Manual Motor Touareg Hibrida2010

Service
Repair Manual
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Service Department. Technical Information

Service
List of Workshop Manual Repair Groups
Repair Group
00 - General, Technical Data
10 - Engine Assembly AG. Volkswagen AG d
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13 - Crankshaft, Cylinder Block Vol
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15 - Cylinder Head, Valvetrain
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19 - Cooling System
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20 - Fuel Supply
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26 - Exhaust System, Emission Controls
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28 - Ignition/Glow Plug System
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Technical information should always be available to the foremen and mechanics, because their
careful and constant adherence to the instructions is essential to ensure vehicle road-worthiness and
safety. In addition, the normal basic safety precautions for working on motor vehicles must, as a
matter of course, be observed.
All rights reserved.

No reproduction without prior agreement from publisher.
Copyright © 2015 Volkswagen AG, Wolfsburg D3E802EBC6C

Touareg 2010 ➤ , Touareg 2015 ➤
Engine Mechanical, Fuel Injection and Ignition (Hybrid) - Edition 07.2015
Contents
00 - General, Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

1 Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.1 Safety Precautions, Working on Fuel Supply System . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.2 Safety Precautions, Vehicles with Start/Stop System . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.3 Safety Precautions, Road Test with Testing Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.4 Ignition System Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
1.5 Cooling System Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
2 Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
2.1 Engine Number/Engine Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
2.2 Cylinder Numbering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
3 Repair Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
3.1 Guidelines for Clean Working Conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
3.2 Foreign Objects in Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
3.3 Contact Corrosion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
3.4 Wire Routing and Securing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
3.5 Radiator and Condenser Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
10 - Engine Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
1 Engine, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
1.1 Engine, Removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
1.2 Engine, Securing to Engine and Gearbox Bracket VAS6095A . . . . . . . . . . . . . . . . . . . . . . 20
1.3 Engine, Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
1.4 Engine and Electro-Drive Drive Motor with Transmission, Separating and Connecting . . 25
1.5 Electro-Drive Drive Motor and Transmission, Separating . . . . . . . . . . . . . . . . . . . . . . . . . . 29
2 Subframe Mount . . . a.g.e.n A .G. .. V.o.lk.s.w.ag. e.n.A.G. d.o. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
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2.1 Overview - SubframeyV
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2.3 Right Engine
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3 Engine Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
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3.1 Engine Compartment Cover, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37

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4 Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
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13 - Crankshaft, Cylinder Block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42

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1 Cylinder Block, Belt Pulley Side . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42

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1.1 Overview - Supercharger Ribbed Belt Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42

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1.2 Supercharger Ribbed Belt, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43

1.3 Supercharger Ribbed Belt Tensioner, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . 44
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1.4 Overview - Ribbed Belt Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44

1.5 Ribbed Belt, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
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1.6 Ribbed Belt Tensioner, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46

1.7 Vibration Damper, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
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1.8 Sealing Flange, Removing and Installing, Belt Pulley Side . . . . . . . . . . . . . . . . . . . . . . . . 48

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2 Cylinder Block, Transmission Side . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52

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2.1 Overview - Drive Plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52

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2.2 Drive Plate, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53

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2.3 Sensor Wheel, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53

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2.4 Sensor Wheel, Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54

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2.5 Crankshaft Seal, Replacing, Transmission Side . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
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3 Crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
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3.1 Overview - Crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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3.2 Crankshaft Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
3.3 Crankshaft, Measuring Axial Play . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
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3.4 Crankshaft, Measuring Radial Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61

3.5 Crankshaft Needle Bearing, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
4 Balance Shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
4.1 Overview - Balance Shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
4.2 Balance Shaft, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
5 Piston and Connecting Rod . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
5.1 Overview - Piston and Connecting Rod . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
5.2 Pistons and Cylinder Bore, Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
5.3 Connecting Rods, Checking Radial Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
6 Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
15 - Cylinder Head, Valvetrain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75

1 Cylinder Head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
1.1 Overview - Cylinder Head . . . . . . . . . . . . . . . . . . . . .g.en. A. G . ..V.o.lk.sw. a. g.e.n.A.G. . . . . . . . . . . . . . . 75
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1.2 Left Cylinder Head Cover, Removing and Installing o lksw. . . . . . . . . . . . . . . . . e. s.n.ot. . . . . . . . . . 78
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1.3 Right Cylinder Head Cover, Removing andrisInstalling ed . . . . . . . . . . . . . . . . . . . . . r.an.te. . . . . 80
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1.4 Cylinder Head, Removing and Installingauth . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .or.a . . 82
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1.5 Compression, Checking . . . . . . . . . s. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
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2 Timing Chain Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
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2.1 Overview - Timing Chain Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
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2.2 Left and Right Timing Chain Covers, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . 93
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2.3 Lower Timing Chain Cover, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
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3 Chain Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
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3.1 Overview - Camshaft Timing Chains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
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3.2 Overview - Timing Mechanism Drive Chain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106
3.3 Overview - Balance Shaft and Oil Pump Drive Chain . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108
3.4 Camshaft Timing Chain, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108
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3.5 Timing Mechanism Drive Chain, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . 110
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3.6 Drive Chain Balance Shaft, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112

3.7 Valve Timing, Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
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4 Valvetrain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118
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4.1 Overview - Valvetrain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118
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4.2 Camshaft Axial Play, Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120
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4.3 Camshaft, Measuring Radial Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121 thi

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4.4 Camshaft, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121

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4.5 Camshaft Adjuster, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128

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4.6 Hydraulic Adjuster, Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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4.7 Valve Stem Seals with Installed Cylinder Head, Removing and Installing . . . . . . . . . . . . . . 139
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4.8 Valve Stem Seals with Removed Cylinder Head, Removing and Installing . . . . . . . . . . . . 142
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5 Intake and Exhaust Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 146
5.1 Valve Guides, Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 146
5.2 Valves, Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 146
5.3 Valve Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147
6 Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 148
17 - Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 153
1 Oil Pan/Oil Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 153
1.1 Overview - Oil Pan/Oil Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 153
1.2 Engine Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 155
1.3 Oil Pan Lower Section, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 157
1.4 Oil Pan Upper Section, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 159
1.5 Oil Pump, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 161
1.6 Oil Level Thermal Sensor G266 , Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . 162
2 Engine Oil Cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 163
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2.1 Engine Oil Cooler, AGRemoving

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3.2 s auCrankcase Ventilation Pipes, Removing and Installing ac ............................ 166
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3.3 Oil Separator, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 166
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4 Oil Filter/Oil Pressure Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 168
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4.1 Overview - Oil Filter Housing/Oil Pressure Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 168
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4.2 Oil Pressure Switch F22 , Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 169
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4.3 Reduced Oil Pressure Switch F378 , Removing and Installing . . . . . . . . . . . . . . . . . . . . . . 170
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4.4 Oil Pressure, Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 171
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4.5 Oil Pressure Switch F22 / Reduced Oil Pressure Switch F378 , Checking . . . . . . . . . . . . 172
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4.6 Oil Filter Housing, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 172
4.7 Oil Pressure Regulation Valve N428 , Removing and Installing . . . . . . . . . . . . . . . . . . . . 174
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5 Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 175
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19 - Cooling System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 177

1 Coolant System/Coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 177
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1.1 Connection Diagram - Coolant Hoses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 177
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1.2 Component Location Overview - Coolant System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 180
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1.3 Overview - Coolant System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 182
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1.4 Coolant System, Checking for Leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 185

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1.5 o
Coolant, Draining and Filling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 188
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1.6 Engine Coolant System, Draining, High Temperature Circuit . . . . . . . . . . . . . . . . . . . . . . 196

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1.7 Fill Quality, Checking, High Temperature Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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gh
2 Coolant Pump/Thermostat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 198
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2.1 Overview - Coolant Pump/Thermostat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 198
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2.2 Electric Coolant Pump, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 199
2.3 Coolant Pump, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
2.4 Coolant Thermostat, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 202
2.5 Coolant Thermostat, Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 202
2.6 Engine Coolant Temperature Sensor G62 , Removing and Installing . . . . . . . . . . . . . . . . 203
2.7 Engine Temperature Control Temperature Sensor G694 , Removing and Installing . . . . . . 204
3 Coolant Pipes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 205
3.1 Overview - Coolant Pipes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 205
3.2 Coolant Pipes for Engine Oil Cooler, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . 206
3.3 Coolant Pipes for Low Temperature Coolant Circuit, Removing and Installing . . . . . . . . . . 208
3.4 Front Coolant Pipe, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 210
3.5 Upper Coolant Pipe, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 211
3.6 Compressor Coolant Pipes, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . 213
4 Radiator/Coolant Fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 215
4.1 Overview - Radiator/Coolant Fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 215
4.2 Radiator, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 216
4.3 Radiator, Disassembling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 221
4.4 Center Radiator for Charge Air Cooling Circuit, Removing and Installing . . . . . . . . . . . . . . 221
4.5 Right Radiator for Charge Air Cooling Circuit, Removing and Installing . . . . . . . . . . . . . . 222
4.6 Fan Shroud, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 223
5 Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 225
20 - Fuel Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 228

1 Fuel Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 228
1.1 Overview - Fuel Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 228
1.2 Fuel Tank, Draining . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 230
1.3 Fuel Tank, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 232
2 Fuel Delivery Unit/Fuel Level Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 237
Contents iii
2.1 Overview - Fuel Delivery Unit/Fuel Level Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 237

2.2 Fuel Delivery Unit/Fuel Level Sensor, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . 238
2.3 Fuel Level Sensor 2 G169 and Suction Jet Pumps, Removing and Installing . . . . . . . . . . 241
3 Fuel Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 245
3.1 Fuel Filter, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 245
4 EVAP System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 248
4.1 Overview - EVAP System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 248
4.2 Fuel System, Checking for Leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 248
5 EVAP Canister System, Engine Code CGFA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 251
5.1 Overview - EVAP System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 251
5.2 Fuel System, Checking for Leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 252
6 Accelerator Mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 259
6.1 Overview - AcceleratorksPedal Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 259
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7.1 Fuel dPump, Checking . . . . . . . . . . . . . u. a.ra. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
b 260
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21 - Turbocharger, Supercharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 271 ce
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1 Charge Air System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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1.1 Overview - Charge Air Cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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271
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1.2 Charge Air Pressure Sensors G31 and G447 , Removing and Installing . . . . . . . . . . . . . . 272
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1.3 Charge Air Cooler, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 273

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2 Supercharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 277
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2.1 Overview - Supercharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 277

2.2 Overview - Drive Head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 279
2.3 Supercharger, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 280
rrectness of i
2.4 Supercharger, Checking for Leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 283

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2.5 Drive Head and Decoupling Spring, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . 285
2.6 Supercharger, Securing to Engine/Transmission Holder for Repair Work . . . . . . . . . . . . . . 288
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ercia
2.7 Supercharger, Securing to Engine/Transmission Holder for Leak Test . . . . . . . . . . . . . . . . 288

m
3 Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 290

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24 - Multiport Fuel Injection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 293

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his
ate
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1 Injection System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 293

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1.1 Vacuum System, Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 293

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1.2 Overview - Vacuum System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 293
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2 Fuel Injectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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2.1 Fuel Injectors, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 295
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3 Air Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 298
3.1 Overview - Air Filter Housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 298
3.2 Air Filter Element, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 299
3.3 Air Filter Housing, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 301
4 Intake Manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 302
4.1 Overview - Intake Manifold Lower Section with Fuel Rail . . . . . . . . . . . . . . . . . . . . . . . . . . 302
4.2 Intake Manifold Lower Section with Fuel Rail, Removing and Installing . . . . . . . . . . . . . . 304
4.3 Throttle Valve Control Module J338 , Removing and Installing . . . . . . . . . . . . . . . . . . . . . . 307
4.4 Regulating Flap Control Unit J808 , Removing and Installing . . . . . . . . . . . . . . . . . . . . . . 309
4.5 Intake Manifold Flap Vacuum Actuator, Removing And Installing . . . . . . . . . . . . . . . . . . . . 310
5 Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 312
5.1 Intake Air Temperature Sensor G42 / Manifold Absolute Pressure Sensor G71 , Removing
and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 312
5.2 Intake Manifold Runner Position Sensor G336 / Intake Manifold Runner Position Sensor 2
G512 , Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 312
6 Engine Control Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 313
iv Contents
AG. Volkswagen AG d
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Engine Mechanical,
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6.1 Engine Control Module J623 , Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . 313
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7 High Pressure Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 315
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7.1 Overview - High Pressure Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 315
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7.2 High Pressure Pump, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 316
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spec
7.3 High Pressure Pipe, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 319
urposes, in part or in wh
t to the co
8 Heated Oxygen Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 322
8.1 Overview - Heated Oxygen Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 322
8.2 Heated Oxygen Sensor G39 , Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . 323
rrectne
8.3 Oxygen Sensor after Three Way Catalytic Converter G130 , Removing and Installing . . . . 325
8.4 Heated Oxygen Sensor 2 G108 , Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . 326
ss
8.5 Oxygen Sensor 2 after Catalytic Converter G131 , Removing and Installing . . . . . . . . . . . . 327
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9 Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 330
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26 - Exhaust System, Emission Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 332

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1 Exhaust Pipes/Mufflers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 332
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1.1 Overview - Muffler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 332

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1.2 Exhaust Pipes/Mufflers, Disconnecting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 333

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1.3 Tail Pipes, Replacing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 334
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1.4 Exhaust System, Installing without Tension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 334
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1.5 Exhaust System, Checking for Leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 335
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2 Emissions Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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336
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2.1 Overview - Emissions Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 336

2.2 Catalytic Converter, Removing and Installing, Left (Bank 2) . . . . . . . . . . . . . . . . . . . . . . . . 337
2.3 Catalytic Converter, Removing and Installing, Right (Bank 1) . . . . . . . . . . . . . . . . . . . . . . 340
3 Secondary Air System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 342
3.1 Overview - Secondary Air Injection System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 342
3.2 Secondary Air Injection Pump Motor V101 , Removing and Installing . . . . . . . . . . . . . . . . 343
3.3 Secondary Air Injection Combination Valves, Checking for Function and Leaks . . . . . . . . 344
3.4 Left Secondary Air Injection Combination Valve, Removing and Installing . . . . . . . . . . . . 345
3.5 Right Secondary Air Injection Combination Valve, Removing and Installing . . . . . . . . . . . . 346
3.6 Secondary Air Injection Sensor 1 G609 , Removing and Installing . . . . . . . . . . . . . . . . . . 347
4 Exhaust Manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 349
4.1 Overview - Exhaust Manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 349
4.2 Exhaust Manifold, Removing and Installing, Left (Bank 2) . . . . . . . . . . . . . . . . . . . . . . . . . . 350
4.3 Exhaust Manifold, Removing and Installing, Right (Bank 1) . . . . . . . . . . . . . . . . . . . . . . . . 352
5 Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 354
28 - Ignition/Glow Plug System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 355

1 Ignition System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 355
1.1 Overview - Ignition System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 355
1.2 Test Data and Spark Plugs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 357
1.3 Ignition Coils with Power Output Stages , Removing and Installing . . . . . . . . . . . . . . . . . . 357
1.4 Knock Sensor 1 and 2 G61 and G66 , Removing and Installing . . . . . . . . . . . . . . . . . . . . 360
1.5 Camshaft Position Sensor G40 and G163 , Removing and Installing . . . . . . . . . . . . . . . . 361
1.6 Engine Speed Sensor G28 , Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . 362
2 Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 364
3 Revision History . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 365
Contents v
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vi Contents
00 – General, Technical Data

1 Safety Precautions
(Edition 07.2015)
⇒ “1.1 Safety Precautions, Working Von Fuel Supply System”,
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1.1 Safety Precautions, Working on Fuel
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There Is a Risk of Injury Because the Fuel Is under Pressure.
Fuel system is under pressure. Possible injuries resulting from
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– Wear protective eyewear.

– Wear safety gloves.
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– Reduce the pressure: Lay clean cloths around the connection

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Leaking Fuel Is a Fire Hazard.

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When the battery is connected, the door contact switch activates

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the fuel pump when opening the driver door. Leaking fuel can
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ignite and start a fire.

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– Before opening the fuel system, interrupt the fuel pump power
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1.2 Safety Precautions, Vehicles with Start/
Stop System
There Is a Risk of Injury Due to the Engine Starting Unexpectedly.
The engine can start unexpectedly when the Start/Stop System
is activated on the vehicle. A message in the instrument cluster
indicates whether the Start/Stop System is activated.
– Deactivate the Start/Stop System: switch off the ignition.
1.3 Safety Precautions, Road Test with

Testing Equipment
There Is a Risk of Injury Caused by Unsecured Testing Equip‐
ment.
If the front passenger airbag deploys during an accident, unse‐
cured testing equipment becomes a dangerous projectile.
– Secure the testing equipment to the rear seat.
or
– Have a second person operate testing equipment on the rear
seat.
1. Safety Precautions 1
1.4 Ignition System Safety Precautions

There Is a Risk of Injury Due to Electric Shock.
With the engine running the ignition system is under high voltage.
Electric shock is possible through contact with the ignition system.
. Volkswagen AG
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– Never touch or remove Vthe olksignition wires when engine
oes
notis run‐
gu
ning or turning at starting
ed by speed. ara
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or
Risk of Damagingathe
ut Components.
h or
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An engine wash as well as connecting and disconnecting electri‐
ce
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cal component wires with the engine running can cause damage.
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– Switch off the ignition before connecting and disconnecting
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wires.
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– Switch off the ignition before an engine wash.
h re
hole
spec
1.5 Cooling System Safety Precautions
es, in part or in w
t to the co
There Is a Risk of Burns from Hot Coolant.
The coolant system is under pressure when the engine is warm.
rrectness of i
Risk of scalding due to hot steam and hot coolant.
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– Wear safety gloves.

– Wear protective eyewear.
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– Reduce the pressure: cover the coolant reservoir cap with a
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cloth and carefully open.

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2 Rep. Gr.00 - General, Technical Data

2 Identification
⇒ “2.1 Engine Number/Engine Specifications”, page 3
⇒ “2.2 Cylinder Numbering”, page 4
2.1 Engine
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Engine Number
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The engine number can only be seen if the front engine cover is
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removed.
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The engine number (“engine code” and “serial number”) is located
hole
spec
at front on cylinder block, below the right cylinder head -arrow-.
es, in part or in w
t to the co
There is also a label attached on the right timing chain cover with
the “engine code” and “serial number”.
The first three digits describe the mechanical structure of the en‐
rrectness of i
gine and are still stamped on the engine. The fourth letter de‐
l purpos
scribes the engine torque and output and depends on the engine
control module. Four-digit engine codes are found on the type
label and vehicle data label. It can also be read via the engine nform
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control module.
m
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Vehicle data label locations. Refer to ⇒ Maintenance ; Booklet

om
io
29.1 ; Vehicle Data Label .

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or
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Engine Data
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for
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Codes CGFA
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Displacement liters 2.968
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Internal combustion engine out‐ kW at RPM 245/5500
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Electro-drive drive motor output kW 30

Internal combustion engine tor‐ Nm at RPM 440/1600
que
Hole diameter in mm 84.5
Stroke mm 89.0
Compression ratio 10.5
RON minimum 98 1)
Injection system and ignition system Motronic MED 17
Emission values in accordance ULEV 2
with
Ignition sequence 1-4-3-6-2-5
Exhaust Gas Recirculation (EGR) no
Charging Supercharger
Knock control 2 sensors
Oxygen sensor regulation 4 heated oxygen sensors
Charge air cooler yes
Camshaft adjustment Intake
Intake manifold change-over no
Secondary Air System yes
Valve per cylinder 4
1) RON 95 is also permissible, but with reduced performance.
2. Identification 3
AG. Volkswagen AG d
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Touareg 2010 ➤ , Touareg 2015 ➤ ut
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Engine Mechanical, Fuel Injection and
s Ignition (Hybrid) - Edition 07.2015
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2.2 Cylinder Numbering
ility
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The numbering of cylinders begins on right side -A- as seen in
ole,
direction of travel (cylinder bank 1) opposite the power transfer
spec
side -C-. Cylinders are counted on each side in sequence. -B- =
t to the co
cylinder bank 2.
rrectness o
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3 Repair Information lksw

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⇒ “3.1 Guidelines for Clean Working Conditions”, page rise 5
d b ara
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⇒ “3.2 Foreign Objects in Engine”, page 5 s au ra
c
s
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⇒ “3.3 Contact Corrosion”, page 5
nl
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⇒ “3.4 Wire Routing and Securing”, page 5
y li
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ab
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⇒ “3.5 Radiator and Condenser Assembly”, page 6
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3.1 Guidelines for Clean Working Condi‐
h re
hole
spec
tions es, in part or in w
t to the co
When working on the fuel supply/injection system, pay careful at‐
tention to the following “rules” of cleanliness:
rrectness of i
♦ Thoroughly clean the connection points and the surrounding
area before loosening.
l purpos
♦ Place the removed parts on a clean surface and cover them.

Only use lint-free cloths.
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♦ Carefully cover or seal opened components if the repair is not
m
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performed immediately.
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♦ Install only clean parts: remove the replacement parts from
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their packaging just before installing them. Do not use parts

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that have been loosely stored or unpackaged (for example, in
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tool boxes etc.).
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♦ If the system is open: do not work with compressed air. Do not t. C rig
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move the vehicle. yri
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♦ Make sure no fuel gets onto the fuel hoses. If necessary, wipe
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off the fuel hoses immediately.
♦ Protect any disconnected connectors from dirt and moisture
and connect them only when they are completely dry.
3.2 Foreign Objects in Engine

To prevent foreign objects from entering when working on the
engine, always seal the open channels of the intake tract and ex‐
haust tract with suitable plugs, for example from the Engine Bung
Set - VAS6122- .
3.3 Contact Corrosion

Contact corrosion can occur if incorrect fasteners (bolts, nuts,
washers, etc.) are used.
For this reason, only fasteners with a special surface coating are
installed.
In addition, rubber or plastic parts and adhesive are made of ma‐
terials that do not conduct electricity.
If there are doubts about whether parts can be used or not, then
use new parts. Refer to the Parts Catalog.
3.4 Wire Routing and Securing

♦ Mark the individual fuel, hydraulic and vacuum lines for the
EVAP canister system as well as the electrical wires before
disconnecting and/or removing them. This will prevent a mix-
up when reconnecting them. Draw a sketch or take a picture
of them if necessary.
♦ Due to the limited space inside the engine compartment, be
especially careful when working near moving or hot parts to
avoid damaging the lines.
3. Repair Information 5
3.5 Radiator and Condenser Assembly

When assembled correctly, the radiator, condenser
AG. Volkswagand turbo‐
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charger may have slight impressions agen do s
olkswon their plates. This is enotnot
V
damage. Do no replace the cooler,
ed by condenser or turbocharger gu
ara
because of impressions like
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t or
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10 – Engine Assembly
1 Engine, Removing and Installing
⇒ “1.1 Engine, Removing”, page 7 wage
n AG. Volkswagen AG do
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⇒ “1.2 Engine, Securing to Engine and Gearbox Bracket ed by ua
ran
VAS6095A ”, page 20 ho
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⇒ “1.3 Engine, Installing”, page 22 ss
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⇒ “1.4 Engine and Electro-Drive Drive Motor with Transmission,
an
d
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Separating and Connecting”, page 25
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⇒ “1.5 Electro-Drive Drive Motor and Transmission, Separating”,
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page 29 , is n
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1.1 Engine, Removing
spec
es, in part or in w
t to the co
Special tools and workshop equipment required
♦ Used Oil Collection and Extraction Unit - SMN372500-
rrectness of i
♦ Step Ladder - VAS5085-
l purpos
♦ Engine Bung Set - VAS6122-

♦ Shop Crane - Drip Tray - VAS6208-
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♦ Hose Clip Pliers - VAS6362-

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♦ Puller - Ball Joint - T10187-
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♦ Scissor Lift Table - Touareg Set - VAS6131/6-
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♦ Scissor Lift Table - Touareg Set - Support - VAS6131/8-
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♦ Torque Wrench 1331 5-50Nm - VAG1331-
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The Engine with Transmission Is Removed Downward.
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Note
♦ Secure all disconnected lines and connections with suitable

fixtures, for example, cable ties to the engine or to the body
(depending on its »origin«). Seal off open connections with
blind plugs.
♦ To rotate the driveshaft freely, move the selector lever into “N”.
♦ So that the front wheels can still be turned with the battery
disconnected, the battery must only be disconnected with ig‐
nition key inserted.
♦ When the engine is installed some components cannot be re‐
moved or can only be removed with great difficulty. Therefore
determine which components are faulty before removing so
that they can replaced while they are removed.
♦ To prevent damage to the removed components, use the Stor‐
age Rack - VAG1698A- for storage.
♦ All cable ties which are loosened or cut open when removing
engine, must be replaced in the same position when installing
engine.
1. Engine, Removing and Installing 7

WARNING
Hybrid vehicles have a high voltage system! Danger of elec‐

trical shock! When performing the following n AGwork, itais
. Volksw genalso
AG
necessary to work on the high voltage lkswage De-energize thedoes n
system.
Vo ot g
high voltage system now. Refersetod b ⇒ Electric Drive; Rep. Gr.
y ua
ran
93 ; De-energizing the High tVoltage
ho
ir
System . tee
o
au ra
c
ss
ce
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nl
pt
Procedure:
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– Disconnect the battery. Refer to ⇒ Electrical Equipment; Rep.
erm
ab
ility
Gr. 27 ; Battery, Disconnecting and Connecting .
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– Evacuate the refrigerant in the A/C system. Refer to ⇒ Heat‐
h re
hole
ing, Ventilation and Air Conditioning; Rep. Gr. 87 .
spec
es, in part or in w
– Remove the front wheels.
t to the co
– Drain the coolant for the high temperature coolant system.
Refer to
rrectness of i
⇒ “1.5.1 Coolant, Draining and Filling, High Temperature Cir‐
cuit”, page 188 .
l purpos
– Drain the coolant for the low temperature cooling system. Re‐
fer to
nf
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o
⇒ “1.5.2 Coolant, Draining and Filling, Low Temperature Cir‐
rm
cuit”, page 192 .
m
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om
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c
– Remove the air guide pipe by removing the hose -1- and loos‐
or
thi
ening the hose clamps -arrows-.
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– Disconnect all the connectors -1 through 4- from the heated

oxygen sensors.
– Remove the windshield wiper arms. Refer to ⇒ Electrical
Equipment; Rep. Gr. 92 ; Windshield Wiper System .
– Remove the plenum chamber cover. Refer to ⇒ Body Exterior;
Rep. Gr. 50 ; Plenum Chamber Cover .
– Remove the anti-theft protection from the engine control mod‐
ule. Refer to
⇒ “6.1 Engine Control Module J623 , Removing and Instal‐
ling”, page 313 .
– Disconnect the engine wiring harness connector from the en‐
gine control module.
8 Rep. Gr.10 - Engine Assembly

– Remove the ground cable and disconnect the connectors

-arrows-.
– Open the cover -A- on the central electric.

– Disconnect all connectors that go to the engine. AG. Volkswagen AG d
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– Remove the engine wiring harness from the d bplenum chamber
y ara
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and lay it on the engine. thor eo
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ole,
spec
– Remove the coolant hose -1- and disconnect the breather
t to the co
lines -arrows-.
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f inform
mer
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n
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– Remove the secondary air injection line -1- and the coolant
t.
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hoses -arrows-. C py
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. Volkswagen AG
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Touareg 2010 ➤ , Touareg 2015 olks➤
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Engine Mechanical, FuelisInjection
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an
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– Remove the coolant hoses
ss -arrows-.
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ab
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hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
– Disconnect the refrigerant line -arrow- for the A/C system. Seal
the open lines with suitable plugs.
nf
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orm
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thi
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– Remove the bolts -1 and 2- and remove the cover plate for the
high voltage connection -A-.
– Open the retainers for both quick-release couplings -arrows-

and remove the coolant lines in direction of -arrow-.

– Release and remove the Electrical A/C Compressor High Volt‐

age Cable - P3- -1-.
AG. Volkswagen AG d
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– Release the pilot contact -1- from the electric drive power and
an
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control electronics and remove it. Release and remove the rm
ab
high voltage cables -2, 3 and 4- in sequence. Unclip the high
pe
ility
voltage cables and place them on the engine.
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hole
spec
es, in part or in w
t to the co
rrectness of i
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– Remove the connector on the A/C compressor -arrow-. Re‐

move the bolt -1- and remove the refrigerant line from the A/
m
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com
C compressor.
tion in
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WARNING
Fuel system is under pressure.

Risk of injury from fuel spraying out.
• Wear protective eyewear.
• Wear safety gloves.
• Reduce the pressure: Lay clean cloths around the con‐
nection point and carefully open the connection point.
– Wrap a cloth around the separating point to catch any fuel

leaking out.
– Remove the fuel supply line -arrow-.

AG. Volkswagen AG d
– Disconnect the connector from the steering gear. agen oes
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– Remove the heat shield -1- for the universal joint -2-.
rrectne
Caution
ss o
cial p
f
♦ Separate universal joint from steering gear only when front
inform
wheels are in straight ahead position.
mer
atio
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♦ Do not change steering wheel position and steering gear

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c
position any more, secure steering wheel with adhesive
i
or
n thi
tape.
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– Remove the universal joint -1- from the steering gear and push
t.
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– Remove the hoses from the coolant pipes -2-.
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– Remove the ground cable from the drive motor -arrow-.

– Remove the clamp -1-. Remove the circlip -arrow- and remove
the clutch mechanism breather. Seal the open lines.
– Loosen the right front wheel housing liner and remove the
connectors -arrows- from the Auxiliary Hydraulic Pump Con‐
trol Module - J922- . Free up the wiring harness.
AG. Volkswagen AG d
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ab
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– Disconnect the ground cable -A- from the right longitudinal
ole,
spec
member.
t to the co
rrectness o
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f inform
mer
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n
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i
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– Remove the bolt -A- and the connections on the transmission

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fluid cooler. Catch any fluid coming out.

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Touareg 2010 ➤ , Touareg 2015 ➤ . Volkswagen AG
gen AG
Engine Mechanical, Fuel Injection andolkIgnition (Hybrid) - Edition
does07.2015
swa no
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– Clamp the power steering hose withhothe
ris Hose Clamps - Up To nte
eo
25mm - 3094- . Disconnect the power
au
t
steering lines -arrows-. ra
c
ss Used Oil Collection and
Catch any escaping fluid using the
ce
le
Extraction Unit - SMN372500- .
un
pt
an
d
itte
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ab
pe
ility
ot
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, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
– Disconnect the coolant hoses -arrows- and remove the upper
l purpos
coolant hose -1- from the brackets.
nform
mercia
a
com
tion in
r
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thi
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– Loosen the upper control arm nut a few turns and pull the joint Prote AG.
off using the Puller - Ball Joint - T10187- .
– Remove the nut completely and disconnect the control arm.
– Disconnect the connectors -arrow- at the left and right on the

front speed sensors.

– Disconnect the connector -arrow- from the wear indicator.
– Remove the cable holder bolts -arrows-.
AG. Volkswagen AG d
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– Remove the bolt -arrow- at the bottom of the coupling rod.
spec
es, in part or in w
– Remove the nut -A- from the control arm. Leave the bolt in the
t to the co
hole.
rrectness of i
Caution
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Be careful not to stretch the lines when removing and installing

the brake caliper. Do not change the bend shape of the brake
nform
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lines.
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– Remove the bolts -arrows- from the brake caliper. Then re‐
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move the brake caliper and secure it in the wheel housing

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t.
using the Tensioning Strap - T10038- .
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– Repeat the procedure on the other side of the vehicle.
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– Disconnect the connector -arrows- from the transmission.
AG. Volkswagen AG d
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– Loosen the clamping sleeves -1 and 2- between the front muf‐
es, in part or in w
fler and the center muffler.
t to the co
– Support the exhaust system between the center muffler and
the rear muffler using the Engine and Gearbox Jack -
rrectness of i
VAS6931- . Remove the exhaust system mounts and lower
the exhaust system.
l purpos
– Remove the rear driveshaft. Refer to ⇒ Transfer Case and

Rear Final Drive; Rep. Gr. 39 ; Driveshaft; Rear Driveshaft,
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Removing and Installing .

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Note
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♦ Ignore -2-.
um
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♦ Do not bend or kink the selector lever cable.
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♦ Always replace the lock washer. rig ht
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– Remove the selector lever cable from the ball head -1- and
then remove the lock washer -3-.
– Remove one of the rear bolts -2- from the subframe.

– Secure the subframe on the body using the Assembly Carrier

Locating Pins - T10300- . Refer to ⇒ Suspension, Wheels,
Steering; Rep. Gr. 40 ; I - Overview: Subframe, Stabilizer Bar
and Lower Control Arm .
– Then proceed the exactly the same with the bolt -2-.
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t to the co
– Remove the bolt -1- at the bottom of the engine. The Scissor
Lift Table - Engine Support - VAS6131/8-1- will be inserted into
rrectness of i
this hole later.
l purpos
– If the engine and the transmission with the drive motor are to
be separated after removing, remove the bolts -arrows-.
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Prepare the Scissor Lift Table - VAS6131B- for the Following

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Procedure:
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1 - VAS6131/6-1
❑ Attachment point: A4;
B3; B4
2 - VAS6131/6-2
❑ Attachment point: H4;
G3; G4
3 - VAS6131/6-3
❑ Attachment point: A5;
C5
❑ Use a turntable with a
short spindle
4 - VAS6131/6-4
❑ Attachment point: F5;
H5
❑ Use a turntable with a
short spindle
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❑ Attachment point: B7 ed b ara
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Support VAS6131/8-1 ss
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❑ Attachment point: D7
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❑ Attachment point: G7
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8 - VAS6131/6-6
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❑ Fastening point: B14
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9 - VAS6131/6-6
❑ Attachment point: G14
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♦ Attach all support to the scissor lift table just hand-tight so that
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♦ Use the turntable with the short spindle for the axle supports
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VAS6131/6-3 and VAS6131/6-4. The turntables with the long C py
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– Position the horizontal scissor lift table under the engine. The
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supports -1- must be guided into the corresponding mount

-arrow- at right and left.

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– At the same time, guide the right and left support for the trans‐
pt
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mission bracket into the corresponding hole -arrow-.
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When all four supports are in the locating holes without contact
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pressure:
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– With light pre-tension, turn the turntables for the axle supports
spec
under the control arms.
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– Guide the supports -2- into the corresponding mounts in the
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subframe. Use the knurled nut to adjust the height of the sup‐
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port, if necessary. om
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– Tighten all mounts on the scissor lift table.
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– Also support the engine with the Scissor Lift Table - Engine
Support - VAS6131/8-1- . To do so, guide the hook from below
into the open bolt hole on the engine. Adjust the height using
the spindle and tighten the mounts on the scissor lift table.
– Remove the right and left bolts -A- from the suspension strut.

– Remove the bolts for the transmission transverse support -1-

and for the subframe -2, 3 and 4-.
Caution
Lower the engine very carefully. Make sure all connections to

the body are disconnected. Rework if necessary.
– Slowly lower the engine/transmission assembly always mak‐

ing sure there is enough clearance.
– Tighten one bolt and nut -arrow- on the right and left sides of
the subframe mount. This will prevent the engine support from
slipping.
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1.2 Engine, Securing to Engine and Gear‐

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box Bracket - VAS6095A-

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spec
♦ Engine Sling - 2024A-

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♦ Engine And Transmission Holder - VAS6095- with Engine/

Transmission Holder - V6 FSI Bracket - VAS6095/1-5-
rrectne
♦ Shop Crane - VAS6100-

s
♦ Lift Arm Extension - VAS6101-

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Conditions:
form
mer
• Electro-drive drive motor is removed from the engine. Refer to

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⇒ “1.4 Engine and Electro-Drive Drive Motor with Transmis‐

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sion, Separating and Connecting”, page 25 .

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Procedure
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– Remove the A/C compressor from the engine.

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– Engage the Engine Sling - 2024A- on the engine lifting eyes

and on the shop crane as shown in the illustration.
Note
To be aligned to the center of gravity of the engine assembly, the

rail with holes of the lifting hook must be inserted as shown in the
illustration.
WARNING
There is the risk of an accident.

♦ The engine may be transported only in the manner de‐
scribed and without the transmission.
♦ Lifting hooks and pins on the engine sling must be secured
with securing pins -arrows-.
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– Tension the engine slightly with shop crane, do not raise. d by gu
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– Remove the nuts from the right and left engine mounts
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-arrow-.
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– Remove the Scissor Lift Table - Q7 Set - Articulated Joint

Support - VAS6131/13-7- from the engine.
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– Raise the engine from the engine support.

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– Remove the bolts -arrows- and the left engine support.

– Remove the bolts -arrows- and the right engine support.
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– Attach the engine using the Engine/Transmission Holder - V6

un
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FSI Bracket - VAS6095/1-5- to the Engine and Gearbox Brack‐
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et - VAS6095A- and tighten to 40 Nm, as shown in the illus‐
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1.3 Engine, Installing

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Note the following whenever working inside the engine com‐
partment due to limited space:
♦ Route all lines and cables in their original locations.
♦ Make sure that there is sufficient clearance to all moving
or hot components.
Note
When moving the engine/transmission assembly into the body, it

is always necessary to bring engine carrier into contact on body
using the Scissor Lift Table - VAS6131- . »Pulling up« the engine
carrier with mounting bolts damages the threaded insert.
Procedure
– Before installing the assemblies, install the exhaust manifold
with the catalytic converters.

Aligning the Scissor Lift Table
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♦ Scissor Lift Table - Positioning Tool - VAS6131/17-
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Individual components of the positioning tool:
spec
♦ Scissor Lift Table - Positioning Tool - Dot Lasers -
t to the co
VAS6131/17-1-
♦ Scissor Lift Table - Positioning Tool - Adapter M14 x 1.5 -
rrectne
VAS6131/17-2-
♦ Scissor Lift Table - Positioning Tool - Adapter M12 x 1.5 -
VAS6131/17-3- ss o
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♦ Scissor Lift Table - Positioning Tool - Adapter M10 -

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VAS6131/17-4-
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The illustration shows an example, other free subframe attach‐

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ment points can be used.
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– Install suitable adapters -A- at the left and right sides in a
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threaded hole on the subframe mount on the vehicle longitu‐ Prote
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dinal member.
– Install the Scissor Lift Table - Positioning Tool - Dot Laser -
VAS6131/17-1- -B- in the adapter -A-.
– Insert the bolts -C- centered in the securing point on the sub‐
frame with the bolt heads facing upward.
– Switch on the Scissor Lift Table - Positioning Tool - Dot Laser
- VAS6131/17-1- and align the scissor lift table so that the laser
beam strikes the bolt head on the left and right. Remove the
dot laser and adapter again after aligning.
Engine, Installing
– Raise the drivetrain up until it comes into contact with the body
using the Scissor Lift Table - VAS6131- . Be careful of the
installed Assembly Carrier Locating Pins - T10300- when do‐
ing this.
– Attach the subframe to the vehicle. Refer to ⇒ Suspension,
Wheels, Steering; Rep. Gr. 40 .

– Reconnect all connections, lines, hoses and connectors that

were disconnected for the removal procedure.
– On hybrid vehicles, it is very important the contact surfaces on
the potential equalization cable are clean and have no grease
on them. Clean the contact surfaces. Refer to ⇒ Rep. Gr. 93 ;
High Voltage System, Energizing; Potential Equalization Ca‐
bles .
– Install the plenum chamber cover. Refer to ⇒ Body Exterior;
– Install the right and left wiper arms. Refer to ⇒ Electrical
Equipment; Rep. Gr. 29 ; Windshield Wiper System, Remov‐ agen
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– Connect the A/C lines. Refer to ⇒ Heating, Ventilation
ho
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Conditioning; Rep. Gr. 87 ; Refrigerant Circuit
aut Components, or
ac
Servicing . ss
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– Refill the A/C system with refrigerant. Refer to ⇒ Heating,
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Ventilation and Air Conditioning; Rep. Gr. 87 ; Refrigerant
rm
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Circuit Components, Servicing .
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– Fill the power steering fluid. Refer to ⇒ Maintenance ; Booklet
, is n
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29.1 ; Power Steering Fluid, Checking Level .
hole
spec
– Fill with coolant for the high temperature coolant circuit. Refer
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– Fill with coolant for the low temperature coolant circuit. Refer
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– If necessary, fill with engine oil.

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– Connect the battery. Refer to ⇒ Electrical Equipment; Rep.
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Gr. 27 ; Battery, Disconnecting and Connecting .

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– Re-energize the high voltage system. Refer to ⇒ Electrical
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Equipment Hybrid; Rep. Gr. 93 ; High Voltage System, Ener‐ cum

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– Bleed the clutch. Refer to ⇒ Automatic Transmission; Rep.
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– Adjust the selector lever cable. Refer to ⇒ Automatic Trans‐
AG.
mission; Rep. Gr. 37 ; Shift Mechanism; Selector Lever Cable,

Checking and Adjusting .
– Fill the ATF. Refer to ⇒ Automatic Transmission; Rep. Gr.
37 ; ATF Level, Checking and Filling .
– Connect the Vehicle Diagnostic Tester .
– Perform a vehicle system test. Refer to Vehicle Diagnostic
Tester in “Guided Fault Finding”.
– End the vehicle system test in such a way that possibly existing
DTC entries are automatically erased.
– Calibrate the electro-drive drive motor. Refer to Vehicle Diag‐
nostic Tester in “Guided Functions”.
– Create the readiness code with a road test.
Always observe all safety precautions when performing the road
test.
– Perform another vehicle system test and correct any faults.

Note
If, during the road test, it is discovered that the steering wheel is
not exactly straight when driving in a straight line, then perform
an axle alignment. Refer to ⇒ Suspension, Wheels, Steering;
Rep. Gr. 44 ; Vehicle Alignment .
Tightening Specifications
Threaded Connection Tightening Specification
Bolts and Nuts M6 10 Nm
M7 15 Nm
M8 25 Nm
M10 40 Nm
M12 60 Nm
deviation from
Subframe Mount Refer to
⇒ “2 Subframe Mount”,
page 32
Drive Axles to transmission Refer to ⇒ Suspension,
Wheels, Steering; Rep. Gr.
40 ; Drive Axle, Servicing .
Transmission support to body Refer to ⇒ Transfer Case and
Rear Final Drive; Rep. Gr.
34 ; Transmission Support
and Bracket, Installing .
Drive Axles to transmission Refer to ⇒ Suspension,
Wheels, Steering; Rep. Gr.
40 ; Front Suspension .
1.4 Engine and Electro-Drive Drive Motor

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Scissor Lift Table - VAS6131B-
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♦ Electric Drive Unit Guide Pins - T10441-

♦ Scissor Lift Table - Q7 Set - Articulated Joint Support -
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VAS6131/13-7-
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♦ Scissor Lift Table - Touareg Set - Mount - VAS6131/6-7-

♦ Bits for VAG1331/13 - Bit - T10099/1-
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Separating the Engine and Electro-Drive Drive Motor with Trans‐

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mission:
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– Remove the right and left front muffler.

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– Remove the right and left catalytic converters.

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1. Engine, Removing and Installing
– Remove the front driveshaft. Refer to ⇒ Transfer Case and

Rear Final Drive; Rep. Gr. 39 ; Driveshaft; Front Driveshaft,
– Remove the bolts -arrows- and the bracket -A- for the catalytic
converter. Remove the bolt -1- from the coolant pipes.
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– Remove the bolts -arrows- and remove the plate -A-. Discon‐ erm
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nect the coolant hose -B-.
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– Remove the bolt -1- and the nut -2-.
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– Disconnect the vacuum hoses -arrows-. Disconnect the cool‐

ant hoses -A- from the electro-drive drive motor and the en‐
gine. Move the coolant hoses and pipes to the side.

– Remove the connector -1- and free up the bleed pipe

-arrow-.
– Remove the bolts -arrows- and remove the ATF lines. Seal off
all open lines and connections with suitable plugs.
– Free up the wiring harness for the transmission.
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– Secure the hydraulic pipe for the clutch mechanism with cable
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– Remove the right front ground cable from the engine and tight‐
r
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en the Scissor Lift Table - Q7 Set - Articulated Joint Support -
s
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VAS6131/13-7- in the threaded hole.

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– Tighten the Scissor Lift Table - Q7 Set - Articulated Joint Sup‐

en
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port - VAS6131/13-7- to 20 Nm on the scissor lift table.
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– Tighten the Scissor Lift Table - Touareg Set - Supports tho - or
VAS6131/6-7- on the scissor lift table as illustrateds auand sup‐ ac
s
port the transmission free of tension under the oil pan. The
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turntables with the long spindle are required for this.
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– Remove the bolts -3 and 9- and install the Electric Drive Unit
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Guide Pins - T10441- .

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Bolt -9- can be removed using the Bits for VAG1331/13 - Bit - cted agen
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T10099/1- .
– Remove all bolts for the electro-drive drive motor.

– Loosen the right and left clamping screws on the Scissor Lift
Table - VAS6131B- . Separate the electro-drive drive motor
with the transmission from the engine.
Caution
Be especially mindful that the hydraulic pipe for the clutch re‐
lease mechanism is not bent. The pipe must be replaced if
there is damage.
Connecting the Engine and Electro-Drive Drive Motor with Trans‐

mission:
Conditions:
• Needle bearing in the crankshaft was replaced.
• Engine and transmission with the electro-drive drive motor are
positioned on the Scissor Lift Table - VAS6131B- as when
separating.
• Alignment bushings are present in the engine.
• Hydraulic pipe for the clutch mechanism secured with cable
ties in its installation position.
– Thinly coat the drive axle splines with Lubricating Grease - N
052 530- .

– Coat the pin -1- thinly with Lubricating Grease - N 052 530- .
– Install the Electric Drive Unit Guide Pins - T10441- in the en‐
gine.
– Align the electro-drive drive motor with the centering pins.
Check if the input shaft is centered in front of the release bear‐
ing.
– Slide the electro-drive drive motor onto the engine. If neces‐
sary, correct the installation position of the transmission.
– Evenly install the electro-drive drive motor and engine.
Electro-Drive Drive Motor to Engine Tightening Specifications

Item Bolt Nm
1, 2, 3 M12x70 65
4 M10x85 with nut 45
5, 6, 7, 8 1) M10x60 20 + 90°
9 M12x70 65
10 M12x60 internal 65
multi-point
• 1) Replace
Assembly is performed in reverse order.
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1.5 Electro-Drive Drive Motor and Trans‐

nl
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mission, Separating
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♦ Shop Crane - VAS6100-

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♦ Lift Arm Extension - VAS6101-

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t to the co
♦ Engine/Gearbox Support Shackle (2 pc.) - 10-222A/12-

Conditions
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• Engine and electro-drive drive motor with transmission are

l purpos
separated. Refer to
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Separating
– Remove the cap -1-. Remove the three nuts for the torque
converter -arrow- through the opening in the transmission. To
do so, turn the input shaft an additional 120°.
– Support the electro-drive drive motor using the Shop Crane -

VAS6100- as shown.
– Remove the bolts -1 through 10- connecting the transmission

to the electro-drive drive motor.
– Remove the electro-drive drive motor using the Shop Crane -
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– To prevent it from falling, secure the torque converter in the h re

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transmission using the Bracket - Multiple Use - 30-211A- .

spec
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Assembling
Replace the bolts.
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– Check if the alignment bushings -arrows- are present in the

electro-drive drive motor.
– Pay attention to the installation position of the bolts -1- in the
torque converter -2-.
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– Position the electro-drive drive motor as shown on the trans‐
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mission using the Shop Crane - VAS6100- .
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– Tighten the bolts -1 through 10- connecting the transmission

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to the electro-drive drive motor.
at
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• Tightening specification: 30 Nm + 90° additional turn Replace

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– Tighten the three nuts for the torque converter -arrow- through
the opening in the transmission. To do so, turn the input shaft
an additional 120°. Insert the cap -1-.
• Tightening specification: 60 Nm

2 Subframe Mount
⇒ “2.1 Overview - Subframe Mount”, page 32
⇒ “2.2 Left Engine Support, Removing and Installing”,
page 32
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❑ Replace
hole
spec
2 - Right Engine Mount
es, in part or in w
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3 - Bolts
❑ 60 Nm
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4 - Bolts
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❑ 40 Nm
5 - Nuts
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❑ 75 Nm
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6 - Right Engine Support
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7 - Left Engine Support
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10 - Bolts
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❑ 60 Nm
11 - Left Engine Mount
12 - Engine Support
2.2 Left Engine Support, Removing and In‐

stalling
♦ Engine Support Bridge - 10-222A- with Engine Support Bridge
- Engine Support 29 - 10-222A/29-
♦ Engine Support - Bracket w/Spindle and Hook - 10-222A/10-
♦ Engine Support Bridge - Engine Support 3 - 10-222A/3-

♦ Quantity: 2 Engine Support - Basic Set - Square Pipes -

T40091/1-
♦ Engine Support - Basic Set - Rail with Holes - T40091/2-
♦ Quantity: 2 Engine Support - Basic Set - Moveable Joints -
T40091/3- n AG. Volkswagen A
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tho
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Removing
nl
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– Remove the A/C compressor. Refer to ⇒ Heating, Ventilation
erm
ab
and Air Conditioning; Rep. Gr. 87 ; A/C Compressor, Remov‐
ility
ot p
ing and Installing, Engine Codes CGEA and CGFA (Hybrid) .
wit
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– Remove the power steering fluid reservoir and move it to the
hole
spec
side.
es, in part or in w
t to the co
– Remove the engine mount nut -arrow-.
rrectness of i
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T40091/3- as well as the Engine Support Bridge - Engine
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Support 3 - 10-222A/3- onto the square pipe of the Engine
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– »Flip up« the right and left plenum chamber cover.
– Mount the Engine Support Bridge - Engine Support 29 -
10-222A/29- onto the square pipe.
– Position the engine support bridge as illustrated.
Caution
Do not mount the engine support bridge on the metal tabs

-arrows-.
2. Subframe Mount 33
– Push the Engine Support - Supplement Kit - Moveable Joint -

T40093/4- and Engine Support Bridge - Engine Support 28 -
10-222A/28- onto the Engine Support - Basic Set - Square
Pipe - T40091/1- .
– Place the Engine Support Bridge - Engine Support 28 -
10-222A/28- on the longitudinal member and slide the Engine
Support - Basic Set - Square Pipe - T40091/1- into the Engine
Support - Basic Set - Moveable Joint - T40091/3- .
– Slide the Engine Support - Basic Set - Rail with Holes -

T40091/2- through the Engine Support - Supplement Kit -
Moveable Joint - T40093/4- on one side.
– Slide the Engine Support - Supplement Kit - Mount - T40093/5-
onto the Engine Support - Basic Set - Rail with Holes -
T40091/2- and then the rail with holes into the moveable joint
agen
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– Install the locking pin and secure it with a splint.horis tee
t or
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– Tighten all threaded connections on the engine
ss support bridge
hand-tight.
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ility
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– Secure the two threaded spindles on the left lifting eyes as
wit
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shown.
h re
hole
spec
– Lift the engine evenly by both spindles until the engine mount
es, in part or in w
threaded pins are »free«.
t to the co
rrectness of i
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– Remove the bolts for the engine mount -arrows-. Remove the
in t
or
engine mount.
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Installing
p
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• Tightening specifications. Refer to op
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⇒ “2 Subframe Mount”, page 32 .
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– Insert and tighten the engine mount. co Vo
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– Slowly lower the engine and guide the threaded pin into the
AG.
engine support.
2.3 Right Engine Support, Removing and

Installing
♦ Engine Support Bridge - 10-222A- with Engine Support Bridge
- Engine Support 29 - 10-222A/29-
♦ Engine Support - Bracket w/Spindle and Hook - 10-222A/10-


♦ Quantity: 2 Engine Support - Basic Set - Square Pipes -
T40091/1-
♦ Engine Support - Basic Set - Rail with Holes - T40091/2-
♦ Quantity: 2 Engine Support - Basic Set - Moveable Joints -
T40091/3-
♦ Engine Support - Supplement Kit - Mount - T40093/5-
♦ Quantity: 2 Engine Support - Supplement Kit - Moveable Joints
- T40093/4-
Removing
– Completely remove the air filter housing. Refer to
⇒ “3.3 Air Filter Housing, Removing and Installing”,
page 301 .
– Remove the engine mount nut -arrow-.
AG. Volkswagen AG d
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– Slide the Engine Support - Basic Set - Moveable Joints -

h re
hole
T40091/3- as well as the Engine Support Bridge - Engine

spec
Support 3 - 10-222A/3- onto the square pipe of the Engine

es, in part or in w
t to the co
Support Bridge - 10-222A- .

– »Flip up« the right and left plenum chamber cover.
rrectness of i
– Mount the Engine Support Bridge - Engine Support 29 -

10-222A/29- onto the square pipe.
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– Position the engine support bridge as illustrated.

nform
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Caution
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Do not mount the engine support bridge on the metal tabs

o
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-arrow-.
at
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Cop py
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2. Subframe Mount 35
– Push the Engine Support - Supplement Kit - Moveable Joint -

T40093/4- and Engine Support Bridge - Engine Support 28 -
10-222A/28- onto the Engine Support - Basic Set - Square
Pipe - T40091/1- .
– Place the Engine Support Bridge - Engine Support 28 -
10-222A/28- on the longitudinal member and slide the Engine
Support - Basic Set - Square Pipe - T40091/1- into the Engine
Support - Basic Set - Moveable Joint - T40091/3- .
– Slide the Engine Support - Basic Set - Rail with Holes -

T40091/2- through the Engine Support - Supplement Kit -
AG. Volkswagen AG d
Moveable Joint - T40093/4- on one side. olkswagen oes
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– Slide the Engine Support - Supplement ris Kit - Mount - T40093/5-
ed
ara
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onto the Engine Support - Basic uSettho - Rail with Holes - eo
ra
T40091/2- and then the rail with
ss aholes into the moveable joint c
on the other side.
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– Install the locking pin and secure it with a splint.
itte
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– Tighten all threaded connections on the engine support bridge
ility
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hand-tight.
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hole
spec
es, in part or in w
– Secure the two threaded spindles on the right lifting eyes as
t to the co
shown.
– Lift the engine evenly by both spindles until the engine mount
rrectness of i
threaded pins are »free«.
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– Remove the bolts for the engine mount -arrows-.

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• Tightening specifications. Refer to
by lksw
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⇒ “2 Subframe Mount”, page 32 .
Prote AG.
– Insert and tighten the engine mount.

– Slowly lower the engine and guide the threaded pin into the
engine support.

3 Engine Cover
⇒ “3.1 Engine Compartment Cover, Removing and Installing”,
page 37
3.1 Engine Compartment Cover, Removing

and Installing
Note
The engine compartment cover is not installed on every vehicle.
Removing
– First remove the center part -1-.
– Carefully lift up parts 2 and 3 at the mounting points
-arrows-.
Installing
. Volkswagen AG
– Make sure the rubber buffers fit correctly into the mounts when wage
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installing. Volks not
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– Push the parts 2 and 3 onto the mounting points -arrows-.
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3. Engine Cover 37
– Install the center part -1-.
AG. Volkswagen AG d
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4 Special Tools
Special tools and workshop

equipment required
♦ Used Oil Collection and Ex‐
traction Unit - SMN372500-
♦ Engine Bung Set -
VAS6122-
♦ Shop Crane - Drip Tray -
VAS6208-
♦ Hose Clip Pliers -
VAS6362-
AG. Volkswagen AG d
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4. Special Tools 39
♦ Electric Drive Unit Guide

Pins - T10441-
♦ Scissor Lift Table - Q7 Set -
Articulated Joint Support -
VAS6131/13-7-
♦ Scissor Lift Table - Touareg
Set - Mount - VAS6131/6-7-
♦ Bits for VAG1331/13 - Bit -
T10099/1-
♦ Scissor Lift Table -
VAS6131B- .
♦ Engine Sling - 2024A-
♦ Engine And Transmission
Holder - VAS6095- with En‐
gine/Transmission Holder -
V6 FSI Bracket -
VAS6095/1-5-
♦ Shop Crane - VAS6100- agen
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VAS6101- horis nte
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♦ Engine Support Bridge - en AG. Volkswagen AG

10-222A- with EngineoSup‐ lksw
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♦ Engine Support
ss - Bracket
w/Spindle and Hook -
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10-222A/10-
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♦ Engine Support Bridge -
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♦ Engine Support Bridge -
spec
Engine Support 28 -
es, in part or in w
t to the co
10-222A/28-
♦ Quantity: 2 Engine Support
- Basic Set - Square Pipes
rrectness of i
- T40091/1-
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♦ Engine Support - Basic Set

- Rail with Holes -
nform
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T40091/2-
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- Basic Set - Moveable
n
c
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Joints - T40091/3-
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♦ Engine Support - Supple‐

p
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or
ment Kit - Mount -

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T40093/5-
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♦ Puller - Ball Joint - T10187-
♦ Not illustrated:
♦ Scissor Lift Table - Touareg Set - VAS6131/6-
♦ Scissor Lift Table - Touareg Set - Support - VAS6131/8-
4. Special Tools 41
13 – Crankshaft, Cylinder Block

1 Cylinder Block, Belt Pulley Side
⇒ “1.1 Overview - Supercharger Ribbed Belt Drive”, page 42
⇒ “1.2 Supercharger Ribbed Belt, Removing and Installing”, page
43
⇒ “1.3 Supercharger Ribbed Belt Tensioner, Removing and In‐
stalling”, page 44
⇒ “1.4 Overview - Ribbed Belt Drive”, page 44
⇒ “1.5 Ribbed Belt, Removing and Installing”, page 45
⇒ “1.6 Ribbed Belt Tensioner, Removing and Installing”,
page 46
⇒ “1.7 Vibration Damper, Removing and Installing”, page 48
⇒ “1.8 Sealing Flange, Removing and Installing, Belt Pulley Side”,
page 48
1.1 Overview - Supercharger Ribbed Belt Drive
1 - Supercharger Ribbed Belt

❑ Check for wear
❑ Removing and instal‐
ling. Refer to
⇒ “1.5 Ribbed Belt, Re‐ AG. Volkswagen AG d
moving and Installing”, agen oes
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page 45 . d by gu
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❑ When installing, make utho eo
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sure it is seated correct‐ ss a c
ly on the ribbed belt pul‐
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2 - Bolt
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❑ 42 Nm
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3 - Washer
hole
spec
4 - Cover
es, in part or in w
t to the co
5 - Supercharger
❑ Removing and instal‐ rrectness of i
ling. Refer to
⇒ “2.3 Supercharger,
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Removing and Instal‐

ling”, page 280 .
nf
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6 - Ribbed Belt Idler Roller

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m
atio
7 - Vibration Damper
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❑ With dual ribbed belt

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pulley
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❑ Installation is only pos‐

rp
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sible in one position be‐

f
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cause of the offset holes
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❑ Removing and instal‐ yri
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ling. Refer to cop Vo
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er, Removing and In‐
stalling”, page 48 .
42 Rep. Gr.13 - Crankshaft, Cylinder Block

8 - Bolt
❑ Tightening specification -item 2- ⇒ Item 2 (page 45) .
9 - Ribbed Belt Tensioner . Volkswagen AG
gen AG does
❑ Removing and installing. Refer toVolkswa not
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⇒ “1.3 Supercharger Ribbed Belt
ed b Tensioner, Removing and Installing”,
y ara page 44 .
n ris tee
10 - Bolt utho or
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ss
❑ 40 Nm
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1.2 Supercharger Ribbed Belt, Removing
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and Installing
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es, in part or in w
t to the co
♦ Locking Pin - T10060A-
Removing
rrectness of i
– Remove the engine compartment cover. Refer to
l purpos

page 37 .
nform
ercia
– Remove the front engine cover -1- upward.

m
at
om
ion
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Caution
in t
or
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ate
do
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Risk of damage due to reversed running direction on a used

p
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or
ribbed belt.
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♦ Before removing the ribbed belt, mark the running direc‐ Cop py
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tion with chalk or a felt-tip pen for reinstallation. gh ht
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– Pivot the tensioner clockwise in direction of -arrow- to release
the tension on the ribbed belt.
– Lock the tensioner using the Locking Pin - T10060A- and re‐
move the ribbed belt.
Installing
Install in reverse order of removal while noting the following:
1. Cylinder Block, Belt Pulley Side 43

– Place the ribbed belt over the pulley as illustrated:

1- Tensioner
2- Supercharger
3- Idler roller
4- Vibration damper
Note
When installing the ribbed belt, ensure it is seated correctly on

the ribbed belt pulleys.
– Start the engine and check the ribbed belt routing.
1.3 Supercharger Ribbed Belt Tensioner,

Removing and Installing
Removing n AG. Volkswagen AG do
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– Remove the supercharger ribbed belt. Refer
ir se
d to
b ua
ran
⇒ “1.2 Supercharger Ribbed Belt, Removing
tho and Installing”, tee
or
page 43 . ss
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– Remove the bolt -1- and remove the ribbed belt tensioner
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• Tightening specification. Refer to

⇒ “1.1 Overview - Supercharger Ribbed Belt Drive”, spec
es, in part or in w
t to the co
page 42 .
– Install the supercharger ribbed belt. Refer to
⇒ “1.2 Supercharger Ribbed Belt, Removing and Installing”,
rrectness of i
page 43 .
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1.4 Overview - Ribbed Belt Drive

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1 - Ribbed Belt
❑ Check for wear
❑ Before removing, mark
direction of rotation us‐
ing chalk or felt-tip mark‐
er
ling. Refer to
⇒ “1.5 Ribbed Belt, Re‐
moving and Installing”,
page 45 .
❑ Do not kink
❑ When installing, make
sure it is seated correct‐
ly on the ribbed belt pul‐
leys
2 - Bolt
❑ 20 Nm + 90° additional
turn
❑ Replace
3 - Vibration Damper
❑ With dual ribbed belt
pulley
❑ Removing and instal‐ AG. Volkswagen AG d
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ling. Refer to Volksw
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⇒ “1.7 Vibration Damp‐ ed by ara
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er, Removing and In‐ horis
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4 - Sealing Flange, Belt Pulley

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❑ Replace. Refer to ab
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hole
spec
page 48 .
es, in part or in w
t to the co
5 - Bolt
rrectness of i
6 - Coolant Pump Ribbed Belt Pulley

❑ Removing and installing. Refer to ⇒ “2.3 Coolant Pump, Removing and Installing”, page 201 .
l purpos
7 - Coolant Pump
nform
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❑ Removing and installing. Refer to ⇒ “2.3 Coolant Pump, Removing and Installing”, page 201 .
m
at
8 - Bolt
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9 - Ribbed Belt Tensioner

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❑ Tighten the bolt to 40 Nm.

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❑ Removing and installing. Refer to ⇒ “1.6 Ribbed Belt Tensioner, Removing and Installing”, page 46 .
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1.5 Ribbed Belt, Removing and Installing
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Prote AG.
Removing:
– Remove the supercharger ribbed belt. Refer to
page 43 .

Caution
Risk of damage due to reversed running direction on a used

ribbed belt.
♦ For installing the ribbed belt again, mark the running di‐
rection with chalk or a felt tip pen.
– Pivot the tensioner clockwise in direction of -arrow- to release

the tension on the ribbed belt.
– Remove the ribbed belt and release the tension on the ten‐
sioner.
Installing
– Place the ribbed belt over the pulley as illustrated.

1- Coolant Pump
2- Ribbed Belt Tensioner
3- Vibration Damper
AG. Volkswagen AG d
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When installing the ribbed belt, sensure it is seated correctly on
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page 43 .
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– Start the engine and check the ribbed belt routing.

spec
es, in part or in w
t to the co
1.6 Ribbed Belt Tensioner, Removing and

Installing
rrectness of i
Removing
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page 37 .
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– Remove the bolt for the coolant pipe -1-. Ignore the -arrows-.
– Remove the noise insulation. Refer to ⇒ Body Exterior; Rep.
Gr. 50 ; Overview - Noise Insulation .
lkswage es n
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– Remove the bolts for theriscoolant
ed pipes -1 through 3-. ran
tee
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– Pivot the tensioner clockwise -arrow- to release the tension on

the ribbed belt.
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– Remove the ribbed belt from the tensioning element and re‐
lease the tension on the tensioner.
nform
ercia
– Remove the bolt -1-.

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Prote AG.

– Push the coolant pipes aside and remove the ribbed belt ten‐
sioner -2- from the cylinder block.
Installing
⇒ “1.4 Overview - Ribbed Belt Drive”, page 44 .
– Install the ribbed belt. Refer to
⇒ “1.5 Ribbed Belt, Removing and Installing”, page 45 .
1.7 Vibration Damper, Removing and Instal‐

ling
♦ Wrench - Pin Type - 3036- agen
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– Remove the supercharger
utho
ribbed belt. Refer to eo
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a
⇒ “1.2 Supercharger
ss Ribbed Belt, Removing and Installing”, c
page 43 .
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– Remove the ribbed belt. Refer to
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– Counterhold with the Wrench - Pin Type - 3036- and remove

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the bolts -1- for the vibration damper. h re

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spec
– Remove the vibration damper. t to the co
Installing
rrectne
♦ Tightening specification. Refer to -item 2-

⇒ Item 2 (page 45) .
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♦ Replace the vibration damper bolts.

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♦ Installation is only possible in one position because of the off‐

mer
atio
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page 43 . Cop py
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1.8 Sealing Flange, Removing and Instal‐
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ling, Belt Pulley Side
♦ Wrench - Pin Type - 3212-
♦ Assembly Tool - T40048A-
♦ Hand drill with plastic brush attachment
♦ Protective eyewear
♦ Sealant. Refer to the Parts Catalog.
Procedure
– Remove the ribbed belt. Refer to

– Remove the vibration damper. Refer to

⇒ “1.7 Vibration Damper, Removing and Installing”, page 48 .
– Remove the supercharger ribbed belt idler roller.
– Remove the bolts for the coolant pump ribbed belt pulley by
counterholding with a Wrench - Pin Type - 3212- .
– Remove the ribbed belt pulley.
– Remove the bolts -arrows-.
Note
The sealing flange on the belt pulley side is always replaced.
– Carefully loosen the sealing flange on the ribbed belt side from
the bond.
Caution
Risk of contaminating the lubricating system.

♦ Cover open parts of the engine.
WARNING
Danger of eye injury.

♦ Wear protective eyewear.
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– Remove the sealant residue on the cylinder block and the up‐
ce
le
un
pt
per section of the oil pan, for example using a rotating plastic
an
d
itte
brush.
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– Clean the sealing surfaces; they must be free of oil and grease. ility
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es, in part or in w
t to the co
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Note
Be sure to check the expiration date of the sealant.
– Cut the tube nozzle at the front marking (nozzle diameter:

about 2 mm).
Caution
The lubrication system could be blocked with excess sealant.

♦ Do not apply sealant bead thicker than indicated.
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– Apply the sealant bead as illustrated
au to the clean sealing sur‐ ac
face of the sealing flange. ss
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• The groove -arrow- of sealing surface must be completely fil‐
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• The sealant bead must be 1.5 to 2.0 mm above the sealing
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surface.
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Note
t to the co
The sealing flange must be installed within five minutes after ap‐
plying the sealant.
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– Place the Seal Installer - Crankshaft - Assembly Device -

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cu
T40048/1- on the Seal Installer - Crankshaft - Pull Sleeve -

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T40048/2- and slide the sealing flange -1- onto the pull sleeve.
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– Remove the assembly aid.
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– Then position the sealing flange -1- with the Seal Installer -
Crankshaft - Pulling Sleeve - T40048/2- installed on the crank‐
shaft.
– Push the sealing flange onto engine sealing surface without
tilting it.
– Tighten the bolts -arrows- diagonally in stages to 9 Nm.
Install in reverse order of removal, note the following:
– Install the coolant pump ribbed belt pulley. Refer to
⇒ “2.1 Overview - Coolant Pump/Thermostat”, page 198 .
– Install the vibration damper. Refer to

⇒ “1.7 Vibration Damper, Removing and Installing”, page 48 .
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2 Cylinder Block, Transmission Side

⇒ “2.1 Overview - Drive Plate”, page 52
⇒ “2.2 Drive Plate, Removing and Installing”, page 53
⇒ “2.3 Sensor Wheel, Removing and Installing”, page 53
⇒ “2.4 Sensor Wheel, Checking”, page 54
⇒ “2.5 Crankshaft Seal, Replacing, Transmission Side”,
page 54
2.1 Overview - Drive Plate
1 - Drive Plate
❑ Installation is only pos‐
sible in one position be‐
cause of the offset holes
ling. Refer to
⇒ “2.2 Drive Plate, Re‐
moving and Installing”, agen
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❑ Replace
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3 - Alignment Pin
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4 - Sensor Wheel
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❑ Sensor wheel, removing
hole
spec
and installing. Refer to
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⇒ “2.3 Sensor Wheel,

Removing and Instal‐ t to the co
ling”, page 53 .
rrectness of i
❑ For Engine Speed Sen‐

sor - G28-
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❑ Engine Speed Sensor -

G28- , removing and in‐
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stalling. Refer to
⇒ “1.6 Engine Speed
m
Sensor G28 , Removing

com
tion in
and Installing”,
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page 362 .
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♦ There is a risk of destroying the C py
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sensor wheel by magnetic force.
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♦ Do not place the sensor wheel cted agen
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near magnets (for example in‐
spection lamp base, or speak‐
ers).
♦ If the drive plate or the sensor
wheel disjoints itself or was re‐
placed, the sensor wheel func‐
tion must be checked before
installing. Refer to
⇒ “2.4 Sensor Wheel, Checking”,
page 54 .

5 - Needle Bearing
Removing and installing. Refer to ⇒ “3.5 Crankshaft Needle Bearing, Removing and Installing”, page 62 .
6 - Shaft Seal
❑ For the crankshaft on the transmission side
❑ Replacing. Refer to ⇒ “2.5 Crankshaft Seal, Replacing, Transmission Side”, page 54 .
7 - Crankshaft
8 - Rubber Plug
9 - Engine Speed Sensor - G28-
❑ Removing and installing. Refer to
⇒ “1.6 Engine Speed Sensor G28 , Removing and Installing”, page 362 .
2.2 Drive Plate, Removing and Installing

♦ Counterhold - Pulley - 3435-
♦ Two M8x20 bolts
wage
Removing: olks es n
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• Engine with transmission removed handor electro-drive drive mo‐
is tee
tor removed from the engine. Refer
au to ⇒ Rep. Gr. 10 .
t or
ac
ss
– Remove the clutch. Refer to ⇒ Rep. Gr. 30 ; Clutch, Removing
ce
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and Installing .
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– Attach the Counterhold - Pulley - 3435- to the drive plate using
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two M8x20 bolts -arrows-.
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Note
es, in part or in w
t to the co
♦ Risk of destroying the sensor wheel for the Engine Speed
Sensor - G28- by magnetic force.
♦ Do not place the sensor wheel near magnets (for example in‐ rrectness of i
spection lamp base, or speakers).
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– Remove the drive plate bolts and the drive plate.

nform
ercia
Installing:
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• Before installing the drive plate, check the function of the sen‐
at
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sor wheel. Refer to

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⇒ “2.4 Sensor Wheel, Checking”, page 54 .

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• Tightening specification. Refer to Cop py
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• Replace the drive plate bolts.
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2.3 Sensor Wheel, Removing and Installing

Removing
• Engine with transmission removed and electro-drive drive mo‐
tor removed from the engine. Refer to ⇒ Rep. Gr. 10 .
– Remove the drive plate. Refer to
⇒ “2.2 Drive Plate, Removing and Installing”, page 53 .
2. Cylinder Block, Transmission Side 53

– Remove the sensor wheel -arrow-.

Installing
Install in reverse order of removal. Note the following:
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olk plate, check the functionnoof
t guthe sen‐
ara
sor wheel. Referris to
ed
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⇒ “2.4 Sensor
ut Wheel, Checking”, page 54 .
ho eo
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– Install the drive plate. Refer to
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2.4 Sensor Wheel, Checking
spec
t to the co
♦ Gauge - Sender Wheel - T10473-
rrectne
Procedure
• Sensor wheel removed.
ss o
– Check the entire circumference of the sensor wheel with the
cial p
f in
Gauge - Sender Wheel - T10473- as shown.
form
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Sensor wheel test diagram

A - Sensor Wheel OK
B - Sensor Wheel Faulty
2.5 Crankshaft Seal, Replacing, Transmis‐

sion Side
♦ Seal Installer - Crankshaft - Guide Piece - T10122/6-
♦ Seal Installer - Crankshaft - T10122A-

♦ Puller - Crankshaft/Power Steering Seal - T20143/2-

Procedure
• Electro-drive drive motor is removed.
– Remove the trigger wheel from the crankshaft stub.
– Pry out the shaft seal using the Puller - Crankshaft/Power
Steering Seal - T20143/2- .
– Clean the running and sealing surface.
– Insert the Guide Piece - T10122/1- on the Seal Installer -

Crankshaft - Guide Piece - T10122/6- and push the shaft seal
-A- on the guide piece.
– Remove the Guide Piece - T10122/1- .
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t to the co
– Position the Crank Shaft Seal Installer - Guide Piece -
T10122/6- on the crankshaft.
rrectness of i
– Attach the Crank Shaft Seal Installer - Guide Piece - T10122/6-
through the mounting points -A- with the bolts -arrows- on the
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crankshaft.
nform
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Caution
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There is a risk of leaks due to incorrect assembly.

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♦ To prevent the shaft seal sealing lip from rolling onto itself,
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insert the shaft seal by hand on the crankshaft.

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– Push the shaft seal by hand using the Crank Shaft Seal In‐
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2. Cylinder Block, Transmission Side 55

– Press the shaft seal in evenly all around with Thrust Piece -
T10122/5- .
– Remove the Crank Shaft Seal Installer - Guide Piece -
T10122/6- .
– Check the shaft seal as well as the sealing lip for correct seat‐
ing. If the sealing lip are partially turned repeat the procedure
with a new shaft seal.
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⇒ “3.1 Overview - Crankshaft”, page 57 horis nte
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⇒ “3.2 Crankshaft Dimensions”, page 60 ss c
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⇒ “3.3 Crankshaft, Measuring Axial Play”, page 60
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⇒ “3.4 Crankshaft, Measuring Radial Clearance”, page 61
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3.1 Overview - Crankshaft
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1 - Sealing Flange, Belt Pulley
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Side
❑ Replacing. Refer to
⇒ “1.8 Sealing Flange,
rrectness of i
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page 48 .
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2 - Bolt
orm
❑ Tightening specification
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and sequence. Refer to

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⇒ “1.8 Sealing Flange,

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page 48 .
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3 - Crankshaft . Cop py
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❑ Axial play, measuring. rig ht
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Refer to
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⇒ “3.3 Crankshaft,
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Prote AG.
Measuring Axial Play”,
page 60 .
❑ Radial play, measuring.
Refer to
⇒ “3.4 Crankshaft,
Measuring Radial
Clearance”, page 61 .
❑ Crankshaft dimensions.
Refer to
⇒ “3.2 Crankshaft Di‐
mensions”, page 60 .
4 - Alignment Sleeve
❑ Quantity: 4
❑ Insert into guide frame.
Refer to
⇒ Fig. ““Sealant Appli‐
cation for Guide Frame,
Position of Alignment
Bushings”“ , page 59
5 - Seal
❑ Replace
6 - Bolt
❑ For guide frame to cylinder block sealing surfaces
❑ There are different bolt lengths and bolt heads
❑ Tightening sequence. Refer to ⇒ Fig. ““Installing Guide Frame”“ , page 59
7 - Long Bolt, Large Collar
❑ For inner row of guide frame
❑ Replace
3. Crankshaft 57
8 - Short Bolt, Small Collar
❑ For outer row of guide frame
9 - Guide Frame
❑ With Oil Pressure Regulation Valve - N428-
❑ To remove, remove the timing chain guide rail -item 1- ⇒ Item 1 (page 106) .
❑ Sealant application. Refer to
⇒ Fig. ““Sealant Application for Guide Frame, Position of Alignment Bushings”“ , page 59
❑ Oil Pressure Regulation Valve - N428- , removing and installing. Refer to
⇒ “4.7 Oil Pressure Regulation Valve N428 , Removing and Installing”, page 174 .
10 - Gasket agen
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11 - Thrust Washer uthor eo
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❑ Only on thesthird crankshaft bearing
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❑ Lubricating grooves face outward

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❑ Note locating point in the guide frame
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❑ Measuring crankshaft axial clearance. Refer to ⇒ “3.3 Crankshaft, Measuring Axial Play”, page 60 .
ility
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12 - Bearing Shell
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ole,
❑ For guide frame without oil groove
spec
❑ mark used bearing shells for reinstallation but not on the running surface
t to the co
❑ Replace the bearing shells worn down to the base layer
❑ Note the installation position rrectne
❑ Insert new bearing shells for guide frame with proper color marking. Refer to
⇒ Fig. ““Allocation of Crankshaft Bearing Shells for Guide Frame”“ , page 60
ss o
13 - Thrust Washer
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❑ Only on the third crankshaft bearing

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❑ Lubricating grooves face outward

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❑ Pay attention to the locating point on the cylinder block

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❑ Measuring crankshaft axial clearance. Refer to ⇒ “3.3 Crankshaft, Measuring Axial Play”, page 60 .
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14 - Bearing Shell
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❑ For cylinder block with oil groove
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❑ mark used bearing shells for reinstallation but not on the running surface
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❑ Replace the bearing shells worn down to the base layer
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❑ Note the installation position
AG.
❑ Insert new bearing shells for cylinder block with proper color marking. Refer to
⇒ Fig. ““Allocation of Crankshaft Bearing Shells for Cylinder Block”“ , page 60
15 - Cylinder Block

Sealing Plug for Crankshaft “TDC” Mark
Note
♦ The sealing plug is located under the left engine support.

♦ Replace the gasket.
– Tighten the locking bolt -arrow- to 14 Nm.
Sealant Application for Guide Frame, Position of Alignment Bush‐

ings
– Clean the sealing surfaces; they must be top and bottom free
from oil and grease.
– Apply sealant beads -arrows- to the clean sealing
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the guide frame as shown in theolkillustration. does
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• The groove of sealing surface
ris
ed must be completely filled with nte
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• The sealant beads must be 1.5 to 2.0 mm above the sealing
ce
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nl
surface.
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– Position the seals -1 and 2-.
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– Check if alignment bushings -3 through 6- are inserted at the
wit
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locations in the guide frame as shown in the illustration.
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hole
spec
es, in part or in w
t to the co
rrectness of i
Installing Guide Frame
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– Replace the bolts -1 through 16- for the guide frame.

– Insert the long bolts in the inner row of the guide frame.
nform
ercia
– Tighten the bolts -1 through 31- in 3 steps as follows:

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om
io
Step Bolts Tightening Specification/Additional

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Turn
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ate
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1. -1 to 16- 50 Nm
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or
2. -1 to 16- Turn an additional 90°.

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3. -17 to 31- 23 NmC py
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3. Crankshaft 59
Allocation of Crankshaft Bearing Shells for Cylinder Block

♦ Bearing shells with the correct thickness are allocated to the
cylinder block in the factory. Colored dots on sides of bearing
shells serve for identifying the bearing shell thickness.
♦ Allocation of bearing shells to cylinder block is marked by a
letter on the respective bearing on guide frame -1 through 4-.
Letter on Guide Frame Color of Bearing
R = Red
G = Yellow
B = Blue
S = gen AG. VolkswaBlack
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Allocation of Crankshaft Bearing Shells for Guide Frame
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♦ Bearing shells with the correct thickness are allocated to the
, is n
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guide frame in the factory. Colored dots on sides of bearing
hole
spec
shells serve for identifying the bearing shell thickness.
es, in part or in w
t to the co
♦ The allocation of the bearing shells to the guide frame is
marked on the transmission flange of the crankshaft by a row
of letters. The first letter in the row of letters represents bearing rrectness of i
“1”, the second letter is for bearing “2”, etc.
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Letter on Crankshaft Color of Bearing

R = Red
nf
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G = Yellow
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B = Blue
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S = Black
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3.2 Crankshaft Dimensions
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Honing Di‐ Crankshaft Bearing Pin Connecting Rod Pin Di‐
mension Diameter ameter
mm mm
Standard di‐ 65.00 – 0.022 56.00 – 0.022
mension – 0.042 – 0.042
3.3 Crankshaft, Measuring Axial Play

♦ Dial Gauge Holder - VW387-
♦ Dial Gauge - 0-10mm - VAS6079-

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For assembly work, secure the engineris on the Engine and Gear‐
ed
nte
box Bracket - VAS6095A- . Referauto
tho eo
ra
⇒ “1.2 Engine, Securing to Engine
ss and Gearbox Bracket c
VAS6095A ”, page 20 .
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Procedure: rm
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– Attach the Dial Gauge - 0-10mm - VAS6079- with the Dial
ot
wit
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Gauge Holder - VW387- to the cylinder block and set against
h re
hole
the crankshaft counterweight.
spec
es, in part or in w
– Press the crankshaft against the dial gauge by hand.
t to the co
– Set the dial gauge to “0”.
– Press the crankshaft off the dial indicator and read the value.
rrectness of i
• Axial play: 0.15 to 0.25 mm.
l purpos
nform
mercia
3.4 Crankshaft, Measuring Radial Clear‐
a
com
tion in
ance
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♦ Plastigage®
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Procedure
t. rig
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Prote AG.
Note
♦ Mark the used bearings for installation later, but not on the
running surface.
♦ If the bearing shells are worn down to the base layer, they must
be replaced.
♦ For assembly work, secure the engine on the Engine and
Gearbox Bracket - VAS6095A- . Refer to
⇒ “1.2 Engine, Securing to Engine and Gearbox Bracket
VAS6095A ”, page 20 .
– Remove the guide frame and clean the bearing journals.

– Place the Plastigage® over entire width of bearing journal or
into the bearing shells.
• Plastigage® must rest in center of bearing shell.
– Install the guide frame and tighten to 50 Nm. Do not turn
crankshaft.
– Install the guide frame.
– Compare the width of Plastigage® with the measuring scale.
Radial clearance:
• New: 0.015 to 0.055 mm.
• Wear limit: 0.08 mm.
3. Crankshaft 61
3.5 Crankshaft Needle Bearing, Removing

and Installing
♦ Counter-support for example Puller - Kukko Counterstay -
22/1-
♦ Internal puller, for example Puller - Kukko Internal - 14-19mm
- 21/2-
Removing
• Engine with transmission removed and electro-drive drive mo‐
tor removed from the engine. Refer to ⇒ Rep. Gr. 10 .
– Remove the clutch. Refer to ⇒ Rep. Gr. 30 ; Clutch, Removing
and Installing .
– Remove the needle bearing using a commercially available
internal puller, for example Puller - Kukko Internal - 12-16mm
- 21/2- and a counter-support, for example Puller - Kukko
Counterstay - 22/1- -A-.
Installing
– Drive in the needle bearing with a suitable drift.
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4 Balance Shaft
⇒ “4.1 Overview - Balance Shaft”, page 63
⇒ “4.2 Balance Shaft, Removing and Installing”, page 63
4.1 Overview - Balance Shaft
1 - Balance Shaft
ling. Refer to
⇒ “4.2 Balance Shaft,
ling”, page 63 .
wage
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❑ 60 Nm ir se
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❑ For loosening and tight‐ s aut or
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3 - Transmission Side Balance
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Weight
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❑ Can only be placed on
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the balance shaft in one
spec
es, in part or in w
position
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4 - Gear Carrier
5 - Bolt
rrectness of i
❑ 13 Nm
l purpos
6 - Balance Shaft Belt Pulley

Side
nform
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❑ Can only be placed on

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position
n
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7 - Bolt
at
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❑ 60 Nm
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❑ For loosening and tight‐

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ening, use the Locating . Cop py
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4.2 Balance Shaft, Removing and Installing

♦ Locating Pins - T40116-
Removing
• Engine removed. Refer to
⇒ “1.1 Engine, Removing”, page 7 .
• Engine and electro-drive drive motor separated. Refer to
– Remove the belt pulley side sealing flange. Refer to
⇒ “1.8 Sealing Flange, Removing and Installing, Belt Pulley
Side”, page 48 .
4. Balance Shaft 63
– Remove the lower timing chain cover. Refer to

⇒ “2.3 Lower Timing Chain Cover, Removing and Installing”,
page 97 .
– Remove the power take-off drive chain. Refer to
⇒ “3.6 Drive Chain Balance Shaft, Removing and Installing”,
page 112 .
– Secure the rear balance weight -1- to the engine using the
Locating Pins - T40116- .
– Remove the bolt -2- and remove the balance weight from the
balance shaft.
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using the drift and remove the balance weight -1- from balance
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shaft at the front of the engine.
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– Remove the bolts -arrows- and the balance shaft and bearing
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end bracket at the rear of the engine.
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– Remove the balance shaft back out of the cylinder block.

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⇒ “4.1 Overview - Balance Shaft”, page 63 .
• Crankshaft -1- secured in “TDC” using Crankshaft Locking Pin
. Volkswagen AG
- T40069- . swagen AG does
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Install in reverse order of removal
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The balance weights can only be positioned one way on balance
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– Install the power take-off drive chain. Refer to
ole,
spec
page 112 .
t to the co
– Install the lower timing chain cover. Refer to
page 97 .
rrectne
– Install the belt pulley side sealing flange. Refer to
s
⇒ “1.8 Sealing Flange, Removing and Installing, Belt Pulley
s o
Side”, page 48 .
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4. Balance Shaft 65
5 Piston and Connecting Rod

⇒ “5.1 Overview - Piston and Connecting
agen
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⇒ “5.2 Pistons and Cylinder
ed
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ac
page 69 ss
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5.1 Overview - Piston and Connecting Rod
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spec
es, in part or in w
❑ Replace
t to the co
❑ Lubricate the threads
and contact surface.
rrectness of i
❑ Use old bolts to meas‐
ure the radial clearance.
l purpos
Tighten to 50 Nm, but do

not turn further
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2 - Connecting Rod Bearing
rm
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Cap
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n in
❑ Mark for installation lat‐
or c
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❑ Mark the allocation to

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the cylinder with paint.

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❑ Installation position of
AG.
the connecting rod

pairs. Refer to
⇒ Fig. ““Connecting
Rod, Installed Loca‐
tion”“ , page 68
3 - Bearing Shells
❑ Make sure the tabs are
secure.
❑ Mark used bearing
shells for reinstallation
but not on the running
surface
❑ Radial play, measuring.
Refer to
⇒ “5.3 Connecting
Rods, Checking Radial Clearance”, page 69 .
❑ For reworked connecting rod pins, oversized bearings are available. Refer to the Parts Catalog.
❑ The connecting rod tabs are above each other
4 - Connecting Rod
❑ Always replace as a set.
❑ Mark the allocation to the cylinder with paint. Refer to ⇒ Fig. ““Connecting Rod, Marking”“ , page 67
❑ Installation position of the connecting rod pairs. Refer to
⇒ Fig. ““Connecting Rod, Installed Location”“ , page 68
❑ Axial play for each new connecting rod pair: 0.20 to 0.45 mm
❑ Radial play, measuring. Refer to ⇒ “5.3 Connecting Rods, Checking Radial Clearance”, page 69 .

5 - Circlip
❑ Replace
6 - Piston Pin
❑ If difficult to move, warm the piston up to approximately 60 °C (140 °F)
❑ Remove and install using the Pilot Drift - VW222A-
7 - Piston
❑ Mark the installation position and cylinder allocation. Refer to
⇒ Fig. ““Piston Installed Position”“ , page 67
❑ Check. Refer to ⇒ Fig. ““Pistons, Checking”“ , page 69 .
❑ Install with piston ring compressor
❑ Checking the cylinder bore. Refer to ⇒ Fig. ““Cylinder Bore, Checking”“ , page 69 .
8 - Piston Rings
❑ Offset gaps by 120°
❑ Use piston ring pliers for removing and installing
❑ Installed position: “TOP” marking or side with writing faces the piston crown.
❑ Measuring the gap. Refer to ⇒ Fig. ““Checking the Piston Ring Gap”“ , page 68
❑ Measuring side clearance. Refer to ⇒ Fig. ““Piston Ring Groove Clearance, Checking”“ , page 68
Piston Installed Position
Caution
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♦ Mark the allocation to the cylinder on the piston hor
crown to eo
ut
install the pistons. Use paint for this. Do not
ss amark the pis‐ ra
c
ton head with a punch, notch or something similar.
ce
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un
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an
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• Installed position: the arrow on piston face points toward belt
pe
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pulley side.
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Connecting Rod, Marking
spec
es, in part or in w
t to the co
Note
rrectness of i
Only replace connecting rod as a set.
l purpos
– Mark the connecting rod and connector rod bearing caps to

each other and to the cylinder -arrow- with paint for installation.
nform
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5. Piston and Connecting Rod 67

Connecting Rod, Installed Location

• The molded tabs -arrows- on the beveled surfaces of the con‐
necting rod pairs “1 and 2”, “3 and 4” and “5 and 6” must face
each other.
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♦ Do not bend the oil spray nozzles.

un
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an
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♦ Replace the oil spry nozzles if they are bent.
erm
ab
ility
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1- Insert the bolt with locking compound and tighten to 9 Nm.
is n
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Refer to the Parts Catalog for the locking compound.
ole,
spec
2- Oil spray jet with spray nozzle valve (opening pressure 2 to
t to the co
2.4 bar (29 to 34.8 psi) excess pressure).
5.2 Pistons and Cylinder Bore, Checking
rrectne
Checking the Piston Ring Gap
ss o
– Push the piston ring squarely from above down to the edge of
cial p
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the cylinder, until it is approximately 15 mm from the edge of
nform
the cylinder.
mer
atio
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– Use a piston without a piston ring for sliding in.

o
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Piston Ring New Wear Limit

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mm mm
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Not determined yet.
AG.
Piston Ring Groove Clearance, Checking

– Clean the piston ring groove before checking.
Piston Ring New Wear Limit
mm mm
Oil Scraping Ring 0.02 to 0.06 0.15

Pistons, Checking

♦ Outside Micrometer - 75-100mm - VAS6071-
– Take measurement approximately 10 mm from lower edge of
piston skirt and offset 90° to piston axis.
• Specified size: 84.49 mm. Maximum deviation: 0.03 mm.
Cylinder Bore, Checking
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♦ Cylinder Dial Bore Gauge - VAS6078-

rrectness of i
– Using a Cylinder Dial Bore Gauge - VAS6078- measure in a

diagonal sequence at three positions transversely -A- and lon‐
l purpos
gitudinally -B-.
• Nominal size: 84.51 mm. Maximum deviation: 0.08 mm.
nform
ercia
5.3 Connecting Rods, Checking Radial

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at
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Clearance
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♦ Plastigage®
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Procedure: Cop py
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– Remove the connecting rod bearing cap. p by
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– Clean the bearing cap and pin. Prote AG.
– Place the Plastigage® over the entire width of the bearing

journal or into the bearing shells.
– Mount the connecting rod bearing cap and tighten the old bolts
to 50 Nm without tightening further. Do not turn crankshaft.
5. Piston and Connecting Rod 69

– Install the connecting rod bearing cap.

Radial clearance:
• New: 0.010 to 0.052 mm.
– Replace the connecting rod bolts.
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Engine Mechanical, Fuel Injection and eIgnition
n AG. Volk(Hybrid)
swagen AG- Edition 07.2015
ag does
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6 Special Tools ris nte
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♦ Locking Pin - T10060A-
itte
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♦ Seal Installer - Crankshaft - T10122A-

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ate
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♦ Gauge - Sender Wheel - T10473-
♦ Puller - Crankshaft/Power Steering Seal - T20143/2-
6. Special Tools 71
♦ Assembly Tool - T40048A-
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♦ Counter-support for example Puller - Kukko Counterstay -

22/1-
♦ Internal puller, for example Puller - Kukko Internal - 14-19mm

- 21/2-
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♦ Wrench - Pin Type - 3036- ss a c
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6. Special Tools 73
♦ Counterhold - Pulley - 3435-
♦ Seal Installer - Crankshaft - Guide Piece - T10122/6-

AG. Volkswagen AG d
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15 – Cylinder Head, Valvetrain

1 Cylinder Head
⇒ “1.1 Overview - Cylinder Head”, page 75
⇒ “1.2 Left Cylinder Head Cover, Removing and Installing”, page
78
⇒ “1.3 Right Cylinder Head Cover, Removing and Installing”, page
80
⇒ “1.4 Cylinder Head, Removing and Installing”, page 82
⇒ “1.5 Compression, Checking”, page 89
1.1 Overview - Cylinder Head
Note
The cylinder head for cylinder bank 2 (left) is shown in the illustration.
1 - Cylinder Head Gasket

❑ Replacing. Refer to
⇒ “1.4 Cylinder Head,
Removing and Instal‐ n AG. Volkswagen AG do
ling”, page 82 . lkswage es n
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❑ Installed position: the ir se
d ran
tee
part number faces the utho
or
cylinder head ss
a ac
ce
le
❑ Change the coolant and

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an
engine oil after replac‐
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2 - Cylinder Head
ot
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, is n
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hole
ling. Refer to
spec
⇒ “1.4 Cylinder Head,
es, in part or in w
t to the co
ling”, page 82 .
❑ Check for distortion. Re‐
rrectness of i
fer to
⇒ Fig. ““Checking the
l purpos
Cylinder Head for Dis‐

tortion”“ , page 77
nform
ercia
❑ Reworking dimension.
Refer to
m
a
com
ti
⇒ Fig. ““Reworking Di‐

on in
mension, Cylinder
r
te o
thi
Head”“ , page 78
s
iva
do
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❑ Change the coolant and

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3 - O-Ring
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❑ Replace
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4 - Camshaft Position Sensor

❑ Cylinder bank 1 (right)
Camshaft Position Sen‐
sor - G40-
❑ Cylinder bank 2 (left) Camshaft Position Sensor 2 - G163-
1. Cylinder Head 75
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gen AG d
Touareg 2010 V➤ olk,s Touareg 2015 ➤
wa oes
not
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Engine Mechanical,
ised b Fuel Injection and Ignition (Hybrid)
ara
n - Edition 07.2015
r tee
ho
ut or
5 - Bolt ss
a ac
ce
le
❑ Tightening specification. Refer to ⇒ Rep. Gr. 28 .
un
pt
an
d
itte
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6 - Cylinder Head Bolt
rm
ab
pe
❑ Replace
ility
ot
wit
, is n
❑ Follow the sequence when loosening. Refer to ⇒ page 86
h re
hole
❑ Tightening specification and sequence. Refer to
spec
⇒ Fig. ““Cylinder Head - Tightening Specification and Sequence”“ , page 77 .
es, in part or in w
t to the co
Note
rrectness of i
♦ Cylinder head bolts without a col‐
lar have a Polydrive wrench pro‐
l purpos
file.
♦ Cylinder head bolts with a collar
nform
ercia
have an internal multi-point

wrench profile.
m
a
com
tion in
♦ If the cylinder head bolt with col‐
r
te o
thi
lar »sticks« on the camshafts
s
iva
when removing the camshafts
do
r
rp
c
must be removed if necessary.
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fo
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7 - Ignition Coil
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❑ Removing and installing. Refer to ⇒ Rep. Gr. 28 . p by
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8 - Cylinder Head Cover Prote AG.

⇒ “1.2 Left Cylinder Head Cover, Removing and Installing”, page 78 for the left side and
⇒ “1.3 Right Cylinder Head Cover, Removing and Installing”, page 80 for the right side.
9 - Seal
❑ Replace if damaged or leaking
10 - Cap
11 - Crankcase Ventilation Pipe
12 - O-Ring
❑ Replace
13 - Bolt
❑ Replace if the seal is damaged
❑ Tightening specification and sequence. Refer to left cylinder head cover
⇒ Fig. ““Left Cylinder Head Cover - Tightening Specification and Sequence”“ , page 77 and right cylinder
head cover ⇒ Fig. ““Right Cylinder Head Cover - Tightening Specification and Sequence”“ , page 77
14 - Bolt
❑ Tightening specification: 5 Nm.
15 - Connector Strip
❑ For the ignition coils
16 - Seal
❑ For the cylinder head cover
❑ Replace if damaged or leaking
17 - Camshaft Adjustment Solenoid Valve
❑ Cylinder bank 1 (right) Camshaft Adjustment Valve 1 - N205-
❑ Cylinder bank 2 (left) Camshaft Adjustment Valve 2 - N208-
18 - Bolt
❑ 5 Nm
76 Rep. Gr.15 - Cylinder Head, Valvetrain

lkswage Mechanical, Fuel
Engine esInjection
n and Ignition (Hybrid) - Edition 07.2015
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19 - O-Ring tho
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❑ Replacess a c
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Left Cylinder Head Cover - Tightening Specification and Se‐
erm
ab
ility
quence
ot p
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– Tighten the bolts to 9 Nm in the following sequence:
h re
ole,
-1 to 12-.
spec
t to the co
rrectness o
cial p
f inform
mer
atio
Right Cylinder Head Cover - Tightening Specification and Se‐
om
quence
n
c
i
or
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e
– Tighten the bolts to 9 Nm in the following sequence:

t
sd
va
-1 to 12-.
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Cylinder Head - Tightening Specification and Sequence
Note
Replace the bolts that were tightened with an additional turn.
– Tighten the bolts in four steps in the sequence shown.

Turn
1. -1 to 8- Install all the way in by hand.
2. -1 to 8- 40 Nm
Checking the Cylinder Head for Distortion

– Check the cylinder head at several locations for distortion us‐
ing a Straight Edge - 500mm - VAS6075- and a feeler gauge.
• Maximum permitted distortion: 0.05 mm.
1. Cylinder Head 77
Reworking Dimension, Cylinder Head

Reworking cylinder head (face lapping) is only permissible to
minimum dimension -a-.
• Minimum dimension -a- = 139.20. Vmm.
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Oil Dipstick Guide Tube - Tightening Specifications
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1.2 Left Cylinder Head Cover, Removing

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trical shock! When performing the following work, it is also
necessary to work on the high voltage system. De-energize the
high voltage system now. Refer to ⇒ Electric Drive; Rep. Gr.
93 ; De-energizing the High Voltage System .

page 37 .

control electronics and remove it. Release and remove the
high voltage cables -2, 3 and 4- in sequence.
– Unclip the high voltage cables from the brackets -arrows- and
move them to the side.
– Remove the ignition coils. Refer to
⇒ “1.3 Ignition Coils with Power Output Stages , Removing
and Installing”, page 357 .
– Remove the crankcase ventilation hose -arrow- by pressing
the release buttons.
– Remove the bolts in a -12 through 1- sequence and remove

the left cylinder head.
Installing
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♦ Replace the O-ring.

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♦ If the cylinder head cover gasket is damaged, replace it.

spec
♦ Replace the cylinder head cover bolts when replacing the

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damaged seal.
rrectne
– Clean the sealing surfaces; they must be free of oil and grease.
– Tighten the left cylinder head cover bolts. Refer to
ss
⇒ Fig. ““Left Cylinder Head Cover - Tightening Specification

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and Sequence”“ , page 77 .

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– Install the ignition coils. Refer to

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– Connect and secure the high voltage cables.

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Equipment Hybrid; Rep. Gr. 93 ; High Voltage System, Ener‐

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1. Cylinder Head 79
1.3 Right Cylinder Head Cover, Removing

and Installing
Removing
page 37 .
– Remove the engine cover -2- upward.
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– Remove the secondary air intake hose -2- by pressing the re‐
lease buttons -1-.

– Release the clips -arrows- and remove the air filter upper sec‐
tion.
– Remove the ignition coils. Refer to
and Installing”, page 357ge.n AG. Volkswagen AG d
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– Loosen the mountings for the fuel pipe -arrows-. The fuel ho‐
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– Remove the crankcase ventilation pipe -arrow- by pressing the

his
ate
release buttons.
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– Remove the bolts in a -12 to 1- sequence and remove the right

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⇒ Fig. ““Right Cylinder Head Cover - Tightening Specification
Note

♦ If the cylinder head cover gasket is damaged, replace it.
♦ Replace the cylinder head cover bolts when replacing the
damaged seal.
– Tighten the right cylinder head cover bolts. Refer to
⇒ Fig. ““Right Cylinder Head Cover - Tightening Specification
– Install the ignition coils. Refer to
1. Cylinder Head 81
1.4 Cylinder Head, Removing and Installing

Removing:
Note
♦ The following describes the simultaneous removal of both cyl‐

inder heads.
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♦ During installation, all cable ties must be installed
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♦ Cylinder heads with cracks between the valve seats, or be‐

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WARNING
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– Remove the upper coolant pipe. Refer to
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⇒ “3.5 Upper Coolant Pipe, Removing and Installing”,

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page 211 .
thi
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– Remove the front coolant pipe. Refer to

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⇒ “3.4 Front Coolant Pipe, Removing and Installing”,
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page 210 .
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⇒ “2.2 Catalytic Converter, Removing and Installing, Left
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⇒ “2.3 Catalytic Converter, Removing and Installing, Right
(Bank 1)”, page 340 .
– Remove the compressor. Refer to
⇒ “2.3 Supercharger, Removing and Installing”, page 280 .
– Only for the left cylinder head: extract the A/C system refrig‐
erant. Refer to ⇒ Heating, Ventilation and Air Conditioning;
Rep. Gr. 87 .
– Only for the left cylinder head: disconnect the refrigerant line
-arrow- for the A/C system. Seal the open lines with suitable
plugs.
Note
Ignore -4-.

– Disconnect the left and right connectors -1, 2 and 3- from the
fuel injectors.
– Remove the camshaft adjuster and the camshaft chain
sprocket. Refer to
⇒ “4.5 Camshaft Adjuster, Removing and Installing”,
page 128 .
– Remove the Locking Pin - T40071- from the left cylinder head.
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– Remove the bolts -1 and 2- and then remove the chain ten‐
an
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The Locking Pin - T40071- remains inserted.
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– Remove the ground cable bolt -2-.
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– Disconnect the connectors from the left cylinder head:

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1 - For Camshaft Position Sensor 2 - G163-

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3 - For Camshaft Adjustment Valve 2 - N208-

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1. Cylinder Head 83
– Disconnect the connector -2-.

– Disconnect the connectors from the right cylinder head:

1- Camshaft Adjustment Valve 1 - N205-
2- Camshaft Position Sensor - G40-
– Move the electrical wiring harness to the side.
Note
Ignore the -arrows-.
– Remove the screw -arrow- and remove the oil dipstick and
guide tube. AG. Volkswagen A
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– Open the clamp and remove the vacuum hose from the vac‐
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AG. Volkswagen AG d
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Engine Mechanical, d by Fuel Injection and Ignition (Hybrid)
V ua - Edition 07.2015
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– Remove the bolts -arrows- on the srear
au of the cylinder head. ac
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♦ Left cylinder head: 3 bolts.
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♦ Right cylinder head: 4 bolts
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1. Cylinder Head 85
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♦ Cylinder head bolts without a collar have a Polydrive wrench
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♦ Cylinder head bolts with a collar have an internal multi-point
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spec
♦ If the cylinder head bolt with collar »sticks« on the camshafts es, in part or in w
when removing the camshafts must be removed if necessary.
t to the co
– Loosen the cylinder head bolts in the sequence -1 to 8-.
rrectness of i
– Remove the bolts, remove the cylinder head and place it on a
soft surface (foam).
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⇒ “1.1 Overview - Cylinder Head”, page 75 .
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♦ Make sure that no long grooves or scratches result.
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Risk of damaging the cylinder block.
♦ No oil or coolant must be in the cylinder head bolt blind
holes in the cylinder block.
Risk of the cylinder head gasket leaking.
♦ Carefully remove all lapping and sanding residue.
♦ Only unpack the new cylinder head gasket immediately
prior to installation.
♦ To prevent cylinder head gasket silicone layer and re‐
cessed area from being damaged, always handle the
gasket extremely carefully.
There is a risk of damaging open valves.
♦ If a replacement cylinder is installed, only remove plastic
base right before cylinder head is installed to protect open
valves.
Risk of damaging the valves and piston heads after working on
valve train.
♦ To ensure valves do not strike pistons when starting, care‐
fully rotate engine at least two full revolutions.

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AG. Volkswagen AG d
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♦ Replace the bolts that were tightened with an additional turn.
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♦ Replace self-locking nuts, sealing rings, seals and O-rings.
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♦ Note the different sealants for the sealing surfaces and the
h re
hole
cylinder head bolts. Refer to the Parts Catalog.
spec
es, in part or in w
♦ If a replacement cylinder head is being installed, the contact
t to the co
surfaces between the hydraulic adjusters, the roller rocker lev‐
ers and the cam running surfaces must be oiled before the
cylinder head cover is installed.
rrectness of i
♦ Secure all hose connections with hose clamps that are specific
l purpos
to that model. Refer to the Parts Catalog.

♦ Change the coolant and engine oil whenever replacing the
nf
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cylinder head or cylinder head seal.
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– Secure the camshaft for cylinder bank 1 in “TDC” using the
thi
te
Camshaft Clamp - T40133/1- .
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– Secure the camshaft for cylinder bank 2 in “TDC” using the

Camshaft Clamp - T40133/2- .
– Secure the crankshaft -1- in “TDC” using the Crankshaft Lock‐

ing Pin - T40069- .
1. Cylinder Head 87
– Install the new seals on the coolant pipe.

– Position the cylinder head gasket.
• Installed position: the marking “oben” (top) or the part number
must be legible.
• Pay close attention to alignment bushings in cylinder block
-arrows-.
– Position the cylinder head.
– Tighten the cylinder head bolts. Refer to

⇒ Fig. ““Cylinder Head - Tightening Specification and Se‐
quence”“ , page 77 .
AG. Volkswagen AG d
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– Tighten the bolts -arrows- for the lower timing chain cover.
Refer to
⇒ Fig. ““Lower Timing Chain Cover - TighteningenSpecification
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♦ Left cylinder head: 3 bolts. ir se nte
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♦ Right cylinder head: 4 bolts ss
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It is not necessary to retighten the cylinder head bolts after re‐
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– Installing camshaft adjuster. Refer to
page 128 .
rrectness of i
– Install the upper coolant pipe. Refer to
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page 211 .
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– Install oil dipstick guide tube. Refer to

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⇒ Fig. ““Oil Dipstick Guide Tube - Tightening Specifications”“ ,
com
tio
page 78 .
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– Connections and wiring routing. Refer to ⇒ Wiring diagrams,
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Troubleshooting & Component locations.
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– Install the catalytic converter. Refer to left

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⇒ “2.2 Catalytic Converter, Removing and Installing, Left Cop py
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(Bank 2)”, page 337 and right yri
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⇒ “2.3 Catalytic Converter, Removing and Installing, Right cop Vo
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(Bank 1)”, page 340 .
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– Install the intake manifold lower section. Refer to

⇒ “4.2 Intake Manifold Lower Section with Fuel Rail, Removing
– Install front coolant pipe. Refer to
page 210 .
– Change the engine oil. Refer to ⇒ Maintenance ; Booklet 29.1 .
– Fill with coolant.
1.5 Compression, Checking

♦ Spark Plug Removal Tool - 3122B-
♦ Compression Tester Kit - VAG1763-
Procedure:
• Engine oil temperature at least 30 ℃ (86 °F).
• Battery voltage at least 12.5 V.
– Remove all ignition coils. Refer to
1. Cylinder Head 89
Note
Ignore -2 and 3-.
– Disconnect the left and right connectors on the back of the

cylinder head -1- for the fuel injectors.
– Remove the spark plugs with the Spark Plug Removal Tool -
3122B- .
– Check the compression using the Compression Tester Kit -
VAG1763- .
Note
Information on using the tester. Refer to the Operating Instruc‐

tions.
– Have a second mechanic press the accelerator pedal down all

the way and start the engine long enough until the tester no
longer indicates that the pressure is increasing.
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– Repeat the procedure
Vol
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Compression Pressure
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New ss 11.0 to 14.0 bar c
(160 to 203 psi)
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Wear limit 10.0 bar (145

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Difference between cylinders maximum 3.0

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bar (43.5 psi)

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es, in part or in w
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– Install the spark plugs and ignition coils. Refer to

rrectness of i
– The faults were stored in the engine control module DTC

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memories Generate Readiness Code in Guided Func-

tions because the connectors were disconnected and the
engine was started. Refer to Vehicle Diagnostic Tester .
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2 Timing Chain Cover

⇒ “2.1 Overview - Timing Chain Cover”, page 91
⇒ “2.2 Left and Right Timing Chain Covers, Removing and In‐
⇒ “2.3 Lower Timing Chain Cover, Removing and Installing”, page
97
2.1 Overview - Timing Chain Cover

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⇒ Fig. ““Lower Timing ss c
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page 93 .
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2 - Shaft Seal
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❑ For the crankshaft on
spec
the transmission side
es, in part or in w
t to the co
❑ Replace. Refer to
⇒ “2.5 Crankshaft Seal,
Replacing, Transmis‐
rrectness of i
sion Side”, page 54 .
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3 - Bolt
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⇒ Fig. ““Lower Timing

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Chain Cover - Tighten‐
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page 93 .
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❑ Quantity: 2
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5 - Threaded Pin
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❑ Tightening specification Prote
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-item 13-
⇒ Item 13 (page 169) .
6 - Left Cylinder Head Gasket
7 - Bolt
❑ Replace
Tightening specification and
sequence. Refer to
⇒ Fig. ““Left Timing Chain Cover - Tightening Specification and Sequence”“ , page 93 .
8 - Bracket
❑ For wiring harness
9 - Left Timing Chain Cover
⇒ “2.2 Left and Right Timing Chain Covers, Removing and Installing”, page 93 .
10 - Bracket
2. Timing Chain Cover 91

11 - Bolt
❑ Replace
Tightening specification and sequence. Refer to
⇒ Fig. ““Left Timing Chain Cover - Tightening Specification and Sequence”“ , page 93 .
12 - Bracket
❑ For wiring harness lkswage es n
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13 - Bolt o
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❑ Replace
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15 - Bracket
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16 - Bolt
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10 Nm
17 - Bolt
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❑ Replace
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⇒ Fig. ““Right Timing Chain Cover, Tightening Specifications and Sequence”“ , page 93 .
nform
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18 - Bracket
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at
❑ For wires
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19 - Right Timing Chain Cover
or
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⇒ “2.2 Left and Right Timing Chain Covers, Removing and Installing”, page 93 .
um
for
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20 - Right Cylinder Head Gasket
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21 - Bracket
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❑ For the heat shield
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22 - Bolt
❑ Replace
⇒ Fig. ““Right Timing Chain Cover, Tightening Specifications and Sequence”“ , page 93 .
❑ Quantity: 2
24 - Bolt
❑ Tightening specification. Refer to
⇒ Fig. ““Lower Timing Chain Cover - Tightening Specification and Sequence”“ , page 93 .
25 - Lower Timing Chain Cover
⇒ “2.3 Lower Timing Chain Cover, Removing and Installing”, page 97 .
27 - Bolt
❑ Tightening specification. Refer to

Left Timing Chain Cover - Tightening Specification and Sequence
Note
AG. Volkswagen AG d
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Replace the bolts that were tightened V with an additional turn.
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♦ The brackets -arrows A and B- thoare
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connected with the left tim‐ eo
ing chain cover. ss au ra
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– Tighten the bolts in two steps in the sequence shown.
an
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1. -1 to 8- 5 Nm
ole,
spec
t to the co
Right Timing Chain Cover, Tightening Specifications and Se‐
quence
rrectnes
Note
s o
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f inform
mer
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– Tighten the bolts in two steps in the sequence shown.
n
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2. -1 through 10- 3 Nm diagonally
3. -1, 2, 4, 5 and 7- andTurn an additional 90°.
-arrows-
4. -8, 9 and 10- 8 Nm
5. -8, 9 and 10- Turn an additional 90°.
6. -3- 16 Nm
7. -6- 20 Nm
8. -6- Turn an additional 90°.
2.2 Left and Right Timing Chain Covers, Re‐

moving and Installing


Removing:
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⇒ “3.4 Left Secondary Air Injection Combination Valve, Re‐
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moving and Installing”, page 345 , and right
⇒ “3.5 Right Secondary Air Injection Combination Valve, Re‐
moving and Installing”, page 346 .
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Replace the O-rings.
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and cylinder head, for example using a rotating plastic brush.

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about 2 mm).
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– Install the secondary air injection combination valve. Refer to
left
moving and Installing”, page 345 , and right

2.3 Lower Timing Chain Cover, Removing

and Installing
Removing
• Engine is secured to the Engine and Gearbox Bracket -
VAS6095A- . Refer to
⇒ “1.2 Engine, Securing to Engine and Gearbox Bracket
VAS6095A ”, page 20 .
Note
During installation, all cable ties must be installed at the same

location.

– Remove the oil filter housing. Refer to
⇒ “4.6 Oil Filter Housing, Removing and Installing”,
page 172 .
page 211 .
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Note
– Remove the right upper alignment bushing from the cylinder

block.
– Grind the alignment bushing down at an angle as shown in the
illustration.
• Dimension -x- = 6.5 mm.
• Dimension -y- = 8 mm.
– Insert the alignment bushing in the cylinder block so the angled
side faces up.
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about 2 mm).

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again in direction of -arrows-.
– Use a flat object such as a feeler gauge to coat the surface
between the cylinder head and seal.
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– Position the lower timing chain cover, guiding it diagonally

from below to the sealing surface on the cylinder block and
cylinder head.
– When positioning, ensure the cylinder head seals are not
damaged.
– Tighten the bolts. Refer to
⇒ Fig. ““Lower Timing Chain Cover - Tightening Specification
– Install the crankshaft seal on the transmission side. Refer to
⇒ “2.5 Crankshaft Seal, Replacing, Transmission Side”, page
54 .
– Install the starter. Refer to ⇒ Electrical Equipment; Rep. Gr.
27 .
– Install the left and right timing chain covers. Refer to
⇒ “2.2 Left and Right Timing Chain Covers, Removing and
Installing”, page 93 .
– Install the oil filter housing. Refer to
⇒ “4.6 Oil Filter Housing, Removing and Installing”,
page 172 .
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3 Chain Drive
⇒ “3.1 Overview - Camshaft Timing Chains”, page 103
⇒ “3.2 Overview - Timing Mechanism Drive Chain”, page 106
⇒ “3.3 Overview - Balance Shaft and Oil Pump Drive Chain”, page
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5 - Left Camshaft Timing Chain
❑ Mark the running direc‐
tion with paint for rein‐
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❑ Remove from the cam‐
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Chain, Removing and
ling. Refer to
⇒ “4.5 Camshaft Adjust‐
6 - Bolt
❑ 9 Nm
3. Chain Drive 103

7 - Gliding Piece
8 - Chain Tensioner
❑ For the left camshaft timing chain
❑ Removing and installing. Refer to ⇒ “3.4 Camshaft Timing Chain, Removing and Installing”, page 108 .
9 - Bearing Plate
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Chain, Removing and
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⇒ Item 15 (page 107) .
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❑ For the right camshaft
timing chain drive
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to

⇒ Fig. ““Installation Lo‐

cation of the Mounting Pins for the Right Camshaft Timing Chain Drive Sprocket”“ , page 107
❑ For the right camshaft timing chain
❑ Installed position. Refer to
⇒ Fig. ““Installation Location of the Mounting Pins for the Right Camshaft Timing Chain Drive Sprocket”“ ,
page 107
8 - Right Camshaft Timing Chain
❑ Mark the running direction with paint for reinstallation
❑ Remove from the camshafts. Refer to
⇒ “3.4 Camshaft Timing Chain, Removing and Installing”, page 108 .
❑ Removing and installing. Refer to ⇒ “4.5 Camshaft Adjuster, Removing and Installing”, page 128 .
9 - Thrust Washer
❑ For the right camshaft timing chain drive sprocket
page 107
10 - Chain Tensioner
❑ For the right camshaft timing chain
❑ Removing and installing. Refer to ⇒ “3.4 Camshaft Timing Chain, Removing and Installing”, page 108 .
11 - Gliding Piece
12 - Bolt
❑ 9 Nm
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3. Chain Drive 105

3.2 Overview - Timing Mechanism Drive Chain
1 - Guide Rail
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3 - Bolts
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page 107
13 - Thrust Washer
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14 - Mounting Pin
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3.3 Overview - Balance Shaft and Oil Pump Drive Chain
1 - Crankshaft
2 - Drive Chain
❑ For power take-off
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⇒ “3.6 Drive Chain Bal‐
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page 112 .
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page 97 .
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page 128 .

Caution
There is a risk of destroying the camshaft timing chain if the

running direction is reversed on a used camshaft timing chain.
♦ Paint arrows to mark the left and right camshaft timing
chain running direction so they can be installed again. Do
not mark the camshaft timing chain with a punch, notch or
something similar.
– Remove the Locking Pin - T40071- and the left camshaft tim‐
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the housing faces the chain tensioner and the piston faces the
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cted AG.
agen
tensioning rail.
Caution
Risk of damaging valves and piston crowns.

♦ If camshafts are rotated, crankshaft may not rest with any
piston at “TDC”.
3. Chain Drive 109

– Install the left camshaft timing chain on the drive chain sprock‐
et according to marking that was made earlier when it was
removed and guide it upward toward the cylinder head.
– Press the guide rail for the left camshaft timing chain tensioner
down and secure the chain tensioner using a Locking Pin -
T40071- .
AG. Volkswagen AG d
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– Install the right camshaft timing chain on the driveed by chain
V gu
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sprocket according to marking that was made horis earlier when it nte
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was removed and guide it upward toward s authe
t
cylinder head. ra
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– Install the drive chain sprocket. Refer to
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⇒ Fig. ““Installation Location of the Mounting Pins for the Right
an
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Camshaft Timing Chain Drive Sprocket”“ , page 107 .
erm
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– Tighten the drive chain sprocket mounting pin bolt -1-.
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– Remove the Locking Pin - T40071- .
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Note
Ignore -arrow-.
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– Install the chain tensioner on the right cylinder head.
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– Tighten the bolts -1 and 2-.

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Cylinder bank 1 (right). Refer to
p by
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⇒ “4.5.2 Camshaft Adjuster, Installing, Cylinder Bank 1 Prote
cted AG.
agen
(Right)”, page 133 .
Cylinder bank 2 (left). Refer to
⇒ “4.5.3 Camshaft Adjuster, Installing, Cylinder Bank 2 (Left)”,
page 135 .
page 97 .
3.5 Timing Mechanism Drive Chain, Re‐

♦ Locking Pin - T40071-
Removing


page 97 .
– Remove the camshaft adjuster. Refer to
page 128 .
– Remove the power take-off drive chain. Refer to
page 112 .
– Press the drive chain tensioner guide rail in the direction of
-arrow- and secure the chain tensioner with a Locking Pin -
T40071- .
Caution
Risk of destroying due to reversed running direction on a used

drive chain.
♦ Mark the drive chain running direction with arrows using
paint for installation later. Do not mark the drive chain with
a punch, notch or something similar.
– Remove the bolts -1- and the guide rail.

– Remove the bolts -2- and the chain tensioner.
– Remove the timing mechanism drive chain.
Installing
⇒ “3.2 Overview - Timing Mechanism
agen Drive
AG. Vo Chain”,
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page 106 . o lksw not
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Install in reverse order
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– Position the timing mechanism drive chain according to the

h re
hole
markings made on the drive chain sprockets during removal.

spec
es, in part or in w
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ate
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3. Chain Drive 111

– Install the guide rail and tighten the bolts -1-.

– Install the chain tensioner and tighten the bolts -2-.
– Press the drive chain tensioner guide rail in the direction of
-arrow- and pull Locking Pin - T40071- out of the chain ten‐
sioner.
– Install the power take-off drive chain. Refer to
page 112 .
– Installing the camshaft adjuster:
Cylinder bank 1 (right). Refer to
⇒ “4.5.2 Camshaft Adjuster, Installing, Cylinder Bank 1
(Right)”, page 133 .
Cylinder bank 2 (left). Refer to
page 135 .
page 97 .
3.6 Drive Chain Balance Shaft, Removing

and Installing
♦ Crankshaft Key - T40049-
♦ Crankshaft Locking Pin - T40069-
Removing
⇒ “1.1 Engine, Removing”, page 7 . AG. Volkswagen AG d
agen oes
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• Engine and electro-drive drive motor separated. Refer to by Vol not
gu
ara
⇒ “1.4 Engine and Electro-Drive Drive Motor with Transmis‐ rise
d
nte
sion, Separating and Connecting”, page 25 . utho eo
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page 97 .
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Caution
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Danger of damaging the drive chain because the bolt thread is

spec
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too long.
t to the co
♦ Only use bolts with a thread length -a- of maximum 22 mm

to attach the Crankshaft Key - T40049- .
rrectness of i
♦ If only longer bolts are available, then the bolt head must
be installed in such a way so that thread length is still only
l purpos
22 mm.
nform
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c
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or
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ate
do
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Cop py
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112
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Rep. Gr.15 - Cylinder Head, Valvetrain Prote
cted AG.
agen
– Install the Crankshaft Key - T40049- with two bolts -arrows- on

the back of the crankshaft.
AG. Volkswagen AG d
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– Remove the alocking
ut bolt -arrow- for the “TDC” marking crank‐or ac
shaft from the cylinder block. ss
ce
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un
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an
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ole,
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t to the co
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– Rotate the crankshaft in the direction of engine rotation
ss
-arrow- to “TDC” using the Crankshaft Socket - T40058- and
o
cial p
wrench. f inform
mer
atio
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• The notch -A- must align with the joint -arrow-.
3. Chain Drive 113

– Install the Crankshaft Locking Pin - T40069- in the hole and

tighten to 20 Nm. Rotate the crankshaft -1- back and forth
slightly to center the pin completely, if necessary.
– Press the chain tensioner guide rail in direction of -arrow- and

secure chain tensioner using a Locking Pin - T40071- .
Caution
Risk of destroying due to reversed running direction on a used

drive chain.
♦ Mark the drive chain running direction with arrows using
paint for installation later. Do not mark the drive chain with
a punch, notch or something similar.
– Remove the bolts -3- and the balance shaft chain sprocket.
– Remove the bolts -1 and 2- and the chain tensioner with the
chain.
AG. Volkswagen AG d
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or c
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Installing
⇒ “3.3 Overview - Balance Shaft and Oil Pump Drive Chain”,
page 108 .
- T40069- .
Note
– Install the chain tensioner with the chain and the drive chain
and the balance shaft chain sprocket.
– Lock the balance shaft in the “TDC” position with the Locating
Pins - T40116- .
• The slots in the balance shaft chain sprocket must be centered
with the threaded holes in the balance shaft. Offset the chain
by one tooth, if necessary.
– Tighten the chain tensioner bolts.
– Install the chain sprocket bolts -1- loosely.
• It must still be possible to rotate the chain sprocket on the bal‐
ance shaft and it must not tip.
– Remove the Locking Pin - T40071- to release the chain ten‐
sioner.
– Press against the chain tensioner guide rail with a screwdriver
in direction of -arrow- and simultaneously tighten the bolts
-1- for the chain sprocket. olkswage es n
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by ara
– Remove the Locating Pins - T40116-
ris
ed from the balance shaft. nte
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nl
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page 97 .
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– Install the locking bolt “TDC” mark crankshaft. Refer to

, is n
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⇒ Fig. ““Sealing Plug for Crankshaft TDC Mark”“ , page 59 .

hole
spec
es, in part or in w
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3.7 Valve Timing, Checking

thi
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– Remove the cylinder head covers. Refer to left side

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⇒ “1.2 Left Cylinder Head Cover, Removing and Installing”,

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page 78 and right side Cop py
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⇒ “1.3 Right Cylinder Head Cover, Removing and Installing”,
t
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3. Chain Drive 115

– Position the crankshaft at “TDC” in the direction of engine ro‐

tation -arrow- using the Crankshaft Socket - T40058- and
offset open-end wrench.
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• The threaded holes -arrows- in the camshafts must face up‐

ward.
nform
mercia
a
Note
com
tion in
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thi
If it is accidentally rotated beyond “TDC”, rotate it back approxi‐

s
iva
do
mately 30° and set it to “TDC” again.

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Cop py
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– Remove the locking bolt -arrow- for the “TDC” marking crank‐
cted agen
Prote AG.
shaft from the cylinder block.


tighten to 20 Nm.
• The Crankshaft Locking Pin - T40069- must engage in the se‐
curing hole on the crankshaft -1-.
AG. Volkswagen AG d
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olksw not
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– The camshaft for cylinder bank 1 must be secured in “TDC”
wit
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using the Camshaft Clamp - T40133/1- .
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es, in part or in w
t to the co
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nform
mercia
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ion
– The camshaft for cylinder bank 2 must be secured in “TDC”
c
in t
or
using the Camshaft Clamp - T40133/2- .
his
ate
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If the camshafts cannot be secured, the valve timing must be ad‐

p
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or
justed.
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3. Chain Drive 117

4 Valvetrain
⇒ “4.1 Overview - Valvetrain”, page 118
⇒ “4.2 Camshaft Axial Play, Checking”, page 120
⇒ “4.3 Camshaft, Measuring Radial Clearance”, page 121
⇒ “4.4 Camshaft, Removing and Installing”, page 121
⇒ “4.5 Camshaft Adjuster, Removing and Installing”, page 128
⇒ “4.6 Hydraulic Adjuster, Checking”, page 138
⇒ “4.7 Valve Stem Seals with Installed Cylinder Head, Removing
and Installing”, page 139
. Volkswagen AG
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⇒ “4.8 Valve Stem Seals with Removed Cylinder Head,
Vol Removing
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and Installing”, page 142 ed
by ara
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4.1 Overview - Valvetrain ss
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The cylinder head for cylinder bank 2 (left) is shown in the illustration.
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1 - Plugs
t to the co
❑ Install with sealant. Re‐
fer to the Parts Catalog
for the sealant.
rrectness of i
2 - Cylinder Head
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❑ Valve Guides, Check‐

ing. Refer to
nform
ercia
⇒ “5.1 Valve Guides,

Checking”, page 146 .
m
a
com
3 - Valve Stem Seal tion in

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❑ Replacing with the cylin‐

s
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der head installed. Re‐

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⇒ “4.7 Valve Stem Seals

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❑ Replacing with the cylin‐
AG.
der head removed. Re‐

fer to
⇒ “4.8 Valve Stem Seals
with Removed Cylinder
Head, Removing and In‐
4 - Valve Spring
to
⇒ Fig. ““Installed Posi‐
tion, Valve Spring”“ ,
page 120
5 - Hydraulic Adjuster
❑ Clipped into roller rocker
lever -8-
❑ Check. Refer to
⇒ “4.6 Hydraulic Adjust‐

er, Checking”,
page 138 .
❑ Mark the installed position for installation later
❑ Lubricate the running surfaces before installing
6 - Valve Spring Retainer
7 - Valve Keepers
8 - Roller Rocker Lever
❑ Check the roller bearing for ease of movement
❑ Lubricate the running surfaces before installing
❑ To assemble, clip onto the hydraulic adjusting
gen AG
. Volkswelement
agen AG -9- with securing clip -5-
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9 - Clip by
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❑ Not available separately.ho
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❑ Make sure it is secure
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10 - Intake Camshaft
pt
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❑ Removing and installing. Refer to ⇒ “4.4 Camshaft, Removing and Installing”, page 121 .
rm
ab
pe
❑ Axial play, measuring. Refer to ⇒ “4.2 Camshaft Axial Play, Checking”, page 120 .
ility
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❑ Radial play, measuring. Refer to ⇒ “4.3 Camshaft, Measuring Radial Clearance”, page 121 .
h re
hole
❑ Maximum run out: 0.04 mm
spec
es, in part or in w
11 - Bolt
t to the co
❑ Replace
rrectness of i
⇒ Fig. ““Camshaft Guide Frame Tightening Specifications and Sequence”“ , page 120 .
l purpos
12 - Guide Frame
❑ With integrated camshaft bearings
nform
ercia
m
13 - Flat Ring
com
tion in
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14 - Compression Rings
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15 - Exhaust Camshaft
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❑ Axial play, measuring. Refer to ⇒ “4.2 Camshaft Axial Play, Checking”, page 120 .
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❑ Radial play, measuring. Refer to ⇒ “4.3 Camshaft, Measuring Radial Clearance”, page 121 .
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p by
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❑ Maximum run out: 0.04 mm cted agen
Prote AG.
16 - Oil Screen
17 - Intake Valve
❑ Do not rework, only lapping is permitted
❑ Check. Refer to ⇒ “5.2 Valves, Checking”, page 146 .
❑ Valve dimensions. Refer to ⇒ “5.3 Valve Dimensions”, page 147 .
❑ Valve guides, checking. Refer to ⇒ “5.1 Valve Guides, Checking”, page 146 .
18 - Exhaust Valve
❑ Do not rework, only lapping is permitted
❑ Check. Refer to ⇒ “5.2 Valves, Checking”, page 146 .
❑ Valve dimensions. Refer to ⇒ “5.3 Valve Dimensions”, page 147 .
❑ Valve guides, checking. Refer to ⇒ “5.1 Valve Guides, Checking”, page 146 .
4. Valvetrain 119
Installed Position, Valve Spring

• The tight spring coils -arrow- face toward the cylinder head.
Camshaft Guide Frame Tightening Specifications and Sequence
Note
♦ The guide frame for the left cylinder head camshaft is shown
in the illustration. The right cylinder head is identical.
– Tighten the bolts in three steps and in thewsequence

agen
AG. Volkshown:
swagen AG
doe
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Vol t gu
by
Step Bolts TighteningiseSpecification/Additional
d ara
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Turn uthor eo
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ss the bolts all the way in by hand c
1. -1 to 21- Install
ce
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• The guide frame must touch the

un
pt
an
d
entire contact surface on the cylin‐

itte
der head. y li
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2. -1 to 21- 8 Nm
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spec
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4.2 Camshaft Axial Play, Checking

rrectne

ss

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Procedure:
form
mer
atio
– Remove the camshafts. Refer to

om
⇒ “4.4 Camshaft, Removing and Installing”, page 121 .

n
c
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or
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– Mark the allocation of the roller rocker lever for installation lat‐
t
sd
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– Remove the roller rocker lever and place it on a clean surface.

t.
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Cop py
– Reinstall the camshafts and the guide frame. Refer to
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⇒ Fig. ““Camshaft Guide Frame Tightening Specifications and
p by
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by c lksw
Sequence”“ , page 120 and tighten the old bolts to 8 Nm. Prote
cted AG.
agen
– Secure the Dial Gauge Holder - VW387- with the Dial Gauge
- 0-10mm - VAS6079- on the cylinder head ash shown in the
illustration.
– Press the camshaft against the dial gauge by hand.
– Set the dial gauge to “0”.
– Press the camshaft off of the dial gauge and read the value.
• Axial play: 0.100 to 0.191 mm.

4.3 Camshaft, Measuring Radial Clearance

♦ Plastigage®
Procedure:
– Mark the allocation of the roller rocker lever for installation lat‐
er.
– Remove the roller rocker lever and place it on a clean surface.
– Clean the bearing and the bearing journals.
– Place Plastigage® over entire width of bearing journal or into
the bearing.
• Plastigage® must rest in center of bearing.
– Install the camshafts, mount the bearing bracket and tighten
to 8 Nm without additional turn. Refer to n AG. Volkswagen AG do
⇒ Fig. ““Camshaft Guide Frame Tightening lksSpecifications
wage and es n
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Sequence”“ , page 120 , do not turn the Vo
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– Remove the bearing bracket sand
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Radial clearance:
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• For 24 mm bearing diameter: 0.024 to 0.066 mm
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• For 36 mm bearing diameter: 0.032 to 0.078 mm
hole
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es, in part or in w
4.4 Camshaft, Removing and Installing
t to the co
rrectness of i
♦ Injector/Combustion Chamber Seal Tool Set - Sliding Hammer
- T10133/3- from Injector/Combustion Chamber Seal Tool Set
l purpos
- T10133B-
nform
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Here, removal and installation at left cylinder head is depicted in p by
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the following description.
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Removing
Left camshaft gear
4. Valvetrain 121
– Disconnect the refrigerant line -arrow- for the A/C system. Seal
the open lines with suitable plugs.
– Remove the vacuum pump.

Right camshaft gear:
– Remove the high pressure pump and high pressure pump

motor housing. Refer to
⇒ “7.2 High Pressure Pump, Removing and Installing”,
page 316 . AG. Volkswagen AG d
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Left and right camshafts: by
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– Remove the camshaft adjuster. Refer to ut
hor eo
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ss a c
page 128 .
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– Remove the bolt -arrow- and remove the Camshaft Adjust‐

ment Valve 1 - N205- / Camshaft Adjustment Valve 2 - N208- . spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
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tion in
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Cop py
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– Disconnect the connector -1- from the Camshaft Position Sen‐

sor -G40- / Camshaft Position Sensor 2 - G163- .
Note
Ignore -arrow-.
Note
Ignore -1-. AG. Volkswagen AG d

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– Free up the vacuum hose -1- on cylinder bank 2 (left).
wit
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– Remove the bolts -arrows- and remove the cover -2-.
hole
spec
es, in part or in w
t to the co
rrectness of i
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nf
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orm
m
atio
om
n in
c
– Loosen the guide frame bolts in the following sequence:

or
thi
-21 through 1-.

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The right guide frame is a mirror image.
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– Remove the bolts, carefully loosen the guide from out of the
bond and place it with the camshafts on a soft surface.
– Remove the Camshaft Clamp - T40133- -arrows-.
4. Valvetrain 123
– Mark the camshafts, remove them and lay them on a clean

surface.
Installing
⇒ “4.1 Overview - Valvetrain”, page 118 .
Note
Replace the seals and the plugs.

- T40069- .
• The hydraulic adjusting elements and roller rocker lever are
inserted.
Caution n AG. Volkswagen AG do

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Risk of contaminating the lubricating system and bearing.
d b ua
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♦ Cover open parts ofstheau engine.
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WARNING
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h re
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spec
es, in part or in w
t to the co
– Remove the sealant residue on the cylinder head and guide

frame, for example using a rotating plastic brush.
rrectness of i
l purpos
– Check the screen -arrow- for dirt; clean it if necessary.

nf
ercia
– Oil the camshaft running surfaces.

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– Insert the camshafts in the guide frame.

• The placement of the camshafts must be exactly within the
axial bearings -arrows- of the guide frame.
• The compression ring ends -1, 2 and 3- must face up or down.
They must never face sideways.
– Rotate the guide frame with the camshafts inserted while hold‐
ing them securely in the frame.
– Rotate the camshafts until the threaded holes -arrows- face

upward.
– Check if the camshafts still lie in the guide frame axial bear‐
ings.
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– Secure the camshafts for cylinder bank 1 in “TDC” using the
ility
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Camshaft Clamp - T40133/1- -arrows- (25 Nm).
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4. Valvetrain 125
Note

about 2 mm).
– Rotate the guide frame again.
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Caution Volksw not
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Risk of contaminating camshaft bearing with excess
ut
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♦ Do not apply sealant beads thicker than indicated. s
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– Apply sealant beads -4 through 8- to the clean sealing surfa‐
ot p
ces on the guide frame as shown in the illustration.
wit
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• Sealant bead thickness: 2.0 mm
spec
– Apply sealant beads -1 through 3- to the clean sealing surfa‐
t to the co
ces on the guide frame as shown in the illustration.
• Sealant bead thickness: 2.5 mm.
rrectnes
Note
s o
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The guide frame must be installed within five minutes after ap‐
form
mer
plying the sealant.
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– Place the guide frame on the cylinder head.
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– Install the Locating Pins - T40116- into the guide frame and
cylinder head.

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– Tighten the camshaft guide frame bolts. Referauto
t ra
c
⇒ Fig. ““Camshaft Guide Frame Tightening Specifications and
ss
ce
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Sequence”“ , page 120 .
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After installing the guide frame, let the sealant harden for approx‐
hole
spec
imately 30 minutes.
es, in part or in w
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– Remove any oil and grease from the hole for the plug in the
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cylinder head.
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– Drive in the sealing plugs until they are flush.
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4. Valvetrain 127
– Remove the Locating Pins - T40116- withwthe genInjector/Com‐

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bustion Chamber Seal Tool Set - Sliding
y V Hammer - T10133/3- .
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Install in reverse order of removal,
tho
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– Install the Camshaft Adjustment
ss Valve 1 - N205- / Camshaft
ce
le
Adjustment Valve 2 - N208- . Refer to
un
pt
⇒ “1.1 Overview - Cylinder Head”, page 75 .
an
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– Install the high pressure pump motor housing and the high
ility
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pressure pump. Refer to
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page 316 .
spec
– Install the vacuum pump. Refer to ⇒ Brake System; Rep. Gr.
t to the co
47 .
– Position the camshaft timing chain on the camshafts. Refer to
rrectne
⇒ “3.4 Camshaft Timing Chain, Removing and Installing”,
page 108 .
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Caution
f inform
mer
Risk of damaging the valves and piston heads after working on
atio
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valve train.
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♦ The motor must not be started for about 30 minutes after
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installing camshafts because the hydraulic equalization

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elements must seat themselves.
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fully rotate engine at least two full revolutions.
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4.5 Camshaft Adjuster, Removing and In‐

stalling
♦ Multipoint Socket - T10035-
♦ Crankshaft Socket - T40058-
♦ Locking Pin - T40071- (quantity: 2)
♦ Camshaft Clamp - T40133-
Refer to ⇒ “4.5.1 Camshaft Adjuster, Removing”, page 129
Refer to
⇒ “4.5.2 Camshaft Adjuster, Installing, Cylinder Bank 1 (Right)”,
page 133
Refer to
page 135

Engine Mechanical, Fuel Injection andwIgnition
agen
AG. (Hybrid)
Volkswage-n A
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4.5.1 Camshaft Adjuster, Removing ed
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WARNING
un
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There is a risk of injury if the radiator fan turns on by itself.
erm
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ility
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♦ The coolant fan can come on even when the ignition is
wit
is n
turned off, for example, caused by the heat still in the en‐
h re
ole,
gine compartment.
spec
t to the co
Note
rrectne
The camshaft timing chains remain on the engine in the following
s
description.
s o
cial p
f inform
– Remove the left and right timing chain covers. Refer to
mer
⇒ “2.2 Left and Right Timing Chain Covers, Removing and
atio
m
o
n
c
i
or
n thi
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– Remove the cylinder head cover. Refer to left side

t
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page 78 and right side

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page 80 . C py
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– Insert the Crankshaft Socket - T40058- guide pins as follows: cop Vo
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• The large diameter -arrow 1- faces the engine.
AG.
• The small diameter -arrow 2- faces the adapter.
– Rotate the crankshaft in the direction of engine rotation

-arrow- to “TDC” using the Crankshaft Socket - T40058- and
wrench.
4. Valvetrain 129
AG. Volkswagen AG d
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t to the co
• The threaded holes -arrows- in the camshafts must face up‐
ward.
rrectness of i
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at
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ion
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ate
do
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– Remove the locking bolt -arrow- for the “TDC” marking crank‐ en
ng
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shaft from the cylinder block.
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tighten to 20 Nm. Rotate the crankshaft -1- back and forth
slightly to center the pin completely, if necessary.



– Press the chain tensioner guide rail for the left camshaft timing
chain inward all the way using a screwdriver -1- and secure
the chain tensioner with a Locking Pin - T40071- .
AG. Volkswagen AG d
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Note Volksw not
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The chain tensioners for the camshaft timing
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with oil. They can only be compressedss slowly by applying con‐
a c
stant pressure.
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ility
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– Press the chain tensioner guide rail for the right camshaft tim‐
hole
ing chain inward all the way using a screwdriver -1- and secure
spec
es, in part or in w
the chain tensioner with a Locking Pin - T40071- .

t to the co
Caution
rrectness of i
The camshafts can get damaged.

l purpos
♦ Do not use the Camshaft Clamp - T40133- to counterhold

when loosening the camshaft adjuster bolt or the camshaft
nform
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sprocket.
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4. Valvetrain 131
– To counterhold, place the Wrench - Pin Type - 3036- on the

respective camshaft adjuster and loosen the bolt using the
Multipoint Socket - T10035- .
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– To counterhold, place the Wrench - Pin Type - 3212- on the urposes, in part or in wh
camshaft chain sprocket and loosen the bolt using the Multi‐
t to the co
point Socket - T10035- .
rrectne
Note
ss
Ignore -1 and arrow-.
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mer
atio
Caution
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There is a risk of destroying the engine.
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♦ To prevent small parts from accidentally entering the en‐

p
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cover the opening with a clean cloth.
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– Remove the bolts -1 and 2- on the left side of the cylinder cov‐
AG.
er, then remove the camshaft adjuster and the camshaft chain
sprocket.
– Remove the bolts -1 and 2- on the right side of the cylinder

cover, then remove the camshaft adjuster and the camshaft
chain sprocket.

4.5.2 Camshaft Adjuster, Installing, Cylinder

Bank 1 (Right)
Note
Caution

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- T40069- .
• Camshafts secured in “TDC” using the Camshaft Clamp -
T40133/1- -arrows- (25 Nm).
rrectness of i
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– Place the timing chain on the camshaft adjuster -A- and place
f
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t.
the camshaft adjuster on the camshaft. Pay attention to the
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• The timing chain must rest »taut« on the guide rail -arrow-. cop Vo
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• The timing chain must be tensioned »by hand« in the direction
of the -arrow-.
4. Valvetrain 133
• The groove -1- in the camshaft adjuster must align with the
adjustment window -2-.
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– Insert the camshaft chain sprocket into the timing chain and ss c
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place the camshaft chain sprocket on the camshaft. Pay at‐

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tention to the following:
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• The marking point -1- must be centered with respect to the
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– Install the bolts -1 and 2- loosely. The camshaft adjuster and

the camshaft chain sprocket must be able to still be rotated on
nform
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camshaft and must not tip.

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ing chain inward all the way using a screwdriver -1- and
remove the Locking Pin - T40071- .

– Position the Wrench - Pin Type - 3212- on the camshaft chain

sprocket.
– Press the Wrench - Pin Type - 3212- in the direction of
-arrow- and check if the timing chain is lying »taut« against the
guide rail -A-. If the timing chain is still »loose«, the camshaft
chain sprocket must be offset by one tooth.
– Have a second technician hold the camshaft timing chain at

pre-load using the Wrench - Pin Type - 3212- in the direction
of -arrow-.
– Tighten the bolts as follows while the camshaft chain sprocket
is still held under tension.
1- Tighten the Bolt for the Exhaust Camshaft to 80 Nm
2- Tighten the Bolt for the Intake Camshaft to 80 Nm
– Tighten the bolts to the final tightening specification. To do so,
counterhold using the Wrench - Pin Type - 3036- or the
Wrench - Pin Type - 3212- .
1- Turn the Bolt for the Exhaust Camshaft an Additional 90°
Turn. While Doing so, Counterhold with the Wrench - Pin
Type - 3212-
2- Turn the Bolt for the Intake Camshaft an Additional 90° Turn.
While Doing so, Counterhold with the Wrench - Pin Type -
3036-
AG. Volkswagen AG d
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4.5.3 Camshaft Adjuster, Installing, Cylinder by
Volksw not
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Bank 2 (Left) ed
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• Tightening specifications. Refer to ss c
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Note
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hole
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Caution

rrectness of i

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4. Valvetrain 135

- T40069- .
• Camshafts secured in “TDC” using the Camshaft Clamp - agen
AG. Volkswagen AG d
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T40133/2- -arrows- (25 Nm). olksw not
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– Place the timing chain on the camshaft adjuster -A- and place
es, in part or in w
the camshaft adjuster on the camshaft. Pay attention to the
t to the co
following:
• The timing chain must rest »taut« on the guide rail -arrow-.
rrectness of i
• The timing chain must be tensioned »by hand« in the direction
l purpos
of the -arrow-.
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• The groove -1- in the camshaft adjuster must align with the
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– Insert the camshaft chain sprocket into the timing chain and
place the camshaft chain sprocket on the camshaft. Pay at‐
tention to the following:
• The marking point -1- must be centered with respect to the
adjustment window -2-. wage
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– Install the bolts -1 and 2- loosely. The camshaft adjuster and
h re
hole
the camshaft chain sprocket must be able to still be rotated on
spec
camshaft and must not tip.
es, in part or in w
t to the co
rrectness of i
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nf
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orm
m
atio
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ing chain inward all the way using a screwdriver -1- and
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remove the Locking Pin - T40071- .

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– Position the Wrench - Pin Type - 3036- on the camshaft ad‐

juster.
– Press the Wrench - Pin Type - 3036- in the direction of
-arrow- and check if the timing chain is lying »taut« against the
guide rail -A-. If the timing chain is still »loose«, the camshaft
chain sprocket must be offset by one tooth.
4. Valvetrain 137
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– Have a second technician hold the camshaft
Vol
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pre-load using the Wrench - Pin Typeed - 3036- in the direction
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– Tighten the bolts as follows while
ss the camshaft adjuster is still c
ce
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held under pretension.
nl
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1- Tighten the Bolt for the Intake Camshaft to 80 Nm
y li
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ab
ility
2- Tighten the Bolt for the Exhaust Camshaft to 80 Nm
ot p
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– Tighten the bolts to the final tightening specification. To do so,
h re
hole
counterhold using the Wrench - Pin Type - 3036- or the
spec
Wrench - Pin Type - 3212- .
es, in part or in w
t to the co
1- Turn the Bolt for the Intake Camshaft an Additional 90° Turn.
While Doing So, Counterhold with the Wrench - Pin Type -
3036-
rrectness of i
2- Turn the Bolt for the Exhaust Camshaft an Additional 90°
l purpos
Turn. While Doing so, Counterhold with the Wrench - Pin

Type - 3212-
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4.6 Hydraulic Adjuster, Checking

m
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Note
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♦ The hydraulic adjuster cannot be repaired.

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♦ Irregular valve noises are normal while starting the engine.
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♦ Feeler Gauge
Procedure
– Start the engine and let it run until the coolant fan switches on
once.
– Increase engine speed for about two minutes to approximately
2500 RPM, perform a road test if necessary.
– If the hydraulic adjusters are still loud, determine which one is
faulty as follows:
WARNING

♦ The coolant fan can come on even when the ignition is
turned off, for example, caused by the heat still in the en‐
gine compartment.
– Remove the cylinder head cover. Refer to left side

page 80 .

AG. Volkswagen AG d
agen oes
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Engine Mechanical,
ut
ho Fuel Injection and Ignition (Hybrid)e -or Edition 07.2015
a ac
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– Insert the Crankshaft Socket - T40058- guide pins as follows:
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le
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pt
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rm
ab
pe
ility
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es, in part or in w
t to the co
rrectness of i
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– Rotate the crankshaft in direction of engine rotation -arrow-
nform
ercia
using the Crankshaft Socket - T40058- and offset open-end

wrench.
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– To determine the play between cam lobes and roller rocker

lever, press the lever down in direction of -arrow-.
– If a 0.20 mm feeler gauge can slide between the cam lobes
and roller rocker lever, replace the hydraulic adjuster. Refer to
Final Procedures
– Install the cylinder head cover. Refer to left side
page 80 .
4.7 Valve Stem Seals with Installed Cylinder

Head, Removing and Installing
♦ Puller - Valve Seal - 3364-
♦ Seal Installer - Valve Stem - 3365-
♦ Valve Keeper Tool Kit - VAS5161A- with the Valve Cotter Tool
Kit - Guide Plate 19c - VAS5161/19C-
♦ Valve Cotter Tool Kit - Adapter - T40012-
Removing
– Mark the allocation of the roller rocker lever and the hydraulic
adjuster so they can be installed again.
– Remove the roller rocker levers with the hydraulic adjuster and
place them on a clean surface.
4. Valvetrain 139
– Remove the spark plugs with the Spark Plug Removal Tool -
3122B- .
– Set the piston for the respective cylinder to “bottom dead cen‐
ter”.
– Position the Valve Cotter Tool Kit - Punch - VAS5161/3- on the
valve spring plate and loosen the stuck valve retainers with a
plastic mallet.
– Place Valve Cotter Tool Kit - Guide Plate 19B - VAS5161/19B-

from Valve Cotter Tool Kit - VAS5161- on the cylinder head.
– Secure the guide plate with the Valve Cotter Tool Kit - Knurled
Thumb Screws - VAS5161/12- .
– Install the Valve Cotter Tool Kit - Adapter - T40012- with gasket
in the spark plug thread and tighten by hand.
– Connect the adapter to the compressed air using a commer‐
cially available intermediate piece and give steady pressure.
• Minimum pressure: 6 bar (87 psi)
AG. Volkswagen AG d
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– Install the Valve riseCotter Tool Kit - Retainer - VAS5161/6-
d ara
ntwith
the Guide Forksutho M6/M8 with Valve Cotter Tool Kit - Threaded
ee
or
Studs - VAS5161/5-
ss
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– Push Valve Cotter Tool Kit - Assembly Cartridge - VAS5161/8-

un
pt
an
d
into guide plate.

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– Engage the Valve Cotter Tool Kit - Pressure Fork -

ility
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VAS5161/2- at the engaging device and press the installation

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cartridge downward.
h re
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spec
– At the same time, rotate the cartridge knurled screw right until
points engage in the valve keepers.

t to the co
– Move the knurled bolt left and right slightly. This presses the
valve keepers apart and captures them in the installation car‐
rrectne
tridge.
– Release the pressure fork.
ss o
cial p
– Remove the cartridge.

inform
mer
– Remove the guide plate and turn it aside.

atio
m
• The pressurized air hose remains connected.

o
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– Remove the valve spring and the valve spring retainer.

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– Remove the valve stem seal with the Puller - Valve Seal -
3364- .
If the Puller - Valve Seal - 3364- cannot be used on some valve
stem seals due to restricted clearance:
– Remove the roll pin -arrow- on the puller with a drift and re‐
move the impact puller attachment.
– Position the lower part of the Puller - Valve Seal - 3364- on the
valve stem seal. agen
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– Secure the puller with a drift or cotter pin drive -1- asd bshown
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the illustration. horise
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– Position the extractor lever on the puller and remove the valve
hole
spec
stem seal in direction of -arrow-.
es, in part or in w
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There is a risk of damage when installing valve stem seals.
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♦ Place the plastic sleeve -A- that is attached to the new
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valve stem seals -B- on the valve stem. Prote AG.
– Lightly oil the valve stem seal sealing lip.

– Slide the valve stem seal onto the plastic sleeve.
– Carefully press the valve stem seal onto the valve guide with
the Seal Installer - Valve Stem - 3365- .
– Remove the plastic sleeve again.
4. Valvetrain 141
If the valve keepers were removed from the installation cartridge,

they must be inserted into the Valve Cotter Tool Kit - Valve In‐
sertion Device - VAS5161/18- first.
• The large diameter of the valve keepers point upward.
– Press the installation cartridge from above onto valve retainer
inserting tool and valve keepers.
– Insert the valve spring and the valve spring retainer.

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• The tight spring coils -arrow- face toward cylinder head. agen oes
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– Install the guide plate on the cylinder head. orised
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– Insert the installation cartridge into the guide plate. ss a c
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– Press the pressure fork down and pull the knurled screw up
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pt
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while turning left and right. This inserts the valve retainers.
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– Release the pressure fork with the knurled screw still raised.
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– Repeat the procedure on each valve.
Assembling
rrectne
– Make sure all the roller rocker levers lie on the ends of the
valve stems correctly and are clipped onto the respective hy‐
s
draulic adjusters.
s o
cial p
f in
– Install the camshafts. Refer to
form
mer
atio
m
– Install the Ignition Coils with Power Output Stages . Refer to

o
n
c
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or
n
thi
e

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4.8 Valve Stem Seals with Removed Cylin‐
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Special tools and workshop equipment required Prote AG.

♦ Seal Installer - Valve Stem - 3365-
♦ Valve Keeper Tool Kit - VAS5161A- with the Valve Cotter Tool
Kit - Guide Plate 19c - VAS5161/19C-
♦ Engine and Gearbox Bracket VAS6095A - VAS6095A-
♦ Cylinder Head Tensioning Device - VAS6419-
Procedure
– Mark the allocation of the roller rocker lever and the hydraulic
adjuster so they can be installed again.
– Remove the roller rocker levers with the hydraulic adjuster and
place them on a clean surface.

– Insert the Cylinder Head Tensioning Device - VAS6419- in the

Engine and Gearbox Bracket VAS6095A - VAS6095A- .
– Tension the cylinder head on the cylinder head tensioning de‐
vice, as shown.
– Connect the cylinder head tensioning device to the com‐
pressed air.
– Slide the air cushion with the lever -arrow- under the combus‐
tion chamber onto the valve stem seal that will be removed.
– Let enough compressed air flow into the air cushion until it
contacts the valve plate.
– Position Valve Cotter Tool Kit - Punch - VAS5161/3- on the

valve spring plate and loosen the stuck valve retainers with a
plastic mallet.
– Place Valve Cotter Tool Kit - Guide Plate - VAS5161/19B- from

Valve Cotter Tool Kit - VAS5161- on the cylinder head.
– Secure the guide plate with the Valve Cotter Tool Kit - Knurled
Thumb Screws - VAS5161/12- .
AG. Volkswagen AG d
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– Install the Valve Cotter Tool Kit - Retainer - VAS5161/6- with

ility
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the Guide Forks M6/M8 with Valve Cotter Tool Kit - Threaded
wit
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Studs - VAS5161/5- in the guide plate.

h re
hole
spec
– Push Valve Cotter Tool Kit - Assembly Cartridge - VAS5161/8-

es, in part or in w
into guide plate.

t to the co
– Engage the 1 Pressure Fork with Lever for Assembly Cartridge

- VAS5161/2- at the engaging device and press the installation
rrectness of i
cartridge downward.
l purpos
– At the same time, rotate the cartridge knurled screw right until
points engage in the valve keepers.
nform
ercia
– Move the knurled thumb screw back and forth slightly. This
presses the valve retainers apart and captures them in the in‐
m
at
om
stallation cartridge.
ion
c
in t
or
– Release the pressure fork.

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ate
do
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– Remove the cartridge.

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– Remove the guide plate and turn it aside.

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– Remove the valve spring and the valve spring retainer.
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4. Valvetrain 143
– Remove the valve stem seal with the Puller - Valve Seal -
3364- .
Installing
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There is a risk of damage when installing valve stem
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♦ Place the plastic sleeve -A- that is attached
ss to the new
valve stem seals -B- on the valve stem.
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– Lightly oil the valve stem seal sealing lip.
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– Slide the valve stem seal onto the plastic sleeve.
h re
hole
spec
– Carefully press the valve stem seal onto the valve guide with
es, in part or in w
the Seal Installer - Valve Stem - 3365- .
t to the co
– Remove the plastic sleeve again.
rrectness of i
If the valve retainers were removed from the installation cartridge,
they must be inserted into the Valve Cotter Tool Kit - Valve In‐
l purpos
sertion Device - VAS5161/18- first.

• The large diameter of the valve keepers point upward.
nform
ercia
– Press the installation cartridge from above onto valve retainer

m
at
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inserting tool and valve retainers.
on
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ate
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Cop py
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– Insert the valve spring and the valve spring retainer.
by lksw
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• The tight spring coils -arrow- face toward cylinder head.
– Install the guide plate on the cylinder head.
– Insert the installation cartridge into the guide plate.
– Press the pressure fork down and pull the knurled screw up
while turning left and right. This inserts the valve retainers.
– Release the pressure fork with the knurled screw still raised.

– Repeat the procedure on each valve.

Assembling
– Make sure all the roller rocker levers lie on the ends of the
valve stems correctly and are clipped onto the respective hy‐
draulic adjusters.
– Install the camshafts. Refer to
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4. Valvetrain 145
AG. Volkswagen
Touareg 2010 ➤ ,lkTouareg
swa
gen 2015 ➤ AG does n
Vo o g
Engine Mechanical,
db
y Fuel Injection and Ignition t(Hybrid)
ua
ra - Edition 07.2015
e nte
ris
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5 Intake and Exhaust Valves
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⇒ “5.1 Valve Guides, Checking”, page 146

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⇒ “5.2 Valves, Checking”, page 146
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⇒ “5.3 Valve Dimensions”, page 147
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spec
5.1 Valve Guides, Checking
t to the co
rrectne
s
Procedure:
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mer
Note
atio
om
n
c
i
♦ If the valve is replaced during repair, use the new valve for
or
n thi
e
measurement.
t
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pr
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♦ Due to different stem diameters, only use an intake valve in
um
r
fo
en
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the intake guide and an exhaust valve in the exhaust guide.

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– Secure the Dial Gauge - 0-10mm - VAS6079- on the cylinder
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head with the Dial Gauge Holder - VW387- as shown in the by c lksw
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illustration. Prote AG.
– Place the valve in the valve guide.

• Valve stem tip must seal with valve guide.
– Determine the tilting clearance.
– If the wear limit is exceeded, measure using new valves.
– Replace the cylinder head if the wear limit is still exceeded.
Note
The valve guides cannot be replaced.
5.2 Valves, Checking

– Check the valves at stem and seating surface for traces of
wear.
– If there are clear traces of wear, replace the valve.

AG. Volkswagen AG d
agen oes Touareg 2010 ➤ , Touareg 2015 ➤
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ara
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5.3 Valve Dimensions
au ra
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Note
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Intake and exhaust valves must not be reworked. Only lapping is
wit
, is n
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permitted.
hole
spec
es, in part or in w
t to the co
Dimension Intake Valve Exhaust Valve
Diameter mm 33.85 ± 0.10 28.0 ± 0.10
a
rrectness of i
Diameter mm 5.98 ± 0.01 5.96 ± 0.01
l purpos
b
c mm 104.00 ± 0.20 101.9 ± 0.20
nform
ercia
α ∠° 45 45
m
at
om
ion
c
WARNING
in t
or
his
ate
do
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Risk of injury if exhaust valves with sodium filling are disposed

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or
of improperly.
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♦ Cut exhaust valve with sodium filling into two parts with a
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metal saw between shaft center and valve plate. While
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doing this, do not come into contact with water.
cop Vo
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♦ Throw at the most 10 such sawed exhaust valves in a
bucket filled with water and step back immediately.
♦ When there is contact with water, a sudden chemical re‐
action occurs which burns the sodium filling.
♦ The treated parts may then be discarded through conven‐
tional disposal channels.
5. Intake and Exhaust Valves 147

6 Special Tools

equipment required
♦ Multipoint Socket - T10035-
♦ Crankshaft Socket -
T40058-
♦ Crankshaft Locking Pin -
T40069-
(quantity: 2)
AG. Volkswagen AG d
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rrectness of i
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nf
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Cop py
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Prote AG.

♦ Spark Plug Removal Tool -

3122B-
♦ Seal Installer - Valve Stem
- 3365-
♦ Valve Keeper Tool Kit -
VAS5161A- with the Valve
Cotter Tool Kit - Guide
Plate 19c - VAS5161/19C-
♦ Valve Cotter Tool Kit -
Adapter - T40012-
AG. Volkswagen AG d
agen oes
olksw not
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nl
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du
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itte
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ility
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wit
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hole
spec
es, in part or in w
t to the co
rrectness of i
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nform
mercia
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ion
c
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or
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ate
do
priv
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for
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t.
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Cop py
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149
cop Vo
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Prote
cted AG.
agen 6. Special Tools

♦ Seal Installer - Valve Stem
- 3365-
♦ Valve Keeper Tool Kit -
VAS5161A- with the Valve
Cotter Tool Kit - Guide
Plate 19c - VAS5161/19C-
♦ Engine and Gearbox
Bracket VAS6095A -
VAS6095A-
♦ Cylinder Head Tensioning
Device - VAS6419-
lkswage es n
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rrectness of i
♦ Injector/Combustion Chamber Seal Tool Set - Sliding Hammer

l purpos
- T10133/3- from Injector/Combustion Chamber Seal Tool Set

- T10133B-
nform
mercia
a
com
tion in
r
te o
thi
s
iva
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cum
fo
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t.
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Cop py
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Prote AG.

♦ Crankshaft Key - T40049-
♦ Locating Pins - T40116- agen

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♦ Camshaft Clamp - T40133-

rrectness of i
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nf
ercia
orm
m
atio
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Cop py
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Prote AG.
6. Special Tools 151

♦ Compression Tester Kit - VAG1763-
AG. Volkswagen AG d
agen oes
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m
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Prote AG.


17 – Lubrication
1 Oil Pan/Oil Pump
⇒ “1.1 Overview - Oil Pan/Oil Pump”, page 153
⇒ “1.2 Engine Oil”, page 155
⇒ “1.3 Oil Pan Lower Section, Removing and Installing”,
page 157
⇒ “1.4 Oil Pan Upper Section, Removing and Installing”,
page 159
⇒ “1.5 Oil Pump, Removing and Installing”, page 161
⇒ “1.6 Oil Level Thermal Sensor G266 , Removing and Installing”,
page 162
1.1 Overview - Oil Pan/Oil Pump
1 - Nut
❑ 9 Nm
2 - Oil Level Thermal Sensor -
G266-
ling. Refer to
⇒ “1.6 Oil Level Ther‐
mal Sensor G266 , Re‐
page 162 .
3 - Gasket
AG. Volkswagen AG d
❑ Replace agen oes
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4 - Oil Pan Lower
rise
d Section nte
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❑ Removing
aut and instal‐ ra
c
ling.
ss
Refer to
ce
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⇒ “1.3 Oil Pan Lower

un
pt
an
Section, Removing and

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5 - Bolt
ot
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❑ 3 Nm +90°
hole
spec
❑ Replace
es, in part or in w
t to the co
6 - Lower Oil Baffle

7 - Bolt
rrectness of i
❑ Replace
l purpos
⇒ Fig. ““Oil Pan Upper
nform
ercia
Section - Tightening
Specifications and Se‐
m
a
com

ion in
r
te o
8 - Oil Pan Upper Section

thi
s
iva
do

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ling. Refer to
fo
en
g
⇒ “1.4 Oil Pan Upper Section, Removing and Installing”, page 159 .
n
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Cop py
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❑ Quantity: 2
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Prote AG.
1. Oil Pan/Oil Pump 153

agen AG olksw
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Engine Mechanical, Fuel Injection andd bIgnition
y V (Hybrid) - Edition 07.2015 gu
a
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10 - O-Ring utho or
a ac
ss
❑ Insert into guide frame
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un
pt
❑ Replace
an
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ab
11 - Bolt
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❑ Insert with locking fluid. Refer to the Parts Catalog for the locking fluid.
wit
, is n
h re
❑ 9 Nm
hole
spec
12 - Upper Oil Baffle
es, in part or in w
t to the co
13 - Seal
❑ Insert into guide frame
rrectness of i
❑ Replace
l purpos
14 - Seal
❑ Replace
nform
ercia
15 - Bolt
m
a
com
t
❑ 3 Nm +90°
ion in
r
❑ Replace
te o
thi
s
iva
do
16 - Engine Oil Cooler
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❑ With oil cooler bypass valve
en
ng
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❑ See note. Refer to ⇒ page 163 . t. Cop py
rig
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❑ Removing and installing. Refer to ⇒ “2.1 Engine Oil Cooler, Removing and Installing”, page 163 .
ht
pyri by
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17 - Bolt
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Prote AG.
❑ 9 Nm
18 - Oil Pump Input Shaft
19 - Pressure Spring
20 - Sleeve
❑ Quantity: 2
21 - Bracket
22 - Bolt
❑ 9 Nm
23 - Chain Sprocket for Oil Pump
❑ Can only be placed onto drive axle in one position
24 - Bolt
❑ 30 Nm +90°
❑ Replace
❑ For loosening and tightening, counterhold on the chain sprocket with a Wrench - Pin Type - 3212-
25 - O-Ring
❑ Replace
26 - Seal
❑ Replace
27 - O-Ring
❑ Replace
28 - Oil Pump
❑ Do not disassemble
❑ Removing and installing. Refer to ⇒ “1.5 Oil Pump, Removing and Installing”, page 161 .
29 - Bolt
❑ 20 Nm
154 Rep. Gr.17 - Lubrication

30 - Bolt
❑ Replace
⇒ Fig. ““Oil Pan Lower Section - Tightening Specification and Sequence”“ , page 155 .
31 - Gasket
❑ Replace
32 - Oil Drain Plug
❑ 30 Nm
AG. Volkswagen AG d
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Oil Pan Lower Section - Tightening Specification andbySequence
Vo gu
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Note ss c
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– Tighten bolts in two stages as follows:
ot
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Step Tightening Specification/Additional Turn
hole
spec
1. 5 Nm diagonally
es, in part or in w
t to the co
2. in a diagonal sequence, turn an additional 90°
rrectness of i
Oil Pan Upper Section - Tightening Specifications and Sequence
l purpos
Note
nform
ercia

m
a
com
tion in
– Tighten bolts as follows:
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Aluminum Bolts
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Turn Cop py
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1. -1 to 6- Install all the way in by hand. py by
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2. -1 to 6- 8 Nm diagonally
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Prote AG.
3. -1 to 6- in a diagonal sequence, turn an addi‐

tional 90°
Steel Bolts
Turn
1. -1 to 6- Install all the way in by hand.
1.2 Engine Oil
Caution
Danger of catalytic converter damage.

♦ The oil level must not exceed the “MAX” mark.

AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
Touareg ris 2010 ➤ , Touareg 2015 ➤
ed
nte
o eo
Engine
aut Mechanical, Fuel Injection and Ignition (Hybrid)
h
ra - Edition 07.2015
ss c
ce
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un
pt
an
d
itte
Note
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ility
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If large quantities of metal shavings or abraded material are found
wit
is n
in the engine oil while servicing the engine, the oil channels must
h re
ole,
be carefully cleaned to prevent subsequent damage and the en‐
spec
gine oil cooler must be replaced.
t to the co
Engine Oil Specification. Refer to ⇒ Fluid Capacity Tables; Rep.
Gr. 03 .
rrectne
Oil Capacity:
s
Refer to ⇒ Fluid Capacity Tables; Rep. Gr. 03
s o
cial p
f i
Refer to
nform
⇒ “1.2.1 Engine Oil Level, Checking with Gauge - Oil Gauge Test‐
mer
atio
er T40178 ”, page 156 .
om
n
c
i
1.2.1
or
Engine Oil Level, Checking with Gauge
n thi
te
sd
a
- Oil Gauge Tester - T40178-

iv
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Checking the engine oil level in the Infotainment display. Refer to

t.
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⇒ Maintenance ; Booklet 29.1 ; Engine Oil Level: Checking . Cop py
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Test Conditions py by
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• The engine oil temperature must be at least 60 °C (140 °F).
Prote AG.
• The vehicle is on level ground.

• After stopping engine, wait a few minutes to allow oil to flow
back into oil pan.
♦ Gauge - Oil Gauge Tester - T40178-
Test Sequence
– Loosen the knurled bolt -arrow- on the adjusting ring. Adjust
the lower edge of the adjusting ring to the adjustment value
1) from the table.
– Install the oil gauge tester all the way into the oil dipstick tube.
Then pull it out and read the oil level again.
– Read the value on the lower scale.

Engine Value on the Upper Ad‐ Minimum Oil Level on the Maximum Oil Level on the
justing Ring 1) Lower Scale. Lower Scale.
3.0 L engine FSI 120 mm 0 mm 13 mm
3.0L FSI engine (only valid 111 mm 0 mm 22 mm
for China)
1.3 Oil Pan Lower Section, Removing and

Installing
Removing:
Note
♦ Place a cloth under the engine oil cooler to catch any oil drip‐
ping out.
♦ The oil pan sealant has strong adhesive properties. Pry off the
oil pan slowly and evenly so that it does not bend.
– Drain the engine oil.

– Remove the engine oil cooler from the engine and secure it to
the side. Refer to
⇒ “2.1 Engine Oil Cooler, Removing and Installing”,
page 163 . The coolant hoses can remain attached.
– Remove the bolts -1 to 3-.
AG. Volkswagen AG d
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hole
spec
es, in part or in w
– Remove the bolt -arrow- from the ATF lines.

t to the co
– Disconnect the electrical connector -2- on the Oil Level Ther‐

mal Sensor - G266- and free up the electrical wire.
rrectness of i
– Remove the bolts -1- for the lower section of the oil pan.
l purpos
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157
copy Vo
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cted 1. Oil Pan/Oil Pump
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Prote AG.
– Slowly loosen the oil pan lower section from the bonding.
While doing so, do not bend the oil pan lower section.
Installing
⇒ Fig. ““Oil Pan Lower Section - Tightening Specification and
Note
♦ Replace seals.
♦ Replace the lower section of the oil pan if the coating on it is
damaged or if it is bent.
♦ Be sure to check the expiration date of the sealant.
Caution

AG. Volkswagen AG d
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WARNING ed b ara
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Danger of eye injury. ss a c
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nl
pt
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itte
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erm
ab
ility
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– Remove any sealant residue on the oil pan lower and upper
wit
, is n
h re
sections using a rotating plastic brush.
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
– Cut the tube nozzle at the front marking (tube nozzle diameter:
or
his
e
approximately 1 mm).
at
do
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Caution
n
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The lubrication system could be blocked with excess sealant. rig ht
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♦ Do not apply sealant bead thicker than indicated. cted agen
Prote AG.

– Apply the sealant bead -arrow- to the clean sealing surfaces

of the lower section of the oil pan as shown in the illustration.
• Sealant bead thickness: approximately 1.5 mm
Note
Install the lower section of the oil pan within five minutes of ap‐
plying the sealant.
– Position the oil pan lower section and tightenolktheswa bolts. Refer
ge es n
ot g
to by V ua
ed ran
⇒ Fig. ““Oil Pan Lower Section - Tightening
horis Specification and tee
Sequence”“ , page 155 . au
t or
ac
ss
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le
un
pt
an
d
itte
– Install the engine oil cooler. Refer to
y li
rm
ab
⇒ “2.1 Engine Oil Cooler, Removing and Installing”,
pe
ility
page 163 .
ot
wit
, is n
h re
– Install the ATF lines. Refer to ⇒ Rep. Gr. 37 .
hole
spec
– Fill the engine oil and check the oil level. Refer to
es, in part or in w
⇒ “1.2.1 Engine Oil Level, Checking with Gauge - Oil Gauge
t to the co
Tester T40178 ”, page 156 .
rrectness of i
1.4 Oil Pan Upper Section, Removing and
l purpos
Installing
nform
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tio
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Removing:
um
fo
en
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t.
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• The engine is secured to the engine and transmission holder.
Co
op py
Refer to
t. C rig
gh ht
yri
⇒ “1.2 Engine, Securing to Engine and Gearbox Bracket p by
co Vo
VAS6095A ”, page 20 .
by lksw
cted agen
Prote AG.
page 97 .
– Remove the oil pump. Refer to
⇒ “1.5 Oil Pump, Removing and Installing”, page 161 .
– Remove the bolts -arrows- and remove the oil baffle down‐
ward.
– Loosen and remove the oil pan upper section bolts
-1 through 6- in a diagonal sequence.

– Carefully loosen the oil pan upperensection

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press it off the cylinder block
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• Tightening to specifications.
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⇒ “1.1 Overview - Oil Pan/Oil Pump”, page 153 .
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Note
pe
ility
ot
wit
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Replace the gasket and O-ring.
h re
hole
spec
es, in part or in w
t to the co
Caution
rrectness of i
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nform
ercia
– Remove any old sealant from the grooves on the oil pan upper
m
a
section as well as from the sealing surfaces.
com
tion in
r
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WARNING
s
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fo

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t.
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op py
♦ Wear protective eyewear. t. C rig
gh ht
pyri by
Vo
co lksw
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cted agen
Prote AG.
– Remove the sealant residue on the cylinder block and the up‐
per section of the oil pan, for example using a rotating plastic
brush.
– Cut the tube nozzle at the front marking (nozzle diameter: ap‐
proximately 1.5 mm).
Note
Caution


AG. Volkswagen AG d
agen
Volksw
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not Touareg 2010 ➤ , Touareg 2015 ➤
by gu
ed Engine Mechanical, Fuel
ara Injection and Ignition (Hybrid) - Edition 07.2015
nte
ris
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– Apply
ss a
a sealant bead -arrow- to the clean sealing surface
c on
the upper section of the oil pan as shown in the illustration.
ce
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nl
pt
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an
• Completely fill the grooves on the sealing surfaces with seal‐
itte
y li
erm
ant.
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ility
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• The sealant bead must be 1.5 to 2.0 mm above the sealing
wit
, is n
surface.
h re
hole
spec
es, in part or in w
t to the co
Note
Install the upper section of the oil pan within five minutes of ap‐
rrectness of i
plying the sealant.
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n in
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– Insert the seal -1- and the O-ring -2- in the guide frame.
cu
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t.
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Cop py
t. rig
gh ht
pyri by
Vo
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by c lksw
cted agen
Prote AG.
– Position the oil pan upper section while paying attention to the
alignment bushings and tighten the bolts. Refer to
⇒ Fig. ““Oil Pan Upper Section - Tightening Specifications and
– Install the oil pump. Refer to
⇒ “1.5 Oil Pump, Removing and Installing”, page 161 .
page 97 .
1.5 Oil Pump, Removing and Installing

Removing
– Remove the oil pan lower section. Refer to
⇒ “1.3 Oil Pan Lower Section, Removing and Installing”, page
157 .

– Remove the oil pump forward from the input shaft.

Installing
Note
Replace the gasket and O-ring.
– Install oil pump onto the drive axle and fasten.

– Install the oil pan lower section. Refer to
⇒ “1.3 Oil Pan Lower Section, Removing and Installing”, page
157 .
1.6 Oil Level Thermal Sensor - G266- , Re‐

Removing
– Drain the engine oil.
– Disconnect the connector -3-. lkswage es n
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byV ua
ed ran
– Remove the nuts -1- and the Oil Level Thermal Sensor or - G266-
is tee
-4-. auth or
ac
ss
Installing
ce
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nl
pt
du
an
itte
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erm
ab
ility
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wit
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– Replace the seal -2-.
hole
spec
es, in part or in w
– Oil Level, Checking. Refer to

t to the co
Tester T40178 ”, page 156 . rrectness of i
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nform
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at
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or
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ate
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t.
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lkswage es n
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tho Touareg
tee
or 2010 ➤ , Touareg 2015 ➤
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ss
a
Engine Mechanical, Fuel Injection and Ignition ac
(Hybrid) - Edition 07.2015
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2 Engine Oil Cooler
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ab
ility
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⇒ “2.1 Engine Oil Cooler, Removing and Installing”, page 163
wit
is n
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2.1 Engine Oil Cooler, Removing and Instal‐
ole,
spec
ling
t to the co
rrectne
Removing
ss o
cial p
f in
Note
form
mer
atio
m
♦ If large quantities of metal particles or abraded material are

o
n
c
i
detected during engine repairs, it may mean the crankshaft or
or
n thi
e
rod bearings are damaged. To prevent damage, perform the

t
sd
va
following steps after completing the repair: carefully clean the

i
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pr
cum
r
oil channels and replace the oil spray jets, the oil cooler and
fo
en
ng
the oil filter.

t.
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♦ Oil injector jet for piston cooling. Refer to
t
gh ht
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⇒ Fig. ““Oil Spray Jet for Piston Cooling”“ , page 68 . cop Vo
by lksw
cted agen
Prote AG.

– Open and then close the coolant expansion tank to reduce the
pressure in the coolant system.
– Clamp off the coolant hoses using the Hose Clamps - Up To
25mm - 3094- as shown.
– Remove the coolant hoses from the oil cooler.
– Remove the oil pan/engine oil cooler bolt -arrow-.

– Place the Used Oil Collection and Extraction Unit -
SMN372500- under the engine.
2. Engine Oil Cooler 163

– Remove the bolts -1 through 4- and remove the engine oil

cooler.
Installing
– Check the coolant level.
– Oil level, checking. Refer to
AG. Volkswagen AG d
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nf
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3 Crankcase Ventilation
⇒ “3.1 Overview - Crankcase Ventilation”, page 165
⇒ “3.2 Crankcase Ventilation Pipes, Removing and Installing”,
page 166
⇒ “3.3 Oil Separator, Removing and Installing”, page 166
3.1 Overview - Crankcase Ventilation
1 - O-Ring
❑ Replace
2 - Oil Check Valve
❑ 20 Nm
❑ For oil supply to right
cylinder head
3 - Seal
❑ Replace
4 - Cover with Oil Separator
❑ With connection for gen AG
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❑ Removing and instal‐rised b ara
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⇒ “3.3 Oil Separator,
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ling”, page 166 .

an
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5 - Bolt
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❑ 9 Nm
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6 - O-Ring
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spec
❑ Replace
t to the co
7 - Connection
❑ For the crankcase ven‐
tilation
rrectne

to
ss
⇒ Fig. ““Installing the

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Crankcase Ventilation
nform
Connector”“ , page 166

mer
atio
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8 - O-Ring
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❑ Replace
thi
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9 - Bolt
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❑ 9 Nm
en
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10 - Bolt
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❑ 3 Nm
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11 - Crankcase Ventilation Pipes
Prote AG.
❑ To the cylinder head covers

⇒ “3.2 Crankcase Ventilation Pipes, Removing and Installing”, page 166 .
12 - O-Rings
❑ Replace
13 - Crankcase Ventilation Hose
❑ To the air guide pipe
3. Crankcase Ventilation 165

14 - Hose Clamp
15 - Oil Check Valve
❑ 20 Nm
❑ For oil supply to left cylinder head
16 - O-Ring
❑ Replace
Installing the Crankcase Ventilation Connector

– Install the crankcase ventilation connector -1- with new O-
rings into the oil separator cover.
• Installed position: the tab -2- must engage into the guide
-arrow-.
3.2 Crankcase Ventilation Pipes, Removing

and Installing
Removing
Note
lkswage es n
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byV ua
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During installation,
oris all cable ties must be installed at the same
tee
location. au th or
ac
ss
ce
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nl

pt
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ab
– Press the release buttons and remove the crankcase ventila‐

ility
ot p
tion pipes -arrows- from the cylinder head covers.

wit
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h re
hole
– Remove the bolt -1- and the connections for the crankcase
spec
ventilation hoses.
es, in part or in w
t to the co
Installing
rrectness of i
⇒ “3.1 Overview - Crankcase Ventilation”, page 165 .

l purpos

nform
ercia
Note
m
at
om
io

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c
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or
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ate
do
– Install the compressor. Refer to

priv

um
for
en
ng
t.
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op py
3.3 Oil Separator, Removing and Installing
t. C rig
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Vo
co
Removing
by lksw
cted agen
Prote AG.
– Remove the crankcase ventilation pipes. Refer to
page 166 .


page 211 .
– Remove the left lower section of the intake manifold. Refer to
– Remove the high pressure pipes and oil separator cover -1-.
Installing
⇒ “3.1 Overview - Crankcase Ventilation”, page 165 .
Note lkswage es n
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byV ua
d ran
ir se
Replace the seal. utho tee
or
a ac
ss
ce
– Install the intake manifold left lower section. Refer to
e
nl
pt
du
an
itte
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erm
ab
ility
ot p
– Install the upper coolant pipe. Refer to
wit
, is n
h re
page 211 .
hole
spec
es, in part or in w
– Install the crankcase ventilation pipes. Refer to
t to the co
page 166 .
rrectness of i
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nf
ercia
orm
m
atio
om
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or c
thi
te
sd
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t.
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Cop py
t. rig
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Prote AG.
3. Crankcase Ventilation 167

4 Oil Filter/Oil Pressure Switch

⇒ “4.1 Overview - Oil Filter Housing/Oil Pressure Switch”,
page 168
⇒ “4.2 Oil Pressure Switch F22 , Removing and Installing”, page
169
⇒ “4.3 Reduced Oil Pressure Switch F378 , Removing and In‐
⇒ “4.4 Oil Pressure, Checking”, page 171
⇒ “4.5 Oil Pressure Switch F22 / Reduced Oil Pressure Switch
F378 , Checking”, page 172
⇒ “4.6 Oil Filter Housing, Removing and Installing”, page 172
⇒ “4.7 Oil Pressure Regulation Valve N428 , Removing and In‐
4.1 Overview - Oil Filter Housing/Oil Pressure Switch
1 - Bolt
❑ 13 Nm
2 - Oil Pressure Switch - F22- lkswage es n
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❑ 20 Nm ir se
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ho
❑ Switching pressure 2.5 aut or
ac
to 3.2 bar (36.25 to ss
ce
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46.41 psi)
nl
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itte
❑ Check in Guided Fault
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ab
Finding . Refer to Vehi‐
ility
ot p
cle Diagnostic Tester .
wit
, is n
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hole
ling. Refer to
spec
⇒ “4.2 Oil Pressure
es, in part or in w
t to the co
Switch F22 , Removing
and Installing”,
page 169 .
rrectness of i
3 - Gasket
l purpos
❑ Replace
4 - Collar Nut
nf
ercia
❑ 13 Nm
rm
m
atio
m
5 - Bolt
o
n in
or c
❑ 9 Nm
thi
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sd
iva
6 - Sleeve
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f
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ng
7 - Rubber Grommet
t.
yi Co
Cop py
8 - Oil Filter Housing
t. rig
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❑ With filter bypass valve
cop Vo
by lksw
cted agen
Prote
❑ With oil check valve
AG.
❑ Oil check valve cannot

be replaced
9 - O-Ring
❑ Replace
❑ Inserting. Refer to ⇒ Fig. ““O-Ring, Inserting on Oil Filter Housing”“ , page 169
10 - Cap
❑ 25 Nm

11 - Gasket
❑ Replace
❑ Removing and installing. Refer to ⇒ Fig. ““Sealing Ring on Cap, Replacing”“ , page 169 .
12 - Oil Filter
❑ Removing and installing. Refer to ⇒ Maintenance ; Booklet 406
13 - Threaded Pin
❑ 16 Nm
14 - Seal agen
AG. Volkswagen AG d
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Sealing Ring on Cap, Replacing
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– Remove the gasket -2- from the cap -1- at the pull tab
itte
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-arrow A-.
erm
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ility
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– Insert the new sealing ring with the semicircular profile in the
wit
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groove -arrow B- on the cap.
h re
hole
spec
• The pull tab -arrow A- must face up.
es, in part or in w
t to the co
rrectness of i
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O-Ring, Inserting on Oil Filter Housing
nf
ercia
o
– Insert the O-ring -2- into the groove -arrow- on the oil filter
rm
m
housing -1-.
atio
om
n in
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thi
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t.
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Cop py
ht. rig
rig ht
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co Vo
by lksw
cted agen
Prote AG.
Reduced Oil Pressure Switch - F378-

1- Reduced Oil Pressure Switch - F378-
2- Connector
♦ 20 Nm
♦ Switching pressure 0.75 to 1.05 bar (10.87 to 15.22 psi)
♦ Check in Guided Fault Finding . Refer to Vehicle Diagnos‐
tic Tester .
♦ Removing and installing. Refer to
⇒ “4.3 Reduced Oil Pressure Switch F378 , Removing and
4.2 Oil Pressure Switch - F22- , Removing

and Installing
♦ Socket - 24mm - T40284-
4. Oil Filter/Oil Pressure Switch 169

Removing
⇒ “2.3 Supercharger, Removing and Installing”,
agen
page
AG. Vol280
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do w es n
olks ot g
– Remove the crankcase ventilation pipes.
ed
by
V ua
ran
ris tee
– Remove the oil filter element. Refer
aut
ho to ⇒ Maintenance ; Book‐ or
ac
let 406 . ss
ce
le
un
– Extract the oil from the oil filter housing using the Used Oil
pt
an
d
itte
Collection and Extraction Unit - SMN372500- .
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erm
ab
– Free up the wires.
ility
ot p
wit
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ole,
Note
spec
t to the co
Place a cloth under the oil filter housing to catch any oil dripping
out.
rrectne
– Disconnect the connector -arrow-.
s
– Remove the Oil Pressure Switch - F22- .
s o
cial p
f i
Installing
nform
mer
atio
m

o
n
c
i
page 168 .
or
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te
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i
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cum
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t.
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Note C py
t. rig
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♦ Replace the gasket.
c by lksw
cted agen
Prote AG.
♦ To prevent oil loss, insert the new Oil Pressure Switch - F22-
in the opening immediately.
– Oil Level, Checking. Refer to

4.3 Reduced Oil Pressure Switch - F378- ,

♦ Reversing Light Switch Connector Release Tool - T40138-
♦ Socket and Jointed Extension - 24mm - T40175-
Removing
page 37 .


– Remove the noise insulation between the oil filter and the su‐
percharger. wage
e
olks s no
yV t gu
edb ara
ris nte
tho eo
au ra
c
ss
ce
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ility
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es, in part or in w
t to the co
rrectness of i
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– Disconnect the connector -2- using the Reversing Light Switch
nform
ercia
Connector Release Tool - T40138- .

m
at
om
ion
Note
c
in t
or
his
ate
do
riv
♦ To catch escaping coolant cover the area around the oil pres‐
p
cum
sure switch carefully with a cleaning cloth.

for
en
ng
t.
yi
♦ For clarity, the installation position is shown with the super‐
Co
Cop py
charger removed. ht. rig
rig ht
py by
co Vo
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cted
– Remove the Reduced Oil Pressure Switch - F378- -1- with a
agen
Prote AG.
Socket and Jointed Extension - 24mm - T40175- .
Installing
⇒ Fig. ““ Reduced Oil Pressure Switch -F378- ”“ , page 169 .
Note
Replace the gasket.
4.4 Oil Pressure, Checking

♦ Oil Pressure Gauge Kit - VAG1342-
♦ Hydraulic Line Socket - 14mm - 3150-
♦
Procedure
• Oil level OK
• Engine oil temperature approximately 80 °C (176 °F)
– Remove the Reduced Oil Pressure Switch - F378- . Refer to

– Remove the 6-edge connection from the Oil Pressure Tester

and insert in the hole for the oil pressure switch.
– Place the union nut from the Oil Pressure Tester on the con‐
nection and tighten using the Hydraulic Line Socket - 14mm -
3150- .
– Install the Oil Pressure Gauge Kit - VAG1342- in the opening
for the oil pressure switch.
– Install the Reduced Oil Pressure Switch
AG. Volk- sF378-
wagen Ain
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sure tester. Volksw not
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– Start the engine. orise tee
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• Oil pressure when
ss
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the vehicle is idling: minimum 1.2 bar (17.4 ac
psi)
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pt
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d
• Oil pressure at 2,000 RPM: minimum 1.5 bar (21.7 psi).

itte
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erm
ab
Assembling:
ility
ot p
wit
is n
– Install the Reduced Oil Pressure Switch - F378- . Refer to
h re
ole,
spec
t to the co
4.5 Oil Pressure Switch - F22- / Reduced Oil
Pressure Switch - F378- , Checking
rrectne
Check the Oil Pressure Switch - F22- / Reduced Oil Pressure
Switch - F378- in Guided Fault Finding . Refer to Vehicle Di‐
ss
agnostic Tester .
o
cial p
f inform
4.6 Oil Filter Housing, Removing and Instal‐
mer
atio
ling
om
n
c
i
or
n thi

te
sd
iva
o
r

p
cum
r
fo
en
ng
t.
Removing Cop
yi Co
py
t. rig
– Remove the compressor. Refer to yri
gh by
ht
⇒ “2.3 Supercharger, Removing and Installing”, page 280 . cop Vo
by lksw
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– Remove the crankcase ventilation pipes. Refer to
AG.

page 166 .
– Remove the oil filter element. Refer to ⇒ Maintenance ; Book‐
let 406 .
– Extract the oil from the oil filter housing using the Used Oil
Collection and Extraction Unit - SMN372500- .
– Free up the wires.
Note
Ignore -1 and 2-.

– Remove the bolts -3- and move the bracket together with the
connectors to the side.
Note
Ignore -1 and 2-.
– Remove the screws -3- and push the secondary air hose to‐
ward the rear.
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– Disconnect the connector -arrow- from the Oil Pressure Switch

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- F22- .
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es, in part or in w
Note
t to the co
Place a cloth under the oil filter housing to catch any oil dripping
out.
rrectness of i
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– Remove the nut -1- and remove the oil filter housing.
Installing
page 168 .
Note
Replace the sealing rings, the seal and the O-ring.
– Install the secondary air injection hose.

4.7 Oil Pressure Regulation Valve - N428- ,

Removing and Installing agen
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– Remove the A/C compressor. Refer to ⇒ Heating, aut Ventilation
h eo
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and Air Conditioning; Rep. Gr. 87 ; A/C Compressor,
ss Remov‐ c
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– Remove the bolt -3- and then remove the Oil Pressure Regu‐
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lation Valve - N428- -4-.
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Installing
spec
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♦ Tightening specification: 9 Nm.
♦ Replace the O-ring -2-.
rrectness of i
♦ Install the A/C compressor. Refer to ⇒ Heating, Ventilation
l purpos

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5 Special Tools
AG. Volkswagen AG d
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♦ Reversing Light Switch ConnectorthRelease
or Tool - T40138- eo
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♦ Gauge - Oil Gauge Tester - T40178-

Touareg 2010 ➤ , Touareg 2015 ➤ agen
AG. Volkswagen AG d
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Engine Mechanical, Fuel Injection and
by VIgnition (Hybrid) - Edition 07.2015
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♦ Socket - 24mm - T40284- au
th or
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♦ Oil Pressure Gauge Kit - VAG1342-
nform
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♦ Hydraulic Line Socket - 14mm - 3150-


19 – Cooling System
1 Coolant System/Coolant
⇒ “1.1 Connection Diagram - Coolant Hoses”, page 177
⇒ “1.2 Component Location Overview - Coolant System”,
page 180
⇒ “1.3 Overview - Coolant System”, page 182
⇒ “1.4 Coolant System, Checking for Leaks”, page 185
⇒ “1.5 Coolant, Draining and Filling”, page 188
⇒ “1.6 Engine Coolant System, Draining, High Temperature Cir‐
cuit”, page 196
⇒ “1.7 Fill Quality, Checking, High Temperature Circuit”,
page 197
1.1 Connection Diagram - Coolant Hoses

⇒ “1.1.2 Connection Diagram - Coolant Hoses, High Tempera‐
ture”, page 178
⇒ “1.1.1 Connection Diagram - Coolant Hoses, Low Tempera‐
ture”, page 177
1.1.1 Connection Diagram - Coolant Hoses,

Low Temperature
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♦ Secure all hose connectionsuth with hose clamps that are specific
o
or
to that model. Refer toss the Parts Catalog.
a ac
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♦ The arrows on the coolant pipes and ends of coolant hoses

un
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d
must align.
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1. Coolant System/Coolant 177

1 - Coolant Expansion Tank

2 - Charge Air Cooler
❑ In supercharger hous‐
ing
3 - Electric Drive Power and
Control Electronics - JX1-
4 - Low Temperature Circuit
Coolant Pump - V468-
5 - Center Radiator for Low
Temperature Coolant Circuit
6 - Right Radiator for Low Tem‐
perature Coolant Circuit
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1.1.2 Connection Diagram - Coolant Hoses,

hole
spec
High Temperature
es, in part or in w
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Note
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♦ The arrows on the coolant pipes and ends of coolant hoses
nf
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must align.
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178 Rep. Gr.19 - Cooling System


2 - Electro-Drive Drive Motor
3 - Drive Motor Shut-Off Valve
for Coolant System
❑ If the Electric Drive
Coolant Valve - N565- is
activated. Component
location. Refer to
⇒ page 182 .
4 - ATF Pre-Heater
5 - Heater Core for the Heater
ling. Refer to ⇒ Rep.
Gr. 87 .
6 - ATF Pre-Heater Shut-Off
Valve
❑ If the Cooling Oil Valve -
N471- is activated.
Cooling Oil Valve -
N471- component loca‐
tion: above the trans‐
mission, near the ATF
pre-heater.
7 - Engine
9 - Coolant Cooler
❑ With ATF cooler and
condenser
AG . Volkswagen AG
10 - High TemperatureksCircuit
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AG. Volkswagen AG d
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1.2 Component Location Overview - Cool‐ tho
ris tee
or
au
ant System
ac
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⇒ “1.2.1 Component Location Overview - High Temperature Cool‐
an
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ant Circuit”, page 180
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⇒ “1.2.2 Component Location Overview - Low Temperature Cool‐ ot p
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ant Circuit”, page 181
is n
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⇒ “1.2.3 Component Location Overview - Electro-Drive Drive Mo‐
spec
tor”, page 182
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1.2.1 Component Location Overview - High Temperature Coolant Circuit
rrectne
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3 - Engine Coolant Tempera‐
form
mer
ture Sensor - G62-
atio
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4 - Coolant Pump
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Engine Temperature Control Sensor - G694- , Removing and in‐

stalling. Refer to
⇒ “2.7 Engine Temperature Control Temperature Sensor G694 ,
Removing and Installing”, page 204 .

1.2.2 Component Location Overview - Low Temperature Coolant Circuit

❑ For low temperature
Control Electronics - JX1-
❑ For charge air cooling
❑ For electric drive power
and control electronics
ling. Refer to
⇒ “4.4 Center Radiator
for Charge Air Cooling
Circuit, Removing and
5 - Right Radiator for Low Tem‐
perature Coolant Circuit
ling. Refer to
⇒ “4.5 Right Radiator for
Charge Air Cooling Cir‐
cuit, Removing and In‐
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1.2.3 Component Location Overview - Electro-Drive Drive Motor
1 - ATF Pre-Heater
2 - To the Heater Core for the
Heater
Valve
N471- is activated, agen
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N471- component loca‐ d b ara
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tion: above the trans‐ thor eo
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4 - Coolant Pump
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7 - Drive Motor Shut-off Valve
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for Coolant System
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location. Refer to
l purpos
⇒ page 182 .
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Electric Drive Coolant Valve - N565- Component Location

1 - The Electric Drive Coolant Valve - N565- is installed between
the oil filter housing and the throttle valve.
1.3 Overview - Coolant System

⇒ “1.3.1 Overview - Coolant System, High Temperature”,
page 183
⇒ “1.3.2 Overview - Coolant System, Low Temperature”,
page 183

⇒ “1.3.3 Overview - Coolant System Electro-Drive Drive Motor”,

page 184
1.3.1 Overview - Coolant System, High Tem‐

perature
Engine Temperature Control Sensor - G694- , Removing and in‐
stalling. Refer to
Replace the O-rings and seals.
Make sure the couplings are tight.
Tightening specifications:
M6 bolts: 10 Nm
M8 bolts: 20 Nm

2 - Connection
3 - Front Coolant Pipe
ling. Refer to
⇒ “3.4 Front Coolant
Pipe, Removing and In‐
ture Sensor - G62-
5 - Coolant Thermostat
6 - Upper Coolant Pipe
❑ Removing and instal‐ AG. Volkswagen AG d
ling. Refer to lksw
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⇒ “3.5 Upper Coolant d by Vo gu
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Pipe, Removing and In‐ orise nte
stalling”, page 211 . auth eo
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8 - Coolant Cooler
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ab

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ture Sensor on Radiator Outlet

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mercia
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c
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1.3.2 Overview - Coolant System, Low Tem‐

a
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perature
for
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Replace the O-rings and seals. C py
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M6 bolts: 10 Nm
M8 bolts: 20 Nm

❑ For low temperature
2 - Coolant Pipes on Charge
Air Cooler
3 - Bleeder Valve
Control Electronics
ling. Refer to
⇒ “4.4 Center Radiator
for Charge Air Cooling
Circuit, Removing and
n AG . Volkswagen AG
7 - Right Radiator for Low Tem‐ wage does
perature Coolant Circuit Volks not
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⇒ “4.5 Right Radiator for

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spec
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t to the co
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1.3.3 Overview - Coolant System Electro-

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Drive Drive Motor

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M6 bolts: 10 Nm
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M8 bolts: 20 Nm
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Valve
N471- is activated.gen AG. Volkswagen AG d
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Cooling Oil Valve Vol
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oes
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N471- componentd by loca‐ ara
se nte
tion: above
thori the trans‐ eo
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s au near the ATF ra
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pre-heater.
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3 - ATF Pre-Heater
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4 - Drive Motor Shut-off Valve
ility
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location. Refer to
⇒ page 182 .
rrectness of i
6 - High Temperature Circuit
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7 - Connection
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1.4 Coolant System, Checking for Leaks

⇒ “1.4.1 Engine Coolant System, Checking for Leaks, High Tem‐
perature”, page 185
⇒ “1.4.2 Engine Coolant System, Checking for Leaks, Low Tem‐
perature”, page 186
1.4.1 Engine Coolant System, Checking for

Leaks, High Temperature
♦ Cooling System Tester - VAG1274B-
♦ Cooling System Tester - Adapter - VAG1274/8-
Procedure:
• Engine at operating temperature.

WARNING

♦ The coolant system is under pressure when the engine is
warm.
♦ Reduce pressure by covering the coolant reservoir cap
with a cloth and carefully opening.
– Open the coolant reservoir cap.

– Position the Cooling System Tester - VAG1274B- with the
Cooling System Tester - Adapter - VAG1274/8- on the coolant
reservoir.
– Generate approximately 1.5 bar (21.75 psi) pressure using the
cooling system tester hand pump.
• The pressure must not drop more than 0.2 bar (2.9 psi) within
10 minutes.
– If the pressure falls more than 0.2 bar (2.9 psi), search for leaks
and correct the problem. n AG. Volkswagen AG age does
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The pressure decrease of 0.2 bar (2.9 psi) within 10 minutes is a
ce
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nl
condition of the cooling of the coolant. The colder the engine the
pt
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more the pressure decrease. If necessary repeat the test with the
itte
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engine cold.
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ility
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DANGER!
spec
es, in part or in w
t to the co
Risk of scalding! The existing pressure must be reduced before

disconnecting the Cooling System Tester - VAG1274B- from
the connecting hose or the Adapter - VAG1274B/1- . To do this,
rrectness of i
press the pressure release valve on the Cooling System Tester

- VAG1274B- until the pressure gauge displays »0«.
l purpos
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Pressure Relief Valve in Cap, Checking

m
at
om

ion
c
Cooling System Tester - Adapter - VAG1274/9- on the cap.

in t
or
his
ate
– Generate pressure with the cooling system tester hand pump.

do
priv
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or
• The pressure release valve must open at 1.4 to 1.6 bar (20.30
f
en
ng
t.
to 23.20 psi).
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1.4.2 Engine Coolant System, Checking for

Leaks, Low Temperature


Test Conditions
• Engine at operating temperature
Test Sequence:
WARNING
Steam can be released when the cap is removed from the ex‐
pansion tank. Cover cap with a cloth and open carefully.

– Install the Cooling System Tester - Adapter - VAG1274/8- in
the coolant expansion tank.
– Place the Adapter - VAG1274B/1- on the Cooling System
Tester - Adapter - VAG1274/8- .
olksw
– Connect the Adapter - VAG1274B/1- to theswCooling
agen System
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Tester - VAG1274B- using the hose provided.
by
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– Generate approximately 1.5 barth(21.75
or
i
psi) pressure with e or
s au ac
s
ce
le
• The pressure must not drop more than 0.2 bar (2.9 psi) within
un
pt
10 minutes.
an
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– If the pressure falls more than 0.2 bar (2.9 psi), search for leaks
pe
ility
and correct the problem.
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Note
es, in part or in w
t to the co
The pressure decrease of 0.2 bar (2.9 psi) within 10 minutes is a
condition of the cooling of the coolant. The colder the engine the
rrectness of i
more the pressure decrease. If necessary repeat the test with the
engine cold.
l purpos
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DANGER!
m
a
com
Risk of scalding! The existing pressure must be reduced before

ion in
disconnecting the Cooling System Tester - VAG1274B- from

r
te o
thi
the connecting hose or the Adapter - VAG1274B/1- . To do this,

s
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do
press the pressure release valve on the Cooling System Tester

r
rp
- VAG1274B- until the pressure gauge displays »0«.

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Checking the Pressure Relief Valve in the Cap
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– Install the cap in the Cooling System Tester - Adapter - cted agen
Prote AG.
VAG1274/9- .
– Clamp the Cooling System Tester Connecting Piece -
VAG1274B/1- in the Cooling System Tester - Adapter -
VAG1274/9- .

– Connect the Adapter - VAG1274B/1- to the Cooling System

Tester - VAG1274B- using the hose provided.
– Operate the hand pump.
• The pressure release valve must open at 1.4 to 1.6 bar (20.30
to 23.20 psi).
1.5 Coolant, Draining and Filling

⇒ “1.5.1 Coolant, Draining and Filling, High Temperature Circuit”,
page 188
⇒ “1.5.2 Coolant, Draining and Filling, Low Temperature Circuit”,
page 192
1.5.1 Coolant, Draining and Filling, High Tem‐

perature Circuit
♦ Cooling System Charge Kit - VAS6096-
♦ Refractometer - T10007A-
Caution
AG. Volkswagen AG d
The coolant system must be drained if larger components wage (for
n oes
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⇒ “1.6 Engine Coolant System, Draining, authHigh Temperature eo
ra
Circuit”, page 196 . Otherwise an incorrect
ss filling will result due c
to air bubbles in the system. The cooling and heating systems
ce
le
un
pt
will have temperature problems.

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t to the co
WARNING
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ss o
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Rep. Gr.19 - Cooling System
agen
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– Remove the quick release -arrow- on the bottom of the radiator

on the right side.
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– Remove the coolant hose -arrow- from the radiator and let the
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coolant drain.
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Coolant, Filling
spec
t to the co
Caution
Only mix distilled water with coolant additives. Using distilled
rrectne
water provides optimum corrosion protection.
ss o
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Note
♦ The mixture of the water used greatly influences the effective‐

ness of the coolant. The water quality to be used is based on
the contents, which can be specific to a country or even a re‐
gion. Distilled water fulfills all requirements. For this reason,
use distilled water when adding coolant or filling coolant for the
first time.
♦ Use only coolant additives listed. Refer to the Parts Catalog.
Other coolant additives may above all reduce the corrosion
protection effect significantly. The damage resulting from this
may lead to loss of coolant and consequently to severe engine
damage.
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♦ Coolant with the correct mixture ratio prevents freezing yV
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corrosion damage and calcium deposits. Additionally, ir se
d the boil‐
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ing temperature will be raised. For this reason tthe
ho cooling tee
or
system must be filled with coolant additive year-round.
ss
au ac
ce
le
♦ Because of its high boiling point, the coolant contributes to

un
pt
engine reliability under heavy engine loads, particularly in
an
d
itte
y li
countries with tropical climates.
rm
ab
pe
ility
♦ The Refractometer - T10007A- MUST be used to determine
ot
wit
, is n
the current freeze protection value.
h re
hole
spec
♦ Protection against frost must be assured down to minimum -25
es, in part or in w
°C (-13 °F) (in arctic climatic countries down to approximately
t to the co
-36 °C (-32.8 °F)). The freeze protection may only be in‐
creased, when stronger freeze protection is needed due to the
climate. But only down to -48 °C (-54 °F), otherwise the effec‐
rrectness of i
tiveness of the coolant decreases.
l purpos
♦ The coolant concentration must not be reduced by adding wa‐

ter even in warmer seasons and in warmer countries. The frost
protection must be at least -25 °C (-13 °F).
nform
ercia
♦ Read the freeze protection value on the scale for the coolant
m
a
com
t
additive that has been added.
ion in
r
te o
♦ The temperature on the Refractometer - T10007A- corre‐

thi
s
iva
sponds to the »freezing point«. At this temperature, ice crys‐

do
r
rp
tals may begin to form in the coolant.

um
fo
en
ng
t.
♦ Do not reuse used coolant.
yi Co
Cop py
t. rig
♦ Only use water/coolant additive to lubricate the coolant hoses.
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote
– Fill the coolant reservoir on the Cooling System Charge Kit -
AG.
VAS6096- with at least 15 liters (15.85 quarts) of premixed

coolant with the proper mixture ratio.
• Coolant additive (40%) and distilled water (60%) for freeze
protection down to -25 ºC (-13 °F)
protection down to -36 ºC (-32.8 °F)
• Coolant additive. Refer to the Parts Catalog.

lkswage es n Touareg 2010 ➤ , Touareg 2015 ➤
o ot g
byV Engine Mechanical, Fuel uaInjection and Ignition (Hybrid) - Edition 07.2015
ed ra
ris nte
utho eo
– Installss the
a Cooling System Tester - Adapter - VAG1274/8- ra
c on
ce
le
un
pt
an
d
– Secure the Cooling System Charge Kit - VAS6096- on the

itte
y li
adapter -VAG1274/8- .
rm
ab
pe
ility
– Close valves -A and B- by turning lever at a right angle to the
ot
wit
, is n
flow direction.
h re
hole
spec
– Place the drain hose -1- in a small container -2-.
es, in part or in w
t to the co
Note
rrectness of i
A small amount of coolant which should be collected is drawn off
l purpos
with the discharged air.
– Connect the hose -3- to compressed air.
nform
mercia
• Pressure: 6 to 10 bar (87 to 145 psi) positive pressure.
a
com
tion in
r
te o
thi
s
iva
do
– Open the valve -B- by turning the lever in the flow direction.
r
rp
cum
fo
en
g
• At least 0.7 bar (10.15 psi) vacuum must be produced.

n
t.
yi Co
Cop py
– Briefly open the valve -A- by turning the lever in the flow di‐
t. rig
gh ht
yri
rection so that the hose on the Cooling