
Tighten further using a solid wrench:

Stage III = 1 / 2 additional turn (180
Step IV = 1 / 2 turn (180
- Install drive gears for camshafts 15-1, Camshaft

installing .
Compression pressures, checking
Note:
With this engine, the static compression test requires

a significant amount of work. Therefore it is
recommended to check idle stabilization control
before disassembly Vehicle Diagnosis, Testing
and Information System VAS 5051 or VAS 5052
"Guided Fault Finding; Repair Group 15; partial
systems, boundary conditions" . Only if one or more
cylinder(s) is/are noticeable at this point is the
compression test warranted.
Cylinder head

required

1331
Adapter V.A.G 1381/12
Compression tester V.A.G 1763
Not illustrated:
Sealing plate T10247
Connecting hose VAS 6278
Requirements:
Page 24 / 28
Cylinder head
Page 25 / 28
Engine oil temperature min. 30
Ignition switched off
Work sequence
- Drain coolant
filling .

- Seal connection for fuel hoses using sealing plate

T10247 .
- Connect fuel supply line - A - using connecting hose

VAS 6278 to fuel return line - B - .
Cylinder head
- Remove upper part of oil filter housing 17-3, Oil filter

housing, assembly overview , Oil filter housing, assembly
overview.
- Remove glow plugs :
Vehicles with engine codes BKW and BWF 28-1,

Glow plugs vehicles with engine code BKW, BWF)
removing and installing, checking
- Remove right plenum chamber cover - D - .

- Disconnect small connectors from Engine Control
Modules (ECM).
Note:
By disconnecting the small harness connectors for

Engine Control Modules (ECM) the engine is
prevented from starting up even though the starter is
turning. If any DTCs are stored in DTC memory
during start procedure, it is necessary to check and
erase (if required) the DTC memory.
After the compression test, check the DTC memory

23-2, Diagnostic Trouble Code (DTC) memory of
Engine control modules (ECM) , checking and
erasing , DTC memory of engine control module
(ECM) , checking and erasing.
Page 26 / 28
Cylinder head
Page 27 / 28
- Screw in adapter V.A.G 1381/12 in place of glow plug at

cylinder to be tested.
- Re-install upper part of oil filter housing 17-3, Oil filter
housing, assembly overview , Oil filter housing,
disassembling and assembling.
- Check compression pressure using compression tester
V.A.G 1763 .
Note:
Using the compression tester

instructions .
Operating
- Operate starter until tester shows no further pressure

increase.
Compression pressure:
New: 25 to 0.31 bar pressure
Wear limit: 19 bar pressure
Permissible difference between all cylinders: 5 bar
- Install glow plugs 28-1, Glow plugs vehicles with

engine code BKW, BWF) removing and installing,
checking :
Vehicles with engine codes BKW 28-1, Glow plugs
vehicles with engine code BKW, BWF) removing and
installing, checking
- Fill with coolant
filling .
- After all cylinders have been checked and engine has

been completely re-assembled, check DTC memory and
Cylinder head
erase it if necessary 23-2, Diagnostic Trouble Code

(DTC) memory of Engine control modules (ECM) ,
checking and erasing , DTC memory of engine control
module (ECM) , checking and erasing.
Page 28 / 28
Valvetrain
Page 1 / 16
15 - 2
Valvetrain
Note:

Cylinder heads with tears between the valve seats

can continue to be used without reducing service
life, as long as the tears have a width of max. 0.5
mm.
Valve gear, assembly overview

assembly overview
15-2, Valvetrain,
Rework valve seats
15-2, Valve seats, refacing
Check valve guides
15-2, Valve guides, checking
Replacing valve stem oil seals

seals, replacing
15-2, Valve stem
Camshaft, removing and installing

Valvetrain, assembly overview
15-2, Camshaft,
Valvetrain
Page 2 / 16

turn (90
Replace

15-2, Camshaft, removing
and installing , removing and
installing camshaft
Rocker arm axle
Do not interchange
Bearing cap
To install, seal joint surfaces

of outer bearing cap with
sealant AMV 176 501
15-
Valvetrain
Page 3 / 16
2, Seal joint surfaces of

outer bearing caps
Valve lifter
Do not interchange
With hydraulic valve

clearance compensation
Place on running surface

when setting down
Before installing, check axial

play of camshafts 15-2,
Camshaft, checking axial
play
Lubricate contact surface
Before removing, remove

bearing caps for camshaft
Valve keepers
Valve spring plate
Outer valve spring
Inner valve spring
Replace 15-2, Valve stem

seals, replacing
Diamond disc

15-2, Valve stem seals,
replacing , Valve stem seals,
replacing
Valve stem seal

15-2, Valve stem seals,
replacing , Valve stem seals,
replacing
Replace
Sleeve
Valvetrain
Read "Notes"
Reface valve seats 15-2,

Valve seats, refacing
Topic 15-2
Valves
Valve dimensions
Valve dimensions
15-2,
Pump-Injector Unit
For linkage mounting

components
Cylinder head
Page 4 / 16

23-1, Pump-Injector Unit,
Washer
For cylinder head bolts
Insert into cylinder head

before assembling bearing
caps
Observe "Precautions"
Topic 15-1
Bearing shell

bearings (mark)
Make sure retaining tabs are

engaged properly in bearing
caps and cylinder head
Camshaft
Checking axial play 15-2,

Camshaft, checking axial
play
Identification, valve timing

15-2, Camshaft
identification, valve timing
Valvetrain
Page 5 / 16

15-2, Camshaft, removing
and installing
Checking radial clearance

with Plastigage, Wear limit:
0.11 mm
Run-out: max. 0.01 mm
Bearing shell

bearings (mark)
Make sure retaining tabs are

engaged properly in bearing
caps and cylinder head
Cylinder head bolt
Replace

Cylinder heads, removing
and installing
Before installing, insert

shims Item - 15 - into
cylinder head
8 Nm plus an additional 1 / 4 turn

(90
Replace
Valvetrain
Camshaft, checking axial play
Dial gauge holder VW 387
Dial gauge
Test sequence
Measurement with valve lifters removed and bearing caps
installed:
Cylinder bank 1:
Bearing caps 2, 4 and 6 installed
Cylinder bank 2:
Bearing caps 9, 11 and 13 installed
Wear limit: max. 0.15 mm
Seal joint surfaces of outer bearing caps
Page 6 / 16
Valvetrain
Page 7 / 16
Sealant AMV 176 501
Work procedure
- Apply sealant AMV 176 501 thinly and evenly on surface
- 1- .
Cylinder bank 1:
Seal bearing caps 1 and 7 with sealant AMV 176

501
Cylinder bank 2:
Seal bearing caps 8 and 14 with sealant AMV 176

501
Valve dimensions
Note:
Valves must not be refaced. Only lapping is

permitted.
Dimension
Intake valve
Exhaust valve
Diameter a
mm
35.950
31.450
Diameter b
mm
6.980
6.956
mm
89.950
89.950
45
45
Valvetrain
Page 8 / 16
Camshaft identification, valve timing
Identification
Base circle of valve cams: a = diameter 52.8 mm
Identification by numbers and letters stamped on

face surface of camshaft drive side.
Drive side - arrow Cylinder bank 1

Cylinder bank 2
07Z G
07Z H
Valve timing at 1 mm valve lift

Intake valve opens after TDC
12.0
Intake valve closes after BDC
21.5
Exhaust valve opens before BDC
30.0
Exhaust valve closes before TDC
20.5
Valve seats, refacing
Depth gauge
Valve seat refacing tool
Note:
When repairing engines with leaking valves, it is not

sufficient to reface or replace valve seats and
valves. It is particularly important to check valve
Valvetrain
Page 9 / 16
guides for wear on engines with longer running

times.
Only reface valve seats enough until a perfect

contact pattern is obtained. The maximum
permissible reworking dimension must be calculated
before work is carried out. If the reworking
dimension is exceeded, the function of the hydraulic
lifters can no longer be guaranteed and therefore the
cylinder head should be replaced.
The maximum permissible reworking dimension is

calculated as follows:
- Insert valve and press firmly against seat.
Note:
If a valve is to be replaced as part of a repair, use a

new valve for the calculation.
- Measure distance - a - between end of valve stem and

upper edge of cylinder head.
- Calculate max. permissible reworking dimension from
measured distance - a - and minimum dimension.
Minimum dimensions:
Intake valve 43.4 mm
Exhaust valve 43.2 mm
Measured distance minus minimum dimension = max.

permissible reworking dimension.
Example:
Valvetrain
Page 10 / 16
Measured distance
44.1 mm
Minimum dimension
43.4 mm
Max. permissible reworking dimension*
Refacing intake valve seat

a - Diameter 35.7 mm
b - 1.6 mm
45 - Valve seat angle
Note:
The 30 relief milling of the valve seat is always

necessary due to flow ratios in the intake canal.
Refacing exhaust valve seat

a - Diameter 31.4 mm
b - 2.7 mm
45 - Valve seat angle
Valve guides, checking
0.7 mm
Valvetrain
Page 11 / 16
Not illustrated:
Dial gauge
Work sequence
- Insert a new valve into guide. The end of the valve stem
must be flush with the guide. Due to the slight difference in
stem dimensions, make sure that only an intake valve is
used in the intake guide and an exhaust valve in the
exhaust guide.
- Determine tilt clearance. Wear limit: max. 1.3 mm
- If tilt clearance exceeds wear limit, the cylinder head
must be replaced.
Valve stem seals, replacing
Valvetrain

required
Valve assembly tool 2036
Removal tool 3047 A
Valve stem seal driver 3129
Valve lever VW 541/1 A
Pressure piece VW 541/5
Removing
(With cylinder head installed)
Page 12 / 16
Valvetrain
- Remove camshaft
installing .
Page 13 / 16
15-2, Camshaft, removing and
- Remove valve lifters and place on running surface when

setting down. Be careful not to switch valve lifters.
- Move piston for respective cylinder to Top Dead Center
(TDC) position.
- Insert valve assembly tool 2036 and adjust mounting to

stud height.
- Remove valve springs with valve lever VW 541/1 A and
pressure piece VW 541/5 .
Note:
Support valves on piston head while doing this.
- Pull off valve stem seals with valve seal removal tool
3047 A .
Installing
Valvetrain
Page 14 / 16
- Attach plastic sleeves provided - A - to the respective

valve stem. This will help avoid damage to new valve stem
oil seal - B - .
- Insert new valve stem oil seal into valve stem seal driver
3129 .
- Grease lip of valve stem oil seal and carefully slide onto
valve guide.
- Install camshaft
installing .
15-2, Camshaft, removing and
Camshaft, removing and installing
Sealant AMV 176 501
Removing
- Remove drive gear for camshaft
10-1, Engine,
15-1, Camshaft
Valvetrain
Page 15 / 16

installing .
- Remove rocker arm axles
Item - 2 - .
- Loosen camshaft bearing cap starting from outside

working inward, whereby the bolts of last two bearing caps
must be loosened alternating in diagonal sequence.
Installing
Note:
Make sure that no valve is pressed onto piston when

installing the camshaft. Bring pistons evenly to just
below Top Dead Center (TDC) position.
Do not interchange run-in connecting rod bearing

shells (mark).
When installing camshaft, make sure bearing shell

retaining tabs are seated properly in bearing caps
and cylinder head.
Before installing bearing cap, make sure that

washers for cylinder head bolts are inserted in
cylinder head.
- Oil bearing cap contact surfaces.

- Tighten inner two bearing caps alternating in diagonal
sequence and tighten to 8 Nm plus an additional 1 / 4 turn
(90
) (replace bolts).
- Install remaining bearing caps and also tighten to 8 Nm

plus an additional 1 / 4 turn. (90 ) (replace bolts).
Note:
Seal joint surfaces of outer bearing caps with sealant

AMV 176 501
15-2, Seal joint surfaces of outer
bearing caps .
- Install rocker arm axles and tighten first the inner and
then outer mounting bolts evenly in diagonal sequence to
tightening torque: 20 Nm plus an additional 1 / 4 turn (90
) turn (replace bolts).
- Re-install drive gear for camshaft
15-1, Camshaft
Valvetrain
Page 16 / 16

installing .
- Install acoustic cover as well as cylinder head cover of

respective cylinder.
- Install engine and transmission
10-1, Engine,
Note:
After installing new valve lifters, the engine may not

be started for approx. 30 minutes. The hydraulic
valve lifters have to settle (otherwise valves will
strike the pistons).
Engine oil
Page 1 / 2
17 - 1
Engine oil
Caution!
The oil level must not be above the max. mark - danger
of damage to catalytic converter! Markings on oil
dipstick 17-1, Engine oil level, checking .
Engine oil, draining
Engine oil specifications
Oil filling quantities
17-1, Oil filling quantities
Engine oil level, checking

checking
17-1, Engine oil level,
Oil filling quantities
Without oil filter 11.2 L

With oil filter 11.5 L
Engine oil level, checking
Markings on oil dipstick
1 - Max. mark
2 - Min. mark
a - Area above hatched field up to Max. mark: Do not
replenish with engine oil!
b - Oil level within hatched field: Can be replenished with
Engine oil
engine oil
c - Area from Min. mark up to hatched field: Replenish with
max. 0.5 ltr. of engine oil!
Page 2 / 2
Oil pan
Page 1 / 6
17 - 2
Oil pan
Caution!
Note:


engine, use frame support T10191 .

Oil pan, assembly overview

overview
Sealant , applying
17-2, Oil pan, assembly
17-2, Sealant , applying
Oil pan, assembly overview
Lower part of oil pan, assembly overview

pan (lower section), assembly overview
17-2, Oil
Upper part of oil pan, assembly overview

pan (upper section), assembly overview
17-2, Oil
Oil pan (lower section), assembly overview
Oil pan
Page 2 / 6
8 Nm
8 Nm
Oil Level Thermal Sensor G266
Seal
Checking Electrical Wiring

Diagrams, Troubleshooting
and Component Locations
binder
Replace
Oil drain plug, 30 Nm
If sealing ring is leaking cut

open and replace.
Oil pan
Page 3 / 6

Oil pan, lower section
Clean sealing surface before

installing
Insert with sealant AMV 176

501
17-2, Sealant ,
applying
Oil tube
8 Nm
O-ring
Replace
Oil pan (upper section), assembly overview
Oil pan
Page 4 / 6
8 Nm
8 Nm
Oil tube
Oil pan (upper section)
Clean sealing surface before

installing
Insert with sealant AMV 176

501
17-2, Sealant ,
applying
Note internal oil lines 172, Oil lines in upper section

of oil pan
10 Nm
Baffle
Cylinder block
Engine, disassembling and

assembling 13-1, Engine,
disassembling and
assembling
Oil lines in upper section of oil pan
Oil pan
- Insert oil lines - A - as shown in illustration and tighten

bolts - B - to 8 Nm.
Sealant , applying
Sealant AMV 176 501
Work procedure
- Remove sealant residue from pan with a rotating brush,

e.g. a hand drill with a plastic brush attachment (wear eye
protection).
- Clean sealing surfaces. Sealing surfaces must be free of
oil and grease.
Note:
Note the expiration date of the sealant .
The oil pan must be installed within 5 minutes of

applying sealant .
Page 5 / 6
Oil pan
Page 6 / 6
- Cut tube nozzle at front marking (nozzle diameter approx.

3 mm).
- Apply silicone sealing compound , as shown, to clean oil
pan sealing surface. Sealing compound bead must be:
2 to 3 mm thick
and run on inside of bolt holes - arrows -
Seal contour for oil pan, lower section
- Apply sealant , as shown, to clean sealing surface of

lower section of oil pan.
Seal contour for oil pan, upper section
- Apply sealant , as shown, to clean sealing surface of

upper section of oil pan.
Oil pump, oil filter housing and oil pressure
Page 1 / 9
17 - 3

Caution!
Note:


engine, use frame support T10191 .

Oil pump, assembly overview

assembly overview
17-3, Oil pump,
Oil filter housing, assembly overview

housing, assembly overview
17-3, Oil filter
Oil pressure and oil pressure switch, checking

Checking oil pressure at engine face
pressure, checking at front of engine
Oil pump, assembly overview
17-3, Oil
17-3,

(90
Oil return line
Gasket
Replace if damaged
Oil pump
Loosening return
connections 17-3,
Loosening return
connections of oil pump
To remove, slide slightly in

direction of engine
management side after
loosening all mounts and
remove
Page 2 / 9
10 Nm
Baffle plate
Slide block
Baffle plate
turn (90
Loosening return connections of oil pump
- Pull out securing clamps - A - in direction of - arrow and slide connecting pieces in direction of - arrow B - .
Oil filter housing, assembly overview
Page 3 / 9
Oil filter cover, 25 Nm
With bypass valve for oil

filter
Loosen and tighten with oil

filter wrench T10192
173, Loosening and tightening
oil filter cover
Oil filter element
Cap
Replace gaskets if damaged
Housing upper section
8 Nm
10 Nm
Page 4 / 9
Gasket
Replace if damaged
Filler tube
Oil cooler
Housing lower section
Loosening and tightening oil filter cover
Oil filter wrench T10192
Work procedure
- Loosen and tighten oil filter cover with oil filter wrench
T10192 .
Torque specification 25 Nm
Page 5 / 9

required
Oil pressure gauge V.A.G 1342
Voltage tester V.A.G 1527 B
Connector test set V.A.G 1594 C
Note:
Function test and service of visual and acoustic oil

pressure indicator Electrical Wiring Diagrams,
Troubleshooting and Component Locations binder
and Vehicle Diagnosis, Testing and Information
System VAS 5051 or VAS 5052 "Guided Fault
Finding"
Page 6 / 9
Work sequence
Vehicles with engine codes BKW
Vehicles with engine coded BWF
Note:
When removing oil pressure switch, counterhold

banjo bolt so that leaks in the vicinity of the oil line
are prevented.
- Remove oil pressure switch F1 and screw it into oil

pressure gauge V.A.G 1342 .
- Screw oil pressure gauge into banjo fitting in place of oil
pressure switch F1 .
- Connect brown wire of oil pressure gauge to Ground (-).
- Connect diode test lamp of voltage tester V.A.G 1527 B
to B+ and oil pressure switch using adapter cables from
connector test set V.A.G 1594 C . LED must not light up.
- Install fuel filter 20-1, Fuel filter (vehicles with engine
- Install bypass flap with cooler for Exhaust Gas
Page 7 / 9

- Start engine and slowly increase engine speed.
- LED must light up at 0.55 to 0.85 bar positive pressure,
otherwise replace oil pressure switch F1 .
- Increase engine speed (RPM) further. At 2000 RPM and
an oil temperature of 80 C, oil pressure must be at least
2.0 bar.
Oil positive pressure must not exceed 7.0 bar at higher
engine speeds.
Oil pressure, checking at front of engine
Oil pressure gauge V.A.G 1342
Work sequence
- Remove covers in engine compartment.
- Remove noise insulation (
heads.
Item - 14 - ) from cylinder
Page 8 / 9
- Remove oil channel sealing plug - A - from cylinder bank

to be tested.
Caution!
The oil channel hole indicates a very low thread depth.
the Adapter VAG1342/19 V.A.G 1342/19 should not be
installed too tightly due to the danger of damaging the
threads.
- Connect oil pressure tester V.A.G 1342 with adapter
V.A.G 1342/19 to oil channel hole.
- Seal test hole for oil pressure switch on oil pressure
tester V.A.G 1342 using engine sealing plug.
- Start engine.
Oil pressure must not reach below a value of 1.4 bar at
1000 RPM and 80 C oil temperature.
Page 9 / 9
Cooling system components
Page 1 / 30
19 - 1

Caution!
clearance issues:

path is followed.

components.
Note:
When the engine is warm the cooling system is

under pressure. If necessary release pressure
before commencing repair work.
Hoses are secured with spring-type clips. In cases of

repair only use spring-type clips.
The spring-type clip pliers VAS 5024 A are

recommended for installing spring-type clips.
When installing coolant hoses, make sure they are

free of stress and do not come into contact with
other components (observe markings on coolant
connections and hoses).
Page 2 / 30
Perform leak test of cooling system using cooling

system tester V.A.G 1274 , adapter V.A.G 1274/8
as well as adapter V.A.G 1274/9 .
Radiator, assembly overview

assembly overview
19-1, Radiator,
Coolant fan, assembly overview

assembly overview
19-1, Coolant fan,
Cooling system components, body side

19-1,
Cooling system components, on engine and at top

19-1, Cooling system components, on engine and at top
Components of fuel and generator cooling
and generator cooling system components
19-1, Fuel
Component location of After-Run Coolant Pump V51

and Pump for fuel cooler 19-1, After-Run Coolant
Pump V51 and Fuel Cooler Pump V166 , component
location
Coolant thermostat housing, assembly overview
1, Coolant thermostat housing, assembly overview
Coolant pump - assembly overview
pump, assembly overview
19-
19-1, Coolant
Coolant hose connection diagram 19-1, Coolant hose

connection diagram (Vehicles with engine codes BKW)
Vehicles with engine code BKW 19-1, Coolant

hose connection diagram (Vehicles with engine
codes BKW)

19-1, Coolant
hose connection diagram, vehicles with engine code
BWF
Cooling system, draining and filling

system, draining and filling
19-1, Cooling
Coolant mixture ratios 19-1, Cooling system, draining

and filling , Coolant, draining and filling
Coolant fan mount, removing and installing
Radiator, removing and installing
19-1,
19-1, Radiator,
Page 3 / 30
Coolant connection, removing and installing

Coolant pump, removing and installing
pump, removing and installing
Radiator, assembly overview
Upper coolant hose
Secured to radiator with a

retaining clip
Radiator

19-1, Radiator, removing
and installing
After replacing replace entire
19-1,
19-1, Coolant
amount of coolant
Condenser
ATF oil cooler
For air conditioning system
For transmission oil
Oil cooler
For power steering oil
Lock carrier
Bolts, 10 Nm
Radiator
Vehicles with engine code
BKW:
For generator and fuel

cooling
For fuel cooling
Bolts, 10 Nm
Rubber bushing
Retaining clip
Check for secure seat
Rubber bushing
Engine Coolant Temperature

(ECT) Sensor (on Radiator) G83
If necessary release
pressure in cooling system
before removing
Lower coolant hose

retaining clip
Page 4 / 30
Junction piece
For coolant hose from

expansion tank
Coolant fan, assembly overview
Coolant fan V7
Coolant fan mount

19-1, Coolant fan mount,
Bolts, 10 Nm
Page 5 / 30
Bolts, 10 Nm
Coolant Fan 2 V177
Coolant Fan Control (FC) control

module J293
Bolts, 10 Nm
Cap
Check using cooling system

tester V.A.G 1274 and
adapter V.A.G 1274/9
Test pressure 1.4 to 1.6 bar
Reservoir
Page 6 / 30
Perform leak test of cooling

system with cooling system
Depending on optional
equipment, connection may
be sealed with a blanking
plug.
Y-piece
Coolant hose
Fastened to lock carrier
Bracket
Radiator
BKW:

cooling

BWF:
For fuel cooling
Cooling system components, on engine and at top
Page 7 / 30
Cap

Reservoir

plug.
Coolant pipe
Page 8 / 30
To thermostat housing
Coolant pipe
BKW:
To auxiliary water heater

BWF:
Coolant hose
To auxiliary water heater
Coolant hose
To cooler for exhaust gas

recirculation
From heat exchanger
Upper coolant hose

retaining clip
Lower coolant hose

retaining clip
Fuel and generator cooling system components
Page 9 / 30
Reservoir

plug.
Cap

Coolant pipe
Page 10 / 30
To Fuel Cooler Pump V166
Coolant pipe
BKW:
To cooler for generator and

fuel cooling Item - 6 -

BWF:
To cooler for fuel cooling

Item - 6 -
Coolant hose
BKW:
From cooler for generator

and fuel cooling Item - 6 -

BWF:
From cooler for fuel cooling

Item - 6 -
Radiator
BKW:

cooling

BWF:
For fuel cooling
Coolant hose
From fuel cooler pump V166

to radiator Item - 6 -
After-Run Coolant Pump V51 and Fuel Cooler Pump
Page 11 / 30
V166 , component location
After-run coolant pump V51
Bolted to engine on right
Fuel Cooler Pump V166
Bolted to engine on right
To Fuel Cooler Pump V166
From Fuel Cooler Pump V166
Check valve
From After-run coolant pump

V51
Page 12 / 30
To After-run coolant pump V51
Coolant thermostat housing, assembly overview
Note:
The coolant thermostat housing is located in the

lower part of oil filter housing.
Routing of coolant hoses to thermostat housing

19-1, Cooling system components, on engine and at
top , Cooling system components - engine side and
top.
Oil filter housing - lower section
With coolant thermostat

housing
Oil filter housing, assembly
Page 13 / 30
Page 14 / 30
overview 17-3, Oil filter

housing, assembly
overview
turn (90
Replace
Hex bolt, 10 Nm
Bracket
Socket head bolt, 10 Nm
Map Controlled Engine Cooling

Thermostat F265
Connecting piece
Gasket
Replace
Coolant thermostat
Checking: Heat up
thermostat in water
Opening begins approx. 80

C
Ends approx. 105
Opening lift min. 7 mm
turn (90
Replace
Coolant pump, assembly overview
Page 15 / 30

Seal
Replace
Coolant drain plug, 40 Nm
Coolant pump

19-1, Coolant pump,
turn (90
Coolant pump cover
8 Nm
Observe tightening
sequence 19-1, Coolant
pump, removing and

installing , Coolant pump,
Seal
Replace
O-ring
Replace
Coolant hose connection diagram (Vehicles with engine

codes BKW)
Heater unit heat exchanger
Auxiliary water heater (auxiliary

heater)
Page 16 / 30
Recirculation Pump V55
Fuel cooler
Generator
Cylinder head/cylinder block
Coolant thermostat housing
Valve body
Radiator
Radiator

cooling
Pump for fuel cooler V166
Check valve
Expansion tank
Coolant hose connection diagram, vehicles with engine

code BWF
Page 17 / 30
Heat exchanger
For heater
Cylinder head/cylinder block
Fuel cooler
Radiator
For Exhaust Gas

Recirculation (EGR) system
Coolant thermostat housing
Valve body
Pump for fuel cooler V166
Radiator
Page 18 / 30
Radiator
For fuel cooling
Check valve
Expansion tank
Cooling system, draining and filling

required
Refractometer T10007
Page 19 / 30

1331

A
Cooling system charge unit VAS

6096
Draining
Warning!
Hot steam may escape when opening expansion tank.
Wear protective goggles and protective clothing to
prevent damage to eyes and scalding. Cover the cap
with a rag and open very carefully.
- Open cap on coolant expansion tank.
- Remove sound insulation
Repair Manual, Body Exterior, Repair Group 50, Sound

insulation
.
- Remove crossmember
Repair Manual, Body Exterior, Repair Group 63, Front

bumper; Bumper cover, removing and installing; Bumper
carrier - Assembly overview
Page 20 / 30
- Remove sealing plug - arrow - from radiator.

Note:
Observe disposal regulations for coolant!
- Disconnect coolant hoses at coolant regulator housing arrows - to drain coolant from engine.
Filling
Note:
Only coolant additive G 12 can be used, in

compliance with TL VW 774 F . Distinguishing
feature: colored violet
G 12 and coolant additives marked in accordance

with TL VW 774 F prevent frost and corrosion
damage, scaling and also raise boiling point of
coolant. For this reason the system must be filled all
year round with frost and corrosion protection
additives.
Because of its high boiling point, the coolant

improves engine reliability under heavy loads,
Page 21 / 30
Page 22 / 30
particularly in countries with tropical climates.
Protection against frost must be assured to about 25 C (in arctic climatic countries to about -35
C).
The coolant concentration must not be reduced by

adding water even in warmer seasons and in
warmer countries. The coolant additive portion must
be at least 40%.
If for climatic reasons a greater frost protection is

required, the amount of G 12 can be increased, but
only up to 60% (frost protection to about -40 C), as
otherwise frost protection is reduced again and
cooling effectiveness is also reduced.
If radiator, heat exchanger, cylinder head or cylinder

head gasket is replaced, do not reuse old coolant.
The refractometer T10007 is recommended for

determining the current anti-freeze density.
Recommended mixture ratios:

Frost protection to
Anti-freeze amount
G 12 1)
Water 1)
-25
40%
5.0 l
8.0 l
-35
50%
6.5 l
6.5 l
1) The
quantity of coolant can vary depending upon the

vehicle equipment.
Work procedure
- Install coolant hoses and secure.

- Thread adapter V.A.G 1274/8 on expansion tank.
- Fill coolant circuit using cooling system charge unit VAS
6096
Operating instructions for cooling system charge
unit VAS 6096
Removing
- Drain coolant
filling .
- Pull off retaining clamps for upper coolant hose, remove

bolt - 1 - .
- Disconnect upper coolant hose from radiator.
- Remove front bumper
Page 23 / 30

bumper

carrier
.
- Disconnect harness connectors for radiator fan.
- Disengage retainer - arrows - and remove fan mount
upward.
Installing
Installation is in reverse order of removal. Note the
following:
- The coolant fan mount must engage into mounting points
intended for it.
- Fill with coolant
filling .
Radiator, removing and installing
Page 24 / 30
Removing
- Remove fan mount
and installing .
19-1, Coolant fan mount, removing
- Remove retaining clips on bumper carrier

bumper; Bumper cover, removing and installing; Bumper
carrier - Assembly overview
- Disengage securing clamps for A/C system condenser

and ATF oil cooler - arrow - .
- Remove upper radiator securing bolts and remove
radiator upward.
Installing
following:
- Fill with coolant
filling .
Page 25 / 30
- Electrical connections and routing Electrical Wiring

Diagrams, Troubleshooting and Component Locations
binder
- Install front bumper

bumper
- Check headlight adjustment and correct, if necessary
Removing
- Drain coolant
filling .
Page 26 / 30
- Pull off coolant hoses from coolant connection.

- Disconnect connector from Engine Coolant Temperature
(ECT) Sensor G62 .
- Remove bolts from coolant connection.
- Slide cylinder connecting pieces in direction of - arrow into coolant housing - 1 - .

Installing
following:
- Always replace seals - 2 - and gaskets.

- Tighten bolts of coolant housing - 1 - to 8 Nm.
- Fill with coolant
filling .
Coolant pump, removing and installing
Page 27 / 30
Page 28 / 30
Removing
- Remove front bumper

bumper

carrier
.
- Remove vibration damper
15-1, Valve timing,
Item - 4 - .
- Drain coolant
filling .
Page 29 / 30
- Disconnect coolant hose - 3 - from coolant pipe.

Unscrew mounting bolts - 1 - and - 2 - and fold coolant
pipe toward front.
- Remove coolant drain plugs
- Remove coolant pump cover
Item - 2 - .
Item - 5 - .
- Remove mounting bolts for coolant pump - arrows - and

remove coolant pump.
Note:
If coolant pump bolts are not accessibly, attach

vibration damper and turn crankshaft using
counterholder T10172 and threaded pins T10172/1
until bolts are accessible.
Installing
following:
- Coat new O-ring with coolant, do not use any other
lubricants.
- Install coolant pump.
- Tighten coolant pump bolts - arrows - to 20 Nm plus an

additional 1 / - 4 - turn (90 ).
- Tighten coolant pump cover bolts in the shown tightening

sequence to 8 Nm.
- Fill with coolant
filling .
Page 30 / 30
Fuel supply system components
Page 1 / 48
20 - 1

Note:
Hose connections are secured with couplings or

spring-type or clamp-type clips.
Always replace clamp-type clips with spring-type

clips.
Fuel hoses at engine must only be secured with

spring-type clips. The use of clamp or screw type
clips is not permitted.
The spring-type clip pliers VAS 5024A are

Observe safety precautions when working on fuel

supply system 20-1, Safety precautions when working
on fuel supply system
Note rules of cleanliness
20-1, Rules for cleanliness
Fuel tank with attachments, assembly overview

1, Fuel tank with attachments, assembly overview
20-
Fuel filter, assembly overview 20-1, Fuel filter

(vehicles with engine code BKW), assembly overview
Vehicles with engine code BKW 20-1, Fuel filter

(vehicles with engine code BKW), assembly
overview

20-1, Fuel filter,
(vehicles with engine code BWF), assembly
Page 2 / 48
overview
Connection diagram of fuel lines and components in
fuel tank 20-1, Connection diagram for fuel lines and
fuel tank components
Connection diagram for fuel hoses in engine
compartment 20-1, Connection diagram for fuel hoses
in engine compartment (vehicles with engine code BKW)
Vehicles with engine code BKW 20-1, Connection

diagram for fuel hoses in engine compartment
(vehicles with engine code BKW)

20-1, Fuel hoses
in engine compartment, vehicles with engine code
BKW, connection diagram
Fuel tank, emptying
20-1, Fuel tank, emptying
Fuel delivery unit, fuel gauge sender and suction jet

pump, removing and installing 20-1, Fuel delivery
unit, fuel gauge sensor and suction jet pump, removing and
installing
Fuel tank with attachments, removing and installing
20-1, Fuel tank with attachments, removing and installing
Fuel filter, removing and installing (Vehicles with
engine code BKW) 20-1, Fuel filter (vehicles with
engine code BKW), removing and installing
Check fuel pumps
20-1, Fuel pumps, checking
Tandem and fuel pump, checking

pump and Fuel Pump (FP), checking
20-1, Tandem
Tandem and fuel pump, removing and installing 201, Tandem pump and Fuel Pump (FP), removing and
installing
Accelerator pedal mechanism, assembly overview
20-1, Accelerator pedal mechanism, assembly overview
Safety precautions when working on fuel supply system
Warning!
clearance issues:

path is followed.
Ensure sufficient clearance to all moving or hot

components.
The fuel or fuel lines in fuel system can become

very hot (danger of scalding)!
In addition, the fuel system is under pressure!

Before opening the system, place rags around
the connection area and release pressure by
carefully loosening the connection!
Wear protective goggles and protective gloves

when working on the fuel system!
Always observe the following when removing and installing

the sender for fuel gauge or the fuel delivery unit from full
or partially filled fuel tanks:
When removing and installing sender for fuel gauge from
full or partially full fuel tanks, the following must be
observed:
Before starting work, switch on exhaust extraction

system and place an extraction hose close to the
installation opening of fuel tank to extract escaping
fuel fumes. If no exhaust extraction system is
available, a radial fan (as long as motor is not in air
flow) with a displacement greater than 15 m 3 /h can
be used.
Prevent fuel from contacting skin! Wear fuelresistant gloves!
Rules for cleanliness
When working on the fuel supply/injection system, pay

careful attention to the following "7 rules" of cleanliness:
Thoroughly clean all connections and the

surrounding area before disconnecting.
Place parts that have been removed on a clean
Page 3 / 48
surface and cover them. Do not use fluffy cloths!
Carefully cover over opened components or seal, if

repairs are not performed immediately.
Only install clean components: Only unpack

replacement parts immediately prior to installation.
Do not use parts that have been stored loose (e.g. in
tool boxes etc.).
Supplied transport and protective packaging and

sealing caps should only be removed immediately
before installing.
When the system is open: Avoid working with

compressed air if possible. Do not move vehicle
unless absolutely necessary.
In addition, do not let diesel fuel flow onto coolant

hoses. If necessary, the hoses must be cleaned
again immediately. Replace corroded hoses.
Fuel tank with attachments, assembly overview
Page 4 / 48
Page 5 / 48

Fuel filler tube
Metering line
Only for vehicles with engine

code BLE (Not available)
Fuel tank
Connection diagram of fuel

lines and components in fuel
tank 20-1, Connection
diagram for fuel lines and
fuel tank components
Draining
emptying

20-1, Fuel tank with
attachments, removing and
installing
20-1, Fuel tank,
Flange
Left side
Note installed position on

fuel tank 20-1, Installation
position of fuel delivery unit
flange
Locking ring, 145 Nm
Use wrench T10202 for

removal and installation
Fuel delivery unit
Left side

20-1, Fuel delivery unit, fuel
gauge sensor and suction jet
pump, removing and
installing , Fuel delivery unit,
fuel gauge sender and
suction jet pump, removing
and installing
Check fuel pumps 20-1,

Fuel pumps, checking
Fuel Level Sensor 3 G237
Left side
Clipped into bottom of tank

pump, removing and
and installing

binder
Page 6 / 48
Suction jet pump
Left side
At fuel delivery unit

pump, removing and
and installing
Protective cover
For bottom of fuel tank
Securing strap
turn (90
Protective cover
For top of fuel tank
Suction jet pump
Left side
Clipped into bottom of tank

pump, removing and
and installing
Metering line
Page 7 / 48
Suction jet pump
Right side

pump, removing and
and installing
Fuel delivery unit
Right side

pump, removing and
and installing
Check fuel pumps 20-1,

Fuel Level Sensor G
Right side

pump, removing and
and installing

binder
Flange
Right side
Page 8 / 48
Note installed position on

fuel tank 20-1, Installation
position of fuel delivery unit
flange
Bracket

Installation position of fuel delivery unit flange
Insert sender flange with marking in direction of travel arrow - .

Fuel filter (vehicles with engine code BKW), assembly
overview

compartment 20-1, Connection diagram for fuel hoses
in engine compartment (vehicles with engine code BKW)
Coolant hose connection diagram 19-1, Coolant
hose connection diagram (Vehicles with engine codes
BKW)
Page 9 / 48
8 Nm
Fuel filter cover
Seal
Connections for fuel hoses

20-1, Fuel hose
connection
Replace
Fuel filter insert
Observe change intervals

Water drain connection
Page 10 / 48
To drain water, extract

approx. 100 cm 3 using
suction pump VAS 5226 .
Tighten sealing plug to 3 Nm
Return tube
To fuel tank
Blue or with blue marking
Supply tube
From fuel tank
White or with white markings
Coolant return line
Coolant supply line
8 Nm
3 Nm
Flexible Fuel (FF) Sensor G133
O-ring, replace
Fuel cooler
Fuel filter housing

20-1, Fuel filter (vehicles
with engine code BKW),
Page 11 / 48
Fuel hose connection
- Replace seal between connection and fuel filter cover.

- Tighten mounting bolts - arrows - to 8 Nm.
Fuel filter, (vehicles with engine code BWF), assembly
overview

compartment 20-1, Fuel hoses in engine compartment,
vehicles with engine code BKW, connection diagram
Coolant hose connection diagram 19-1, Coolant
hose connection diagram, vehicles with engine code
BWF
Page 12 / 48
Fuel line
Between fuel filter cover

Item - 6 - (identification on
connection - RT - ) and fuel
cooler Item - 16 -
Fuel supply line
From fuel tank to fuel filter

cover Item - 6 (identification on connection
- VF - )
Page 13 / 48
Locking bolt, 5 Nm
Seal
To drain water, extract

approx. 100 cm 3 using
suction pump VAS 5226 .
Fuel filter cover
Only possible to install in

one position
Seal
Replace
Water drain connection
Page 14 / 48
Replace
Fuel filter insert
Observe change intervals

8 Nm
Seal
Replace
Fuel filter
Item -
Bracket
Secured to bracket
12 -
For fuel filter Item - 11 and fuel cooler Item - 16 -
turn (90
Replace
Fuel return line
Fuel cooler
Coolant hose
Page 15 / 48
Secured to bracket
12 -
Item -
Fuel return line
From connection at fuel line

Item - 3 - to fuel filter
cover Item - 6 (identification on connection
- RF - )
Fuel supply line
From fuel filter cover Item

- 6 - (identification on
connection - VM - ) to
connection at fuel line
Item - 2 -
Connection diagram for fuel lines and fuel tank

components
- A - : Left half of tank

- arrow - : Direction of travel
- B - : Right half of tank
Supply line for suction jet pump
Left side
Supply line
BKW:
To fuel filter
Item - 7 -

BWF:
To fuel filter
Item - 2 -
Return line
Vehicles with engine code,
Page 16 / 48
Page 17 / 48
BKW:
From fuel filter
Item - 6 -
Flange
Right side
Supply line for auxiliary heater
Supply line for suction jet pump
Suction jet pump
Right side
Delivery line
Black
To fuel delivery unit on left

side
Delivery line
Black
To fuel delivery unit on right

side
Suction jet pump
Right side
Suction jet pump
To fuel delivery unit, right

side
Fuel delivery unit
Right side
Left side
Fuel delivery unit
Left side
Suction jet pump
To fuel delivery unit, left side

compartment (vehicles with engine code BKW)
Caution!
When installing fuel lines and hoses, ensure there is
clearance to other components or to body. Contact
can cause leaks.
Return line
To fuel tank
Page 18 / 48
Supply line
From fuel tank
Fuel rail
For cylinder bank 2
Fuel cooler
Test connection
For cylinder bank 1
Tighten sealing plug to 27

Nm
Not available on all vehicles
Fuel rail
Tandem pump
For cylinder bank 1
With vacuum pump
Tandem and fuel pump,

checking 20-1, Tandem
pump and Fuel Pump (FP),
checking

20-1, Tandem pump and
Fuel Pump (FP), removing
and installing
Fuel Temperature Sensor G81
For cylinder bank 1
For cylinder bank 1
Fuel filter
Page 19 / 48
Fuel Pump (FP)
For cylinder bank 2

checking

and installing
Fuel Temperature Sensor 2 G248

20-1, Fuel filter (vehicles
with engine code BKW),
For cylinder bank 2
Test connection
For cylinder bank 2

Nm
Fuel hoses in engine compartment, vehicles with engine

code BKW, connection diagram
Warning!
When installing fuel lines and hoses, ensure there is
clearance to other components or to body. Contact
can cause leaks.
Page 20 / 48
Test connection
For cylinder bank 2

Nm
Fuel supply line
From connection at fuel filter

cover Item - 18 -
Fuel return line
To connection at fuel filter
Page 21 / 48
cover
Fuel line
For cylinder bank 1

Nm
Fuel rail
For cylinder bank 1
Tandem pump
For cylinder bank 1
With vacuum pump

checking

and installing
Must not be disassembled
Fuel Temperature Sensor G81
For cylinder bank 2
Test connection
Secured to intake manifold

of cylinder bank 2
Fuel rail
Item - 17 -
For cylinder bank 1 and 2
Fuel Pump (FP)
Page 22 / 48
For cylinder bank 2

checking

and installing
Fuel tank, emptying
Fuel siphoning unit VAS 5190
Wrench T10202
Not illustrated:
Page 23 / 48
Work procedure
- Read safety precautions before beginning work 20-1,
Safety precautions when working on fuel supply system .
- Open fuel tank flap and remove fuel tank cap.
Note:
Secure Ground (GND) wire of fuel extraction unit

VAS 5190 to a bare area of the chassis.
- Slide extraction hose - arrow - of fuel extraction unit

VAS 5190 approx. 170 to 180 cm into fuel filler tube and
extract fuel.
Note:
When no more fuel can be extracted, the tank is

emptied only enough for the sender flange to be
opened without danger. The tank may be removed
while containing the remaining fuel. If work must be
performed on the fuel pumps or fuel tank senders,
proceed as follows:
- Fold rear seat bench forward.
Page 24 / 48
- Cut open carpet from point - A - to point - B - in pre-cut

area - arrows - .
- Remove nuts - 1 - for cover. If necessary, remove

anchor plate - 2 - .
- Disconnect harness connector for fuel pump and tank

sensor - 4 - .
- Disconnect return line - 1 - , supply line - 2 - as well as
supply line for auxiliary heater - 3 - from right sensor
flange.
Note:
Press in securing ring to disengage the fuel lines.
Page 25 / 48
- Remove locking ring from sensor flange using wrench

T10202 .
- Carefully pry out sensor flange and raise it slightly.
- Insert extraction hose of fuel extraction unit VAS 5190 as
deeply as possible into right or left side of fuel tank and
extract fuel.
- For work on left side of fuel tank, proceed as described
above.
- When disconnecting fuel lines, it is possible that the
securing rings on the hose connections cannot be pressed
in. To do this, insert assembly tool T10118 .
For additional work on components inside of fuel tank,
sensor flanges may remain removed.
If fuel tank needed only to be emptied, install sensor
flanges again.
- Check that sensor flange seals are properly seated.
Note:
If seals are swollen with fuel, always replace.
Page 26 / 48
- Insert sensor flange with marking in direction of travel arrow - .

- Tighten left and right locking rings using wrench T10202
to 145 Nm.
Note:
Do not interchange supply and return lines (return

line blue - 1 - , supply line black - 2 - ).
Ensure fuel hoses are seated securely.
Fuel delivery unit, fuel gauge sensor and suction jet

pump, removing and installing
Page 27 / 48
Page 28 / 48
Wrench T10202
Requirements
The fuel tank must be drained

emptying , emptying fuel tank
20-1, Fuel tank,
Connectors and lines for left and right sender

flanges are disconnected
Locking rings for left and right sender flanges are

removed
Removing
- Observe safety precautions before performing repair
work 20-1, Safety precautions when working on fuel
supply system .
- Disconnect harness connectors - 1 - and - 2 - , as well

as hose couplings - 3 - , - 4 - and - 5 - below right sensor
flange.
Note:
Press in securing ring to disengage the fuel lines.
- Remove sensor flange.
- Unclip black filler hose - arrow - from fuel delivery unit

housing on left and right sides of fuel tank.
- Disconnect fuel supply line from fuel delivery unit - arrow

- on left and right sides of fuel tank to suction jet pumps.
- Disconnect supply and return lines between both fuel
delivery units on left side of fuel tank.
- Unscrew Fuel Pump (FP) unit in bottom of fuel tank by
turning approx. 90 to left.
Note:
The fuel pump (FP) unit housing is filled with fuel.

Fuel may run out if the housing is tipped.
- Unclip fuel level sensors on both sides of fuel tank and

pull them out.
- Unclip suction jet pumps from bottom on each side and
remove with a slight turn.
- Pull out hose ends through left and right sender
openings.
Page 29 / 48
Installing
following:
Connections for fuel lines must engage audibly when

joined.
Route fuel hoses kink-free.
Make sure fuel hoses are seated securely.
Fuel tank with attachments, removing and installing

required
Fuel extraction unit VAS 5190
Page 30 / 48
Page 31 / 48
Polydrive key T10202

1331

V.A.G 1332
Engine/transmission jack V.A.G

1383 A
Removing
Note:
Read safety precautions before beginning work

20-1, Safety precautions when working on fuel
supply system .
The fuel tank must be drained

emptying , emptying fuel tank.
20-1, Fuel tank,

- Remove middle and rear mufflers of exhaust system
26-1, Muffler with mountings (vehicles with engine code
BKW), assembly overview .
- Remove rear muffler of exhaust system 26-1, Muffler
with mountings (vehicles with engine code BWF),
assembly overview .
- Remove rear driveshaft
Repair Manual, Rear Final Drive, Repair Group 39,

Driveshafts, removing and installing
- Remove rear subframe
Group 42, I - Assembly overview: Subframe, stabilizer bar,

stone impact protection
- Open fuel tank flap and remove fuel tank cap.
- Pull rubber gasket off filler neck.
- Remove securing bolts - 1 - on filler neck and pull off

Ground (GND) wire - 2 - .
- Remove right rear wheelhousing liner
Repair Manual, Body Exterior, Repair Group 66,

Wheelhousing liners
- Unbolt cover plate - arrow - .
Page 32 / 48
- Unclip fuel tank breather lines at securing clip attached

on longitudinal member.
- Remove mounting nut for filling pipe - arrow - in wheel

housing.
- Disconnect fuel pump connectors, on left next to fuel

tank.
- Remove securing straps with covers on left and right
below fuel tank.
- Support fuel tank using engine/transmission jack V.A.G
1383 A and remove tension strap at center of fuel tank.
- Carefully lower fuel tank about 30 cm.
Page 33 / 48
- Grab between fuel tank and vehicle floor and disconnect

fuel lines from sensor flange. When pulling off fuel supply
line, hold a cloth around fuel supply line.
Note:
This step eliminates having to cut open the carpeting

in the vehicle interior in the vicinity of sender flange
cover.
- Lower and remove fuel tank.

Installing
following:
Line connections for metering, ventilation and fuel

lines must engage audibly when joined.
Do not interchange supply and return lines (return

line blue or with blue marking - 1 - , supply line
black - 2 - ).
Clip in the metering and fuel lines at the fuel tank.
Make sure metering, ventilation and fuel hoses are

not kinked when installed.
Make sure metering and fuel lines are securely

positioned.
If necessary, fill up additive for additive tank

Page 34 / 48
Fuel filter (vehicles with engine code BKW), removing

and installing

required
Hose clamps up to 25 mm dia.

3094

1331

A
Suction pump VAS 5226
Removing
Page 35 / 48
- Disconnect supply hose - 3 - (white marking) and return

hose - 2 - (blue marking) from fuel filter.
- Connect suction pump VAS 5226 to water drain

connection - arrow - of fuel filter.
- Operate suction pump VAS 5226 until fuel no longer
flows out.
- Remove both mounting bolts - 1 - and remove

connection with fuel lines.
- Open cap on coolant expansion tank.
- Clamp off both coolant hoses - 4 - using hose clamps up
to dia. 25 mm 3094 .
Page 36 / 48
- Disconnect coolant hoses and catch escaping coolant

using a rag.
- Remove both mounting bolts - arrows - and pull fuel

filter slightly toward front.
Note:
Be careful not to lose the rubber mount bushing on

the top and bottom of the fuel filter mounting holes.
- Unclip lines at rear side of fuel filter.

- Disconnect harness connector for Flexible Fuel (FF)
Sensor G133 and remove fuel filter.
Installing
following:
- Replace seal between connection and fuel filter cover.
- Tighten sealing plug of water drain connection to 3 Nm.
- Fill with coolant
filling .
Page 37 / 48
Voltage tester V.A.G 1527 B
Hand multimeter V.A.G 1526 C or Multimeter V.A.G

1715
Not illustrated:
Requirements
The fuses must be OK
Battery voltage must be at least 11.5 Volts
All electrical consumers such as, lights and rear

window defroster must be switched off
Function and voltage supply, checking

- Fold rear seat bench forward.
- Briefly operate starter. Fuel Pumps (FP) must run
audibly.
Page 38 / 48
- Switch off ignition.

If Fuel Pumps (FP) do not start up:
- Cut floor carpet in pre-cut area - arrows - from points A - to - B - on left and right vehicle sides.
- Remove nuts - 1 - for cover. If necessary, unscrew

anchor plate - 2 - .
Check voltage supply of each individual Fuel Pump (FP) as
follows:
- Disconnect 4-pin harness connector from right flange of
fuel delivery unit.
- Connect diode test lamp V.A.G 1527 B using adapter
Page 39 / 48
cables from connector test kit V.A.G 1594 C to outer

terminals of connector.
- Switch on ignition, LED must light up for approx. 2
seconds.
If LED does not light up:
- Check activation of fuel pump relay and check wires for
open circuit and short circuit Vehicle Diagnosis, Testing
and Information System VAS 5051
LED lights up (voltage supply OK):
- Remove right Fuel Pump (FP) unit 20-1, Fuel delivery
unit, fuel gauge sensor and suction jet pump, removing and
installing .
- Check if electrical wiring between flange and fuel pump is
connected and has continuity.
If no open circuits are found:
- Right fuel pump is faulty. Replace fuel delivery unit 201, Fuel delivery unit, fuel gauge sensor and suction jet
pump, removing and installing .
- Repeat test on left fuel delivery unit.
Current pick-up of fuel pumps, checking
- Check current consumption of each fuel pump separately
as follows:
- Connect current clamp of multimeter V.A.G 1715 to the

wire of the 4-pin connector contact - 1 - - arrow - from
wiring harness to right fuel delivery unit.
- Start engine and let run at idle speed.
- Measure Fuel Pump (FP) current draw: Specification:
max. 8 amperes.
Page 40 / 48
If current draw is exceeded:

- Right fuel pump is faulty. Replace fuel delivery unit 201, Fuel delivery unit, fuel gauge sensor and suction jet
pump, removing and installing .
- Repeat test on left fuel delivery unit.
Tandem pump and Fuel Pump (FP), checking
Note:
The tandem pump delivers fuel for cylinder bank 1

and Fuel Pump (FP) delivers fuel for cylinder bank
2.
Pressure Gauge VAS 5187 with Adapter Set VAS

5187/6
Not illustrated:
Vehicle Diagnostic, Testing and Information System
Page 41 / 48
Page 42 / 48
VAS 5051 A with diagnostic cable
Adapter Set VAS5187/6
Requirements
Coolant temperature must be at least 85
C.
Pump-injector units OK
Fuel filter and fuel lines must not be blocked
Work sequence
Vehicles with test connections (engine code BKW)
- Connect pressure gauge VAS 5187 to test connection

for cylinder bank 1 - 1 - or to test connection for cylinder
bank 2 - 2 - .
Vehicles with test connections (engine code BWF)
- Connect test unit for tandem pump VAS 5187 to test

connection for cylinder bank 1 - 1 - or to test connection
for cylinder bank 2 - 2 - .
Vehicles without test connections (engine code BKW)

- Connect test unit for tandem pump VAS 5187 to supply

line for cylinder bank 1 - 1 - or to supply line for cylinder
bank 2.
Connect vehicle diagnosis, testing and information system
VAS 5051 as follows:
- Open cover - 1 - (if equipped) and connect the connector

of the diagnostic cable to the Data Link Connector (DLC).
- Start engine and run at idle speed.
- On Vehicle diagnostic, testing, and information system ,
select operating mode "Vehicle Self Diagnosis" . Then, go
into engine control module (ECM) J623 with address word
"01 - Engine electronics" .
- Press diagnostic function "08 - Read measuring value
blocks" .
Page 43 / 48
- Enter "display group 1" via number keypad and confirm

input by pressing Q button.
- Read idle RPM in "display field 1" .
- Increase engine speed to 1500 RPM.
- Observe pressure displayed on pressure gauge.
Specification: at least 7.5 bar.
- Press
key twice.
- Press function "06 - End output" .

- Replace tandem pump or Fuel Pump (FP) 20-1,
Tandem pump and Fuel Pump (FP), removing and
installing .
Note:
After removing pressure gauge for tandem pump ,

tighten supply line and sealing plug to 27 Nm.
Tandem pump and Fuel Pump (FP), removing and

installing
Caution!
The tandem pump must not be disassembled under
any circumstances because it can cause the vacuum
part to malfunction. The result would be brake booster
failure.
Page 44 / 48
Page 45 / 48
Spring-type clip pliers VAS 5024 A
Removing
Note:
Work sequence for removing and installing tandem

pump is described. Work sequence for Fuel Pump
(FP) is identical up to disconnecting the vacuum
line.

- Remove intake manifold
23-1, Intake manifold,
- Disconnect vacuum line - 1 - from brake booster of

tandem pump - 5 - .
- Disconnect central connector for Pump-Injector Units - 3
- .
- Disconnect fuel hose - 2 - at tandem pump - 5 - .
- Remove mounting bolts - arrows - .
- Remove tandem pump - 5 - from cylinder head.
- Pull tandem pump - 5 - slightly upward, unscrew fuel
hose - 4 - and remove tandem pump.
Installing
following:
Note:
Make sure that the tandem pump coupling has

proper seating in camshaft.
Tandem pump seals must always be replaced.
- Connect fuel line - 4 - with new sealing rings to tandem

pump - 5 - and tighten banjo bolt to 25 Nm.
- Install tandem pump and tighten mounting bolts - arrows
- .
Torque specification:
M6: 8 Nm
M8: 20 Nm
Page 46 / 48
- Connect fuel hose - 2 - and vacuum line - 1 - to tandem

pump.
- Connect central connector for Pump-Injector Units.
- Install bypass flap with cooler for Exhaust Gas
- Install intake manifold
and installing .
23-1, Intake manifold, removing
- Perform test drive and check DTC memory 23-2,

Diagnostic Trouble Code (DTC) memory of Engine control
modules (ECM) , checking and erasing , DTC memory of
Engine Control Module (ECM) , checking and erasing.
Note:
By disconnecting the central connection for the

pump-injector unit, DTCs will be stored. Check the
DTC memory and erase, if necessary.
Accelerator pedal mechanism, assembly overview
Page 47 / 48
Bracket
Connector
Black, 6-pin
10 Nm
Throttle position (TP) sensor

G79
Not adjustable
Remove footwell cover to

remove sensor
Page 48 / 48
Charge air system with turbocharger
Page 1 / 9
21 - 1

Observe safety precautions
precautions .
21-1, Safety
Observe installation of hose connections with

connector couplings 21-1, Hose connections with
connector couplings, installing
Turbocharger, assembly overview
21-1,
Charge air cooler, assembly overview 21-1, Charge

air cooler components, assembly overview
Safety precautions
Caution!
clearance issues:

path is followed.

components.
Observe the following if test and measuring instruments

are required during a test drive:
Test and measuring instruments must be secured to

rear seat and operated by a 2nd person from this
location.
If test and measuring instruments are operated from the

front passengers seat and the vehicle is involved in an
accident, there is a possibility that the person sitting in this
seat may receive serious injuries when the airbag is
triggered.
Warning!
Secure Scan Tool (ST) on the rear seat and operate it
from there by second technician.

When working on turbocharger, carefully observe the

following "7 rules" of cleanliness:
Thoroughly clean all connections and surrounding

area before disconnecting.



tool boxes etc.).

before installing.
During repair, clean oil from connections and hose

ends.

Hose connections with connector couplings, installing
Caution!
Connector coupling sealing ring can be damaged if
securing clamp is in locked position when installing.
This would result in a leak. Follow assembly
instructions.
Removing
Page 2 / 9
- Release connection coupling by pulling securing clip arrow - . Separate hose/tube without assistance from
tools.
Installing
- When replacing sealing ring, lay ring in charge air hose
groove. Ensure gasket is completely seated in groove all
the way around.
- Oil sealing surfaces and sealing ring.
- Bring securing clip into release position - 1 - .
- Slide charge air hose into clutch as far as stop.
- Bring securing clip into lock position - 2 - and then press

charge air hose back again.
- Check for correct seating and proper locking of connector
by pulling on hose.
Page 3 / 9
Page 4 / 9
Note:
Various hose connections are secured.
Charge air system must be properly sealed.
Replace self-locking nuts.
Before screwing on oil supply line, fill turbocharger

with engine oil at connecting tube.
After installing turbocharger, let engine run at idle for

approx. 1 minute and without increasing engine
speed. This ensures that Turbocharger is
lubricated.


precautions .
Observe rules for cleanliness
cleanliness .
21-1, Safety
21-1, Rules for
Page 5 / 9

To connecting pipe

BKW Item - 12 -

BWF Item - 11 -
Exhaust manifold
Exhaust manifold, assembly

overview 26-1, Exhaust
manifold, assembly
overview
Turbocharger Intake
Temperature Sensor , 45 Nm
Only on vehicles with engine

code BWF
Cylinder bank 1:
Turbocharger (TC) Intake

Temperature Sensor G507
Cylinder bank 2:

Temperature Sensor 2
G499
Securing clamp, 8 Nm
Turbocharger
Can only be replaced when

engine is removed from
engine compartment 10-1,
Engine, removing and
installing , Engine, removing
and installing
Tighten oil supply line to 23

Nm
To front exhaust pipe with

catalytic converter

BKW Item - 7 -

BWF Item - 11 -
40 Nm
Servo motor for turbocharger
Component of the
turbocharger cannot be
replaced
Cylinder bank 1:
Turbocharger (TC) 1 Servomotor V280
Cylinder bank 2:
Turbocharger (TC) 2 Servomotor V281
Page 6 / 9
Seal
Replace
Before installing, check

sealing surfaces for
contamination and clean if
necessary
8 Nm
Connecting pipe
To charge air tube
Item - 8 -
Sealing sleeve
Replace if damaged
Connecting pipe
From crankcase ventilation

valve
Charge air cooler components, assembly overview
Note:
Various hose connections are secured.
If necessary, use lubricant (water without additive) to

assist assembly. Do not use lubricants containing
oil.
Charge air system must be properly sealed.


Page 7 / 9
Page 8 / 9

precautions .
Air duct
8 Nm
Spacer bushing
Air charge cooler
21-1, Safety
To remove, remove bumper

cover
Repair Manual, Body Exterior, Repair

Group 63, Front bumper
O-ring
Replace if damaged
3 Nm
Charge Air Pressure Sensor G31

with Intake Air Temperature (IAT)
Sensor G42
Cylinder bank 1:
Charge Air Pressure Sensor

G31 with Intake Air
Temperature (IAT) Sensor
G42
Cylinder bank 2:
Charge Air Pressure Sensor

2 G447 with Intake Air
Temperature (IAT) Sensor 2
G299
Charge air pipe
Retaining clip
Check for secure seat
To intake manifold

BKW Item - 1 -

BWF Item - 15 -
Connecting hose
8 Nm
From connecting pipe
Item - 11 -
Page 9 / 9
Diesel-Direct Fuel Injection System, servicing
Page 1 / 28
23 - 1

Note:
Engine control modules for Diesel-Direct fuel

injection system are equipped with a DTC memory.
Before and after repairs or adjustment work, DTC
memory must be checked 23-2, Diagnostic
Trouble Code (DTC) memory of Engine control
modules (ECM) , checking and erasing ; DTC
memory of Engine Control Modules (ECM) ,
checking and erasing.
23-1, Safety

precautions .
Intake manifold, removing and installing

manifold, removing and installing
23-1, Intake
Intake connection, assembly overview 23-1, Intake

connection (vehicles with engine code BKW), assembly
overview
Vehicles with engine code BKW 23-1, Intake

connection (vehicles with engine code BKW),
assembly overview

23-1, Intake
connection (vehicles with engine code BWF),
assembly overview
Air filter, assembly overview

overview
23-1, Air filter, assembly
Pump-injector unit, assembly overview

injector unit, assembly overview
23-1, Pump-
Pump-injector unit, removing and installing

Pump-Injector Unit, removing and installing
O-rings for pump-injector unit, replacing
rings for pump-injector unit, replacing
23-1,
23-1, O-
Safety precautions
Caution!

clearance issues:

path is followed.

components.
Observe the following if test and measuring instruments

are required during a test drive:
Test and measuring instruments must be secured to

rear seat and operated by a 2nd person from this
location.
If test and measuring instruments are operated from the

front passengers seat and the vehicle is involved in an
accident, there is a possibility that the person sitting in this
seat may receive serious injuries when the airbag is
triggered.
Warning!
Secure Scan Tool (ST) on the rear seat and operate it
from there by second technician.
To reduce the risk of personal injury and/or damage to the
fuel injection and glow plug system, always observe the
following:
Only disconnect and reconnect wires for glow plug

and fuel injection systems, including test leads,
when ignition is turned off.
Obtain radio code for radios with anti-theft coding

before disconnecting battery.
The battery must only be disconnected and

connected with the ignition switched off, otherwise
the Engine Control Modules (ECM) could be
damaged.
Page 2 / 28
When working on the fuel supply/injection system, pay

careful attention to the following "7 rules" of cleanliness:




tool boxes etc.).

before installing.

In addition, do not let diesel fuel flow onto coolant

hoses. If necessary, the hoses must be cleaned
again immediately. Replace corroded hoses.
Intake manifold, removing and installing
Requirements:
Fuel filter unit removed 20-1, Fuel filter (vehicles

with engine code BKW), removing and installing
Bypass flap with cooler for Exhaust Gas

Recirculation (EGR) removed 26-2, Bypass flap
with cooler for Exhaust Gas Recirculation (EGR)
overview
Page 3 / 28
Upper part of oil filter housing removed 17-3, Oil

filter housing, assembly overview , Oil filter housing Assembly overview
Note:

In order to be able to remove intake manifold without

disassembling the fuel rail, intake manifold bolts
must be completely removed.
Cylinder head

Page 4 / 28

Cylinder heads, removing
and installing
Gasket
Replace
Intake manifold
Intake connection - Assembly
overview:

BKW 23-1, Intake
connection (vehicles with
engine code BKW),
assembly overview

BWF 23-1, Intake
connection (vehicles with
engine code BWF),
assembly overview
20 Nm
Fuel rail

(90
Seal
Replace
Replace
Connecting piece
Long
For supply
Remove and install using

pliers VAS 6275
Connecting piece
Short
Page 5 / 28
For return
Remove and install using

pliers VAS 6275
Glow plug , 15 Nm
Cylinder bank 1
Glow plugs 1 through 5 Q10

to Q14
Cylinder bank 2
Glow plugs 6 through 10

Q15 to Q19
Removing and installing,

checking:
Vehicles with engine codes

BKW and BWF 28-1,
Glow plugs vehicles with
engine code BKW, BWF)
removing and installing,
checking
Intake connection (vehicles with engine code BKW),

assembly overview
Note:
When engine is switched off, the intake connection

is closed for approx. 3 seconds and then opens
again. This reduces the stop jolt.

Page 6 / 28
Intake connection with intake

flap motor
Cylinder bank 1:
Intake Flap Motor V157
Cylinder bank 2:
8 Nm
Seal
Intake Flap Motor 2 V275
Replace
Before installing, check

necessary
Page 7 / 28
EGR Vacuum Regulator

Solenoid Valve N18
Intake manifold
Checking mechanically
26-2, Exhaust Gas
Recirculation (EGR) valve
(vehicles with engine code
BKW), checking

Gasket
Replace
20 Nm
From exhaust manifold
Item - 2 -
Connecting pipe
Bracket
For connecting pipe
Item - 9 -
Intake connection (vehicles with engine code BWF),

assembly overview
Note:
When engine is switched off, the intake connection

is closed for approx. 3 seconds and then opens
again. This reduces the stop jolt.

Page 8 / 28
Test connection bracket
Cylinder bank 1
Item - 6 -
Cylinder bank 2
Item - 1 -
8 Nm
Seal
Replace
Before installing, check the

necessary
Gasket
Replace
Page 9 / 28
To the bypass flap

Item - 16 -
Connecting pipe
20 Nm
From the bypass flap

Item - 17 -
Bracket
For connecting pipe
-
Connecting pipe
Connecting pipe
8 Nm
From exhaust manifold
Item - 10
Item - 2 -

flap motor
Cylinder bank 1:
Cylinder bank 2:

Solenoid Valve with EGR
Potentiometer
Cylinder bank 1:

Solenoid Valve N18 with
EGR Potentiometer G212
Cylinder bank 2:
Page 10 / 28

(EGR) valve 2 N213 with
(EGR) Position Sensor
G466
If the Exhaust Gas

Recirculation (EGR) valve with
EGR Potentiometer is replaced,
then do the following:
- Switch ignition on and off.
- Then wait for one minute
for the control module
after-run.
- Start engine and let run at
idle for at least 1 minute.
- Then, check the DTC
memory of the engine
control module (ECM)
23-2, Diagnostic Trouble
Code (DTC) memory of
Engine control modules
(ECM) , checking and
erasing , DTC memory of
engine control module
erasing.
If a fault is stored in DTC
memory:
- Repeat work procedure.
Intake manifold

Air filter, assembly overview
Note:
Page 11 / 28


Line connection to compressor for air suspension

23-1, Line connection to compressor for air
suspension
Page 12 / 28
Lower section of air filter
Filter element
Upper section of air filter
Securing pins

23-1, Removing and
installing securing pins
O-ring
Replace if damaged
Intake manifold
Mass air flow (MAF) sensor

Cylinder bank 1:
Page 13 / 28
Mass air flow (MAF) sensor

G70
Cylinder bank 2:
Mass Air Flow (MAF) Sensor

2 G246
6 Nm
Spring-type clip
Use pliers for spring-type

clamps VAS 5024 A to
remove and install
Transition piece
Connecting pipe
Connecting hose
To turbocharger
Removing and installing securing pins
Removing
- Using an appropriate socket, turn securing pins until
markings - A - on pins and - B - on housing align.
- Remove pins upward.
Installing
- Press pins into holes up to stop and twist them approx.
180 using an appropriate socket.
Page 14 / 28
Line connection to compressor for air suspension
- Using a screwdriver - C - , pry off green sealing ring - 1

- from line flange - 3 - .
- Press securing sleeve - 2 - in direction of - arrow - and
disconnect line - B - from air filter connection - A - .
Pump-injector unit, assembly overview
Note:
Always replace seals and O-rings.
Page 15 / 28
turn (90
Replace
Lock nut, 30 Nm
Adjustment screw
Replace with each

separation from ball pin
Rocker arm axle
With rocker arm

Page 16 / 28
Pump-Injector Unit
Tension block
turn (270

Replace ball pins when

separating from adjusting
screw
O-ring
Replace 23-1, O-rings for
pump-injector unit,
replacing
Heat protection seal
Replace
Pump-Injector Unit
Replace
Circlip
Pump-Injector Unit, removing and installing
Page 17 / 28

required
Multi-point socket 3410
Puller T10055

1331
Not illustrated:
Gauge T10210
Page 18 / 28
Dial gauge
Removing

- Rotate crankshaft until cam pair of respective PumpInjector Unit to be installed and removed face upward
simultaneously.
- Loosen lock nuts of adjustment bolts - 1 - and unscrew

adjustment bolts as far until respective rocker arm makes
contact at plunger spring of Pump-Injector Unit.
- Loosen bolts - 2 - for rocker lever shaft from the outside
toward the inside, using the socket insert 3410 and
remove the rocker lever shaft.
- Loosen mounting bolt - 3 - for tension block using socket
insert T10054 and remove tension block.
- Pry out connector from Pump-Injector Unit using a
screwdriver. In order to avoid canting, support opposite
side of connector with light finger pressure.
Page 19 / 28
- Insert puller T10055 in place of tension block into side

slit of pump-injector unit.
- Using careful knocking motions, pull Pump-Injector Unit
upward out of its cylinder head seat.
Installing
Note:
Install a new pump-injector unit, and also replace the

corresponding adjustment bolt in rocker arm.
For every procedure that requires adjustment of the

pump-injector unit, the adjustment screw in the
rocker lever and the ball pin of the pump-injector unit
must be replaced.
New Pump-Injector Units are shipped with O-rings

and heat protection seal.
- Install pump-injector unit again, replace O-rings and heat

protection seal 23-1, O-rings for pump-injector unit,
replacing .
- Before installing Pump-Injector Unit, check that the three
sealing rings, heat protection seal and securing ring are
seated properly.
Note:
Sealing rings must not be twisted on themselves.
Page 20 / 28
- Oil sealing rings and insert Pump-Injector Unit with great

care into cylinder head seat.
- Drive Pump-Injector Unit in using uniform pressure into
cylinder head seat until stop.
- Insert tension block into lateral slot of Pump-Injector Unit.
Note:
If Pump-Injector Unit does not stand at right angle to

tension block, securing bolt can loosen and thereby
cause damage to Pump-Injector Unit / cylinder head.
Align pump-injector unit as follows:

- Screw new bolt into tension block so far that the pumpinjector unit can still be lightly turned.
- Insert gauge T10210 between thrust bearing and PumpInjector Unit as shown.
- Turn pump-injector unit against gauge by hand.
- Re-align pump-injector unit if necessary and tighten
securing bolt as follows: 12 Nm plus an additional 3 / 4 turn
(270 ) further (additional rotation can occur in several
stages).
- Install rocker arm axle and tighten new mounting bolts as
follows.
- Tighten first inner and then both outer bolts by hand.
Then, in the same sequence to 20 Nm plus an additional
1 / turn (90
) further.
4
Page 21 / 28
- Place a dial gauge as shown onto adjustment screw of

pump-injector unit.
- Rotate crankshaft in direction of engine rotation until
rocker arm roller stands at camshaft point.
Roller side - arrow A - is positioned at highest

point
Dial gauge - arrow B - is positioned at lowest point
- Remove dial gauge .

- Thread adjusting screw into rocker arm against spring
force of pump-injector unit until significant resistance is
detected (pump-injector unit is positioned at stop).
- Turn back adjustment bolt from stop approx. 180

- Hold adjustment bolt in this position and tighten lock nut
to 30 Nm.
- Connect connector of the pump-injector unit and install
cylinder head cover and acoustic cover.
Position of pump pistons in pump injector units,
checking and adjusting
Page 22 / 28

required
Socket XZN16 T10198
Crankshaft anchor T10195
Dial Gauge Set, 4-part VAS 6341
Requirement:
Page 23 / 28
Engine removed
Work procedure
- Remove fuel or tandem pump from respective cylinder
head 20-1, Tandem pump and Fuel Pump (FP),
- Rotate engine with Counterhold Tool Touareg V10
T10172 to TDC 15-1, Valve timing, checking and
remove vibration damper
13-4, Front sealing flange and
vibration damper, assembly overview .
- Install Camshaft Tool T10195 .
- Position dial gauge from Dial Gauge Set, 4-part VAS

6341 using Dial Gauge Holder VW 387 and approx. 1 mm
pre-tension as shown on pump injector unit spring seat.
- Remove Camshaft Tool T10195 pin and rotate engine
opposite engine rotation direction until dial gauge needle
no longer moves.
- Set dial gauge to "0" .

- Now turn motor again in direction of rotation to TDC and
Page 24 / 28
Page 25 / 28
insert camshaft tool securing pin.

- Read out value on dial gauge.
Specified values
Engine code BKW: 5.18 mm
0.1 mm
Engine code BWF: 4.95 mm
0.1 mm
If specified value is not achieved:

- Complete engine.
- Remove outer bearing cap - A - , place clamping device
T10199 on camshaft gear and tighten its bolt to 40 Nm.
- Loosen camshaft gear bolt - B - using Socket XZN16

T10198 .
- Rotate camshaft with Socket T10336 until specified
value is reached.
- Tighten camshaft to 150 Nm and repeat measurement.
- If specified value is now reached, tighten camshaft gear
threaded connection an additional 90 .
- Reinstall cylinder head cover
15-1, Tightening
sequence of bolts for cylinder head cover as well as
acoustic cover.
O-rings for pump-injector unit, replacing
Assembly sleeve T10056
Removing
- Remove pump-injector unit
- Pry off old O-rings from Pump-Injector Unit extremely

carefully.
- Above all, make sure that no burrs develop at O-ring
seat.
Installing
Note:
Always use assembly sleeves T10056 for installing

O-rings. Not using them may cause the O-rings to be
damaged during installation.
O-rings without distinguishing color markings are

gradually introduced. Ensure the correct allocation of
O-rings to grooves: ring strength decreases in
direction toward injector.
Avoid rolling movements when sliding on O-rings. Orings must not be twisted on itself in the seat of
Pump-Injector Unit.
- Pull off heat protection seal together with securing ring.

- Clean seating surfaces for O-rings on Pump-Injector Unit
very carefully.
Page 26 / 28
Page 27 / 28

- Insert assembly sleeve T10056/1 up to stop on PumpInjector Unit.

- Slide upper, thicker O-ring carefully on assembly sleeve
and into seat of Pump-Injector Unit.
- Remove assembly sleeve.
- Insert assembly sleeve T10056/2 up to stop on PumpInjector Unit.

- Slide center, thinner O-ring carefully onto assembly
sleeve and into seat of pump-injector unit.
- Insert assembly sleeve T10056/3 up to stop on Pump-
Injector Unit.
- Slide lower O-ring carefully on assembly sleeve and into
seat of Pump-Injector Unit.
- Slide on a new heat protection seal together with
securing ring.
- Install pump-injector unit
Page 28 / 28
Engine Control Modules (ECM)
Page 1 / 5
23 - 2

Note:
Engine control modules for Diesel-Direct fuel

injection system are equipped with a DTC memory.
Before and after repairs or adjustment work, DTC
memory must be checked 23-2, Diagnostic
Trouble Code (DTC) memory of Engine control
modules (ECM) , checking and erasing ; DTC
memory of Engine Control Modules (ECM) ,
checking and erasing.

precautions .
23-1, Safety
DTC memory of Engine control modules (ECM) ,

checking and erasing 23-2, Diagnostic Trouble Code
(DTC) memory of Engine control modules (ECM) ,
checking and erasing
Adapting functions and components
and adapting components
23-2, Functions
Engine Control Modules (ECM) , removing and

installing 23-2, Engine Control Modules (ECM) ,
Diagnostic Trouble Code (DTC) memory of Engine
control modules (ECM) , checking and erasing

Work procedure

VAS 5051 A as follows:
- Open cover - 1 - (if equipped) and connect connector of

diagnostic cable to the Data Link Connector (DLC).
- Start engine and run at idle speed.
Only when engine does not start:
- Switch ignition on.
Selecting operating mode:
- Press button on display for "Vehicle Self-Diagnosis" .
Selecting vehicle system:
- Press "01 - Engine electronics" on display to check
Engine Control Module (ECM) J623 for cylinder bank 1, or
"11 - Engine electronics 2" on display to check Engine
Control Module (ECM) 2 J624 for cylinder bank 2.
The control module identification with code - 2 - of engine

control module , as well as chassis number and
immobilizer identification number will be indicated on the
display.
Note:
Page 2 / 5
A print-out is available. Press Print button if

required.
Selecting diagnosis function:

- Press button "02 - Check DTC memory" on display.
- If no DTC is stored in engine control module "0
malfunction(s) detected" is displayed.
- If DTCs are stored in engine control module , these are
shown one below the other on the display.
- Press
key.
- Press button "05 - Erase DTC memory" on display.

- Press function "06 - End output" .
Functions and adapting components

Work procedure
VAS 5051 A as follows:
Page 3 / 5
- Open cover - 1 - (if equipped) and connect connector of

diagnostic cable to the Data Link Connector (DLC).
On Vehicle diagnostic, testing, and information system
VAS 5051 A , select "Guided Fault Finding" .
After all control modules have been checked:
- Press "Go to" button.
- Select "Function/component selection" .
- Select "powertrain" .
- Select "engine code" .
- Select "01-Systems capable of self-diagnosis" .
- Select "engine management system" .
- Select "Functions" .
- Select "Function or component" .
Engine Control Modules (ECM) , removing and installing
Caution!
This vehicle is equipped with two Engine Control
Modules (ECM) which cannot be visually distinguished
from each other. If engine control modules are
installed interchanged, the DTC memories are not
detected. Therefore it is recommended to mark the
engine control modules , as well as their
corresponding harness connectors, before removing
in order to prevent interchanging the engine control
modules .
- Before removing Engine Control Modules (ECM) , the
control module identification and with it also the coding of
the previous control module must be checked 23-2,
Diagnostic Trouble Code (DTC) memory of Engine control
Page 4 / 5
modules (ECM) , checking and erasing ; DTC memory of

Engine Control Module (ECM), checking and erasing.
Work procedure
- Switch off ignition.
- Remove right plenum chamber cover - D - .
- Release and disconnect connector of engine control

module - 1 - and/or - 2 - .
- Remove old control module and install new control
module.
- Verify old coding and code new control module 23-2,
Functions and adapting components ; Adapting functions
and components.
- Check DTC memory of new Engine Control Module
(ECM) and erase if necessary 23-2, Functions and
adapting components ; DTC memory of Engine Control
Module (ECM) , checking and erasing.
- Perform test drive.
- Again, check engine control module DTC memory.
Page 5 / 5
Exhaust system components, removing and installing
Page 1 / 18
26 - 1
Exhaust system components, removing and

installing
Ring spanner 7-piece set 3337
Caution!
clearance issues:

path is followed.

components.
Note:
After exhaust system repairs, make sure exhaust

system is not under stress and that it has sufficient
clearance from the body. If necessary, loosen
double clamps and clamp and align exhaust pipe so
that sufficient clearance is maintained to the body
and support rings carry uniform loads.
Always replace self-locking nuts.
Do not use sealants containing silicone. Particles of

silicone drawn into the engine, will not be burned in
the engine and damage the oxygen sensor .

Exhaust manifold, assembly overview
manifold, assembly overview
26-1, Exhaust
Front exhaust pipe with catalytic converter and

attachments, assembly overview 26-1, Front exhaust
pipe with catalytic converter and attachments (vehicles with
engine code BKW), assembly overview
Muffler with mountings, assembly overview:
Vehicles with engine code BKW 26-1, Muffler with

mountings (vehicles with engine code BKW),
assembly overview

26-1, Muffler with
mountings (vehicles with engine code BWF),
assembly overview
Exhaust manifold, assembly overview
Note:

Page 2 / 18
Cylinder head
Exhaust manifold

and installing

Temperature Sensor , 45 Nm
Only on vehicles with engine

code BWF
Cylinder bank 1:

Page 3 / 18
Cylinder bank 2:

G499
To turbocharger
Item - 5 -
Spacer piece
23 Nm
Replace
Observe tightening
sequence 26-1,
Tightening sequence of nuts
for exhaust manifold
4.5 Nm
Heat shield
To connecting pipe

BKW Item - 12 -

BWF Item - 11 -
Gasket
Replace
Page 4 / 18
Tightening sequence of nuts for exhaust manifold
- Tighten nuts in the tightening sequence shown as

follows:
Pre-tighten all nuts to 5 Nm
Then tighten all nuts to 23 Nm
Front exhaust pipe with catalytic converter and

attachments (vehicles with engine code BKW), assembly
overview
Note:

Page 5 / 18
Turbocharger
Turbocharger, Assembly
overview 21-1,
Turbocharger, assembly
overview
Gasket
Replace
25 Nm
25 Nm
Connector
For Heated oxygen sensor

(HO2S) and Oxygen sensor
(O2S) heater
Page 6 / 18
Cylinder bank 1:
Connector (black)
Cylinder bank 2:
Connector (brown)
Heated Oxygen Sensor (HO2S) ,

50 Nm
Can only be replaced with

the engine removed 10-1,
installing
Grease only threads with

High-temperature lubricant G
052 112 A3 (anti-seize
compound). Hightemperature lubricant G 052
112 A3 must not get into
slots on sensor body.
To remove, use ring wrench

for oxygen sensor 3337
Cylinder bank 1:
Oxygen sensor G39
Cylinder bank 2:
Heated Oxygen Sensor

(HO2S) 2 G108
Front exhaust pipe with catalytic

converter

installing
Catalytic converter
Suspended mount
Bracket
Front exhaust pipe with catalytic converter, particle filter

and attachments, vehicles with engine code BLE and
Page 7 / 18
BWF, Assembly overview
Note:

Turbocharger
Gasket
Turbocharger - Assembly
overview 21-1,
Turbocharger, assembly
overview
Replace
25 Nm
Page 8 / 18
Heated Oxygen Sensor (HO2S) ,

50 Nm

installing
Grease only threads with hot

bolt paste G 052 112 A3
(anti-seize compound). Hot
bolt paste G 052 112 A3
must not get into slots on
sensor body.
To remove, use ring wrench

for oxygen sensor 3337
Cylinder bank 1:
Oxygen sensor G39
Cylinder bank 2:
Heated Oxygen Sensor

(HO2S) 2 G108
Pre-Particle Filter Temperature

Sensor , 45 Nm
Cylinder bank 1:
Pre-Particle Filter
Cylinder bank 2:
Particle Filter Intake

G498
Pressure line
Cylinder bank 1:
To exhaust pressure sensor

1 G450
Cylinder bank 2:
To exhaust pressure sensor

2 G451
Page 9 / 18
To rear muffler
Item - 9 -
Transmission crossmember
Suspended mount
Particle filter
after replacing, the

adaptation of the soot load
measurement must be set to
"0" Vehicle Diagnosis,
Testing and Information
System VAS 5051
Front exhaust pipe with catalytic

converter

and installing
with engine code BWF with

metering pump connecting
pieces at catalytic converter
26-1, Post-injection
metering pump, engine code
BWF
Bracket
Post-injection metering pump, engine code BWF
Metering pumps are secured on subframe and inject diesel

fuel behind catalytic converters. The goal is to increase the
exhaust temperature in order to burn the particle filter.
- 1 - : Bank 2 Particle Filter Post-Injection Metering
Pump V337
Page 10 / 18
Page 11 / 18
- 2 - : Bank 1 Particle Filter Post-Injection Metering

Pump V336
Metering pumps, securing
- A - : Bolts, tightening torque 9 Nm
- B - : To cylinder bank 2 catalytic converter

Metering pumps, connecting line
- C - : From fuel tank
- D - : To cylinder bank 1 catalytic converter

Metering Pumps for Post-injection in Particle Filter
26-1,
26-1,
The metering pump fuel line is secured directly behind the

catalytic converter in order to utilize its exhaust
temperature.
Muffler with mountings (vehicles with engine code BKW),
assembly overview
Double clamp
Page 12 / 18
Threads M8:
Fasten evenly to 25 Nm
Threads M10:
Center muffler
Suspended mount
25 Nm
Rear muffler
As standard, center and rear

mufflers are installed as a
single component. In cases
of repair, the center and rear
muffler are supplied
individually and with a
double clamp for connecting.
Cut through connecting pipe

with body repair saw V.A.G
1523A at right angles at
separating point 26-1,
Separating points between
center muffler and rear
muffler
End pipe
Align in bumper cutout
Clamp
Fasten to 60 Nm
Dimension - a - = approx. 10 mm
Exhaust system must be

cold
Arrow points in direction of

travel
Repair double clamp
Page 13 / 18
Double clamp viewed in

direction of travel
Repair double clamp

direction of travel

cold

travel
Double clamp
Bolt heads must point toward

transmission
Suspended mount
Separating points between center muffler and rear muffler
Body repair saw V.A.G 1523A
Page 14 / 18
Work procedure
- Separate connecting pipes at a right angle between
center muffler and rear muffler at the locations marked with
a groove:
Dimension - a - approx. 510 mm
Dimension - b - approx. 535 mm
Muffler with mountings (vehicles with engine code BWF),

assembly overview
Suspended mount
Right, in driving direction
Particle filter
Page 15 / 18
Item - 10
Double clamp
Threads M8:
Threads M10:
Particle filter
Left, in driving direction

Item - 10 -
Double clamp
Threads M8:
Threads M10:
25 Nm
Suspended mount
Repair double clamp
Threads M8:
Threads M10:
Rear muffler
Suspended mount
Page 16 / 18
End pipe

cold

travel
Clamp
Fasten to 60 Nm

cold

travel
End pipe
Repair double clamp

direction of travel
Repair double clamp

direction of travel
Page 17 / 18
Double clamp
Bolt heads must point toward

transmission
Suspended mount
Repair double clamp
Threads M8:
Threads M10:
Separating point
For repairs
Marked by two grooves

around circumference of
respective exhaust pipe
At factory, exhaust pipe and

rear mufflers are installed as
a single component.
Replacement exhaust pipe
and rear muffler are supplied
separately, with replacement
double clamp for connecting
joint
Cut through exhaust pipes

with body repair saw V.A.G
1523A at right angles at
separating point
Page 18 / 18
Exhaust Gas Recirculation (EGR) system
Page 1 / 18
26 - 2

precautions .
26-2, Safety
Exhaust Gas Recirculation (EGR), assembly overview:
Vehicles with engine code BKW 26-2, Exhaust

Gas Recirculation (EGR) (vehicles with engine code
BKW), assembly overview

26-2, Exhaust
Gas Recirculation (EGR) (vehicles with engine code
BWF), assembly overview
Bypass flap with cooler for Exhaust Gas Recirculation

(EGR) - Assembly overview (Vehicles with engine code
BWF) 26-2, Bypass flap with cooler for Exhaust Gas
Recirculation (EGR) (vehicles with engine code BWF),
assembly overview
Connection diagram for vacuum hoses:
Vehicles with engine code BKW 26-2, Vacuum

hose connection diagram (vehicles with engine code
BKW)

26-2, Vacuum
hose connection diagram (vehicles with engine
codes BWF)
Exhaust Gas Recirculation (EGR) valve (vehicles with

engine code BKW) , checking 26-2, Exhaust Gas
Recirculation (EGR) valve (vehicles with engine code
BKW), checking
Safety precautions
Caution!
clearance issues:

path is followed.

components.
When working on the exhaust gas recirculation (EGR)

system, pay careful attention to the following "7 rules" of
cleanliness:




tool boxes etc.).

before installing.
During repair, clean oil from connections and hose

ends.


code BKW), assembly overview
Note:
Exhaust gas recirculation is controlled by Engine

Control Module (ECM) J623 and Engine Control
Page 2 / 18
Page 3 / 18

Module (ECM) 2 J624 via EGR Vacuum Regulator

Solenoid Valve N18 (electro-pneumatic) and EGR
Valve 2 N213 (electro-pneumatic) to the mechanical
exhaust gas recirculation valves.
The mechanical EGR valve with cone-shaped valve

plunger makes different opening diameters possible
at different valve lift.


flap motor
Cylinder bank 1:
Cylinder bank 2:
8 Nm
Seal
Replace

necessary

Solenoid Valve
Checking mechanically
26-2, Exhaust Gas
Recirculation (EGR) valve
(vehicles with engine code
BKW), checking
Intake manifold

20 Nm
Gasket
Replace
8 Nm
Exhaust manifold

manifold, assembly
overview
8 Nm
20 Nm
Page 4 / 18
Connecting pipe

code BWF), assembly overview
Note:
Activation of the Exhaust Gas Recirculation (EGR)

system occurs from Engine Control Module (ECM)
J623 and Engine Control Module 2 J624 via the
EGR Potentiometer G212 and the EGR Position
Sensor G466 .


Recirculation (EGR), assembly overview 26-2,
Recirculation (EGR) (vehicles with engine code
BWF), assembly overview .
Page 5 / 18
Test connection bracket
Cylinder bank 1:
Item - 6 -
Cylinder bank 2:
Item - 1 -
8 Nm
Seal
Replace

necessary
Gasket
Replace
Page 6 / 18
To the bypass flap

Item - 16 -
Connecting pipe
20 Nm
From the bypass flap

Item - 17 -
Bracket
For connecting pipe
-
Connecting pipe
Connecting pipe
8 Nm
To turbocharger
Item - 5 -
Exhaust manifold
Item - 10

manifold, assembly
overview

flap motor
Cylinder bank 1:
Cylinder bank 2:

Solenoid Valve with EGR
Potentiometer
Page 7 / 18
Cylinder bank 1:

Solenoid Valve N18 (electropneumatic) with EGR
Potentiometer G212
Cylinder bank 2:
EGR Valve 2 N213 (electropneumatic) with Exhaust

Gas Recirculation (EGR)
Position Sensor G466
If EGR Vacuum Regulator

Solenoid Valve is replaced with
EGR Potentiometer , you must
then:
- Switch ignition on and off.
- Then wait for one minute
for the control module
after-run.
- Start engine and let run at
idle for at least 1 minute.
- Then, check the DTC
memory of the engine
control module (ECM)
23-2, Diagnostic Trouble
Code (DTC) memory of
Engine control modules
erasing , DTC memory of
engine control module
erasing.
If a DTC is stored in DTC
memory:
- Repeat work procedure.
Intake manifold

Page 8 / 18
Bypass flap with cooler for Exhaust Gas Recirculation

(EGR) (vehicles with engine code BWF), assembly
overview
Note:
Hose connections are secured with either springtype or clamp-type clips.
Always replace clamps.

Exhaust Gas Recirculation (EGR), assembly

overview 26-2, Exhaust Gas Recirculation (EGR)
overview .
Page 9 / 18
8 Nm
Vacuum tube
Vacuum line
For cylinder bank 2
To Exhaust Gas
Recirculation (EGR) Cooler
Switch-Over Valve 2 N381
Connection diagram for

vacuum hoses 26-2,
Vacuum hose connection
diagram (vehicles with
engine codes BWF)
Vacuum hose
Page 10 / 18
For cylinder bank 1
To Exhaust Gas
Recirculation (EGR) Cooler
Switch-Over Valve N345
Connection diagram for

vacuum hoses 26-2,
Vacuum hose connection
diagram (vehicles with
engine codes BWF)
Coolant hose
Between cooler for Exhaust

Gas Recirculation (EGR)
and bypass flap
40 Nm
Coolant hose

remove and install
5 Nm
Coolant line
Bracket
For coolant pipe
20 Nm
Coolant hose
Item - 9 -

remove and install
To heat exchanger for heater

unit
Page 11 / 18
Vacuum actuator
For cylinder bank 1
Check operation with hand

vacuum pump V.A.G 1390
at vacuum connection
Connecting pipe
For cylinder bank 1
from EGR Vacuum

Regulator Solenoid Valve
N18 (electro-pneumatic) with
EGR Potentiometer G212
Item - 16 -
Connecting pipe
For cylinder bank 1
To connecting pipe of
exhaust manifold Item 11 -
Connecting pipe
For cylinder bank 2
From EGR Valve 2 N213

(electro-pneumatic) with
(EGR) Position Sensor
G466
Item - 16 -
Connecting pipe
For cylinder bank 2
To connecting pipe of
exhaust manifold Item 11 -
Gasket
Replace
Page 12 / 18
Bracket
For bypass-flap
-
Fastened to cylinder block
Bypass-flap
Remove and install together

with cooler for exhaust gas
recirculation ( Item - 25 )
Vacuum actuator
For cylinder bank 2
Check operation with hand

vacuum pump V.A.G 1390
at vacuum connection
Ball pin, 3 Nm
Fastened to flange of
generator
Rubber bushing
Bracket
For cooler for Exhaust Gas

Recirculation (EGR) Item
- 25 -
Cooler for Exhaust Gas

Recirculation (EGR)
Item - 20
Remove and install together

with bypass flap ( Item 20 - )
Coolant hose

remove and install
Page 13 / 18
From coolant pipe
Vacuum hose connection diagram (vehicles with engine

code BKW)

Solenoid Valve N18 (electropneumatic)

Solenoid Valve (mechanical)
For cylinder bank 1
For cylinder bank 1

Solenoid Valve (mechanical)
Page 14 / 18
For cylinder bank 2
EGR Valve 2 N213
For cylinder bank 2
Filter
Vacuum line
Between tandem pump and

brake booster
Tandem pump
Component location:
Cylinder bank 1
For fuel and vacuum supply
Vacuum hose connection diagram (vehicles with engine

codes BWF)
Page 15 / 18
Vacuum actuator
For cylinder bank 1
Vacuum actuator
For cylinder bank 2
Vacuum tube

(EGR) Cooler Switch-Over Valve
N345
For cylinder bank 1
Component location: at right

rear wheelhousing
Page 16 / 18
(EGR) Cooler Switch-Over Valve

2 N381
For cylinder bank 2
Component location: at right

front wheelhousing
Tandem pump
Component location:
Cylinder bank 1
For fuel and vacuum supply
From brake booster
Exhaust Gas Recirculation (EGR) valve (vehicles with

engine code BKW), checking
Hand vacuum pump V.A.G 1390
Work sequence
- Remove connecting hose charge air pipe/intake
manifold.
Note:

- Disconnect vacuum hose at EGR vacuum regulator

solenoid valve.
Page 17 / 18
- Connect hand vacuum pump with additional equipment

V.A.G 1390 to valve.
- Operate hand vacuum pump and observe diaphragm rod.

Diaphragm rod must move in direction of - arrow - .
- Disconnect hose of hand vacuum pump from EGR valve.
Diaphragm rod must move back in opposite direction of arrow - into output position.
Page 18 / 18
Glow plugs
Page 1 / 4
28 - 1
Glow plugs
Glow plugs , removing and installing, checking:
Vehicles with engine codes BKW and BWF 28-1,


Visual characteristics of ceramic sheathed element glow plugs
Caution!
Ceramic sheathed element glow plugs are susceptible
to shock and bending. For this reason, do not use
sheathed element glow plugs which have dropped
(even from a height of approx. 2 cm) under any
circumstances, even if no visible damage can be
detected. Installation instructions must be performed
in sequence, otherwise there is a danger the plug
breaks and will cause damage to engine.
Visual characteristics of ceramic sheathed element glow

plugs
A - Ceramic sheathed element glow plugs, phased

stepping on tip (see magnified area), white color coding
arrow
B - Metal glow plugs, green color coding arrow
Ceramic sheathed element glow plugs, removing, installing
and checking 28-1, Ceramic sheathed element glow
plugs, removing, installing and checking .
Glow plugs
Ceramic sheathed element glow plugs, removing,

installing and checking

required
Flex wrench 3220

1331
Portable multimeter V.A.G 1526
A
Not illustrated:
Page 2 / 4
Glow plugs
Page 3 / 4
Pliers 6275
Requirements
Engine is cold
Ignition is switched off
Work procedure
Note:
Observe visual characteristics of ceramic sheathed

element glow plugs 28-1, Visual characteristics of
ceramic sheathed element glow plugs .
When removing and installing, do not cant ceramic

sheathed element glow plugs. Remove components
which hinder installation.
- Remove intake manifolds 23-1, Intake manifold,

removing and installing , Intake manifold, removing and
installing.
- Disconnect connectors from ceramic sheathed element
glow plugs using pliers 6275 .
- Remove ceramic sheathed element glow plugs using flex
wrench 3220 .
following:
- Clean deposits from cylinder head bore and threads
completely before installing.
Note:
Never oil or grease thread of bore in cylinder head

and ceramic sheathed element glow plugs.
- Screw ceramic sheathed element glow plugs into cylinder

head by hand using flex wrench 3220 .
- Tighten ceramic sheathed element glow plugs. Torque
specification: 15 Nm
Caution!
After installing and before first engine start with a cold
Glow plugs
Page 4 / 4
engine, always perform a resistance test at all ceramic

sheathed element glow plugs.
Specification: max. 1.0
- If specified value is exceeded, replace malfunctioning

ceramic sheathed element glow plug.
Note:
If the malfunctioning ceramic sheathed element glow

plug is broken, remove all broken pieces from
engine, otherwise they can cause damage to
engine.
Electrical components of transmission control, removing and installing, checking
Page 1 / 27
38-1
Electrical components of
transmission control,
removing and installing,
checking
Safety precautions
WARNING!
Observe the following for all installations,
especially in engine compartment due to lack
of room:
Route lines of all types (e.g. for fuel,
hydraulic, EVAP canister system, coolant
and refrigerant, brake fluid, vacuum) and
electrical wiring so that the original path is
followed.
Watch for sufficient clearance to all moving
or hot components.
Shift selector lever into position -P- and
engage parking brake before working with
the engine running.
If special testing equipment is required during
road test, note the following:
Test equipment must always be secured to the
rear seat and operated from there by a second
person.
Page 2 / 27
38-2
If test and measuring equipment is operated

from the passenger seat, the person seated
there could be injured in the event of an accident
involving deployment of the passenger-side
airbag.
Notes:
For the electric components to work properly, a
voltage of at least 11.5 V is required.
Transmission Control Module (TCM) is
equipped with On Board Diagnostic (OBD).
It is possible that the control module will
recognize a malfunction and store a DTC during
some tests. Therefore the following work steps
must be performed in the mentioned sequence
after ending all tests and repairs.
- - Check DTC memory Page ST-23 ,
Diagnostic mode 3: Check DTC Memory,
- - Erase DTC memory
Page ST-28 ,
Diagnostic mode 4: Reset/erase diagnostic
data
- - For completion, generate readiness code
Page ST-50 .
Page 3 / 27
38-3
Multi-Function Transmission
Range (TR) Switch, removing
and installing, adjusting
Recommended special tools and
equipment
V.A.G 1331 torque wrench (5 to 50
Nm)
T10173 adjustment tool
Page 4 / 27
38-4
Note:
For the sake of illustration, work procedure
shown with transmission removed.
Removing
- Place selector lever in position "P".
- Remove noise insulation panel below
transmission.
- Remove cap nut -4-.
- Remove cover -3- from shift rod.
- Carefully bend hooks of locking washer using a screwdriver.
Note:
If a hook breaks off, replace locking washer
- Now remove nut -2- and locking washer shift rod.
- Disconnect harness connector from Multi
Function Transmission Range (TR) Switc
F125- (arrow -A-).
- Unscrew mounting bolts (arrows -B-) and
remove Multi-Function Transmission Ran
Switch -F125- (arrow -A-) from shift rod.
Page 5 / 27
38-5
Installing and adjusting

- Shift the lever/switch rod at the transmiss
N- position.
- Connect Multi-Function Transmission Ra
(TR) Switch -F125- (arrow -A-) on shift ro
- Hand-tighten mounting bolts (arrows -B-)
Multi-Function Transmission Range (TR)
- Place adjustment tool (T10173) on shift ro

- Disengage selector lever cable.
- Rotate Multi-Function Transmission Rang
Switch until tab on connector -arrow 1- en
in groove of adjustment tool.
Page 6 / 27
38-6
- Tighten mounting bolts -arrows Bof Multi-Function Transmission

Range (TR) Switch.
Tightening torque: 6 Nm
- Remove adjustment tool (T10173)
from shift rod.
- Hook in selector lever cable.
Rest of installation is performed in
the reverse order of removal.
- Check adjustment of selector
lever cable:
Repair Manual, 6 Spd. Automatic
Transmission 09D All Wheel Drive,
Repair Group 37; servicing shift
mechanism
Page 7 / 27
38-7
Multi-Function Transmission Range (TR)

Switch, checking
Recommended special tools and equipment
V.A.G 1526 multimeter or V.A.G 1715
multimeter
V.A.G 1594 connector test kit
Wiring diagram
Test requirements
Respective fuses in fuse box (instrument
panel, right) must be OK:
Electrical Wiring Diagrams and Component
Locations
Control Module with indicator unit in
instrument panel insert -J285- must be OK.
Battery voltage must be at least 11.5 volts.
All electrical consumers such as, for
example, lights and rear window defroster
must be switched off.
Parking brake must be engaged or else
daylight driving lights will be switched on.
Selector lever must be in -P- position.
Ground (GND) connections to transmission
must be OK.
Page 8 / 27
38-8
Function test
- Switch ignition on.
- Depress brake pedal and maintain depressed.
- Shift into all selector lever positions.
Selector lever position must correspond to
display of Control Module with indicator unit
in instrument panel insert -J285-.
- Switch ignition off.
If selector lever position does not correspond to
display of Control Module with indicator unit in
instrument panel insert -J285- Check wires according to wiring diagram
Page 38-9 .
Page 9 / 27
38-9
Checking wiring
- Connect test box to control module wiring
harness Page ST-10 , connect test box
wiring test.
- Disconnect 10-pin harness connector -ar
to Multi-Function Transmission Range (T
Switch -F125-.
Page 10 / 27
38-10
- Check wires between test box

and 10-pin connector to
Transmission Control Module
(TCM) for open circuit according
to wiring diagram.
Terminal 1+socket 47
Terminal 3 + socket 1
Wire resistance: max. 1.5
- Also check wires for short circuit
to each other.
Specified value:
If no malfunctions are found in
wires:
- Check adjustment of MultiFunction Transmission Range
(TR) Switch -F125- Page 38-3 ,
Multi-Function Transmission
Range (TR) Switch, removing and
installing, adjusting.
- Check adjustment of selector
lever cable:
Repair Group 37; servicing shift
mechanism
Page 11 / 27
38-11
- Erase DTC memory of Transmission Control

Module (TCM) Page ST-28 , Diagnostic mode
4: Reset/erase diagnostic data.
- Generate readiness code
Page ST-50 .
If no malfunctions are detected in wires and

adjustments of selector lever cable and MultiFunction Transmission Range (TR) Switch are
OK:
- Replace Multi-Function Transmission Range
(TR) Switch -F125- Page 38-3 , MultiFunction Transmission Range (TR) Switch,
removing and installing, adjusting.
Page ST-50 .
Page 12 / 27
38-12
Sensor for transmission RPM, checking

multimeter
Wiring diagram
Test requirements
Locations
must be OK.
Ignition switched off.
Page 13 / 27
38-13
Checking wiring
wiring test.
- Disconnect 8-pin harness connector -arro
- Check wires between test box and 8-pin

connector to Transmission Control Modu
(TCM) for open circuit according to wiring
diagram.
- Also check wires for short circuit to each
Specified value:
Page 14 / 27
38-14
If no malfunctions are found in wires:

- Replace Sensor for transmission RPM -G182-.
Page ST-50 .
Page 15 / 27
38-15
Sender for transmission output RPM

checking
Recommended special tools and equipm
multimeter
Wiring diagram
Test requirements
Respective fuses in fuse box (instrumen
Locations
Battery voltage must be at least 11.5 vo
Ground (GND) connections to transmiss
must be OK.
Checking wiring
wiring test.
Page 16 / 27
38-16

to wiring diagram.
to each other.
Specified value:
wires:
- Replace Sender for transmission
output RPM -G195-.
- Erase DTC memory of
(TCM) Page ST-28 , Diagnostic
mode 4: Reset/erase diagnostic
data.
ST-50 .
Page
Page 17 / 27
38-17
Transmission Fluid Temperature

Sensor, checking
multimeter
Wiring diagram
Test requirements
Locations
must be OK.
Page 18 / 27
38-18
Test sequence
- Disconnect 8-pin harness
connector -arrow 3-.
Checking resistance
- Measure resistance of
Transmission Fluid Temperature
Sensor-G93- between terminals 1
+ 2 at connector to sensor:
ATF
temperature
Specified
value
37.0 to 51.0
K
approx. -30
approx. 10
5.0 to 8.0 K
approx. 25
3.0 to 5.0 K
approx. 110
230.0 to 265.0
approx. 145
100.0 to 120.0
If one of the specified values is not

obtained:
- Replace Transmission Fluid
Temperature Sensor -G93-.
data.
ST-50 .
Page
Page 19 / 27
38-19
If specified values are obtained:

- Check wires according to wiring diagram
Page 38-19 .
Checking wiring
wiring test.
connector to Transmission Control Modu
diagram.
Terminal 1+socket 45
Terminal 2+socket 8
Specified value:
- Replace Transmission Control Module (T
J217- Page 38-29 .
Page 20 / 27
38-20
Solenoid valves in valve body, checking

multimeter
Wiring diagram
Test requirements
Locations
must be OK.
Page 21 / 27
38-21
Test sequence
- Disconnect 14-pin harness
connector -arrow 2- to solenoid
valves (Solenoid Valve 1 -N88- to
Solenoid Valve 6 -N93-, Solenoid
Valve 9-N282-, Solenoid Valve 10
-N283-).
Page 22 / 27

38-22
Checking resistance
- Check resistances of solenoid valves
at connector to the solenoid valves:
Component
Connector
Specified
value
Terminal
Solenoid
Valve 1 N88-
1+Ground
(GND)
transmission
10.0 to
16.0
Solenoid
Valve 2 N89-
2+Ground
(GND)
transmission
10.0 to
16.0
Solenoid
Valve 3 N90-
7+8
4.0 to 8.0
Solenoid
Valve 4 N91-
11+12
4.0 to 8.0
Solenoid
Valve 5 N92-
3+4
4.0 to 8.0
Solenoid
Valve 6 N93-
13+14
4.0 to 8.0
Solenoid
Valve 9 N282-
5+6
4.0 to 8.0
Solenoid
Valve 10 N283-
9+10
4.0 to 8.0
Note:
Resistance value is valid at approx. 20
C. At higher temperatures, resistance
value increases.
Page 23 / 27
38-23
If one of the specified values is not obtained:

- Replace the respective solenoid valve.
Page ST-50 .
If specified values are obtained:

- Check wires according to wiring diagram
Page 38-23 .
Checking wiring
harness Page ST-10 , connect test box for
wiring test.
connector to Transmission Control Module
diagram.
Component
Connector
Test box
Solenoid Valve 1 N88-
Terminal 1
Socket
41
Terminal 2
Socket
15
Terminal 7
Socket
30
Terminal 8
Socket
18
Page 24 / 27
38-24
Component
Connector
Test box
Solenoid Valve 4 -N91-
Terminal
11
Socket 5
Terminal
12
Socket
43
Terminal 3
Socket
42
Terminal 4
Socket 6
Terminal
13
Socket
31
Terminal
14
Socket
17
Terminal 5
Socket
16
Terminal 6
Socket
32
Terminal 9
Socket 4
Terminal
10
Socket
44

other.
Specified value:
- Replace Transmission Control Module (TCM) J217- Page 38-29 .
Page 25 / 27
38-25
Sender for hydraulic pressure, checking

multimeter
Wiring diagram
Test requirements
Locations
must be OK.
Page 26 / 27
38-26
Checking wiring
wiring test.
Page 27 / 27
38-27

to wiring diagram.
Component
Connector
Test
box
Sender 1 for
hydraulic
pressure,
automatic
transmission
-G193-
Terminal 7
Socket
24
Sender 2 for
hydraulic
pressure,
automatic
transmission
-G194-
Terminal 8
Socket
25

to each other.
Specified value:
wires:
- Replace the respective sender for
hydraulic pressure:
Repair Group 38
data.
ST-50 .
Page

Touareg 2003-07 Engine Repairs

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Touareg 2003-07 Engine Repairs

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Volkswagen Touareg 2003->

00-1, Engine identification

00-1, Engine specifications

The engine number ( "engine code" and "serial number" )

Numbering of cylinders begins on right side - A - as seen

Volkswagen Technical Site: http://volkswagen.msk.ru http://vwts.info http://vwts.ru

transfer side - C - . Cylinders are counted on each side in

Emission values in accordance with

Exhaust gas recirculation

Charge air cooler

Engine, removing and installing

Engine, removing and installing

10-1, Engine, removing

Removing engine from Scissor Lift Table VAS 6131

10-1, Notes on installation

Special tools, testers and auxiliary items

Scissor lift table VAS 6131

Drip tray V.A.G 1306

Frame support T10191

Engine, removing and installing

Spring-type clip pliers VAS 5024

Torque wrench (40 to 200 Nm)

Tensioner Hooks (2) VW 552

Standard set for Touareg VAS 6131/6

Support F/Vas6131 For V6/V10/V8 VAS6131/8

Container for removed components V.A.G 1698

Engine bung set VAS 6122

The engine with transmission is removed downward.

To allow free rotation of the driveshaft, move the

Leave the key in the ignition lock to prevent the

It is advisable to remove the front wheels before the

Engine, removing and installing

When the engine is installed in the engine

To prevent damage to removed components, use

All cable ties which are opened or cut open when

Repair Manual, Electrical Equipment, Repair Group 27,

Repair Manual, Electrical Equipment, Repair Group 92,

Engine, removing and installing

- Remove covers - A - , - B - (if equipped) and - C - in

- Disconnect smaller connector - A - from Engine Control

- Open fuse box cover on left in plenum chamber and

With connector couplings, follow the installation

Vehicles with engine code BKW

Engine, removing and installing

- Disconnect vacuum lines - arrows - for Exhaust Gas

- Disconnect vacuum line - arrow - for Exhaust Gas

- Disconnect vacuum lines - 1 - for the bypass flap

Engine, removing and installing

- Disconnect the following connections and free up wiring

- Disconnect harness connectors - arrows - for glow

Engine, removing and installing

- Secure suspension struts using spring compressor VW

Repair Manual, Suspension, Wheels, Steering, Repair

Repair Manual, Body Exterior, Repair Group 50, Noise

Repair Manual, Heating Air Conditioning, Repair Group

19-1, Cooling system, draining and

Engine, removing and installing

- Disconnect line - arrow - from transmission oil cooler

- Disconnect line - A - from servo oil cooler at lower left.

- Loosen clamp - arrow - from connecting pipe to air filter

Engine, removing and installing

- Disconnect coolant hoses - arrows - and place them so

- Unclip transmission ventilation line - arrows - .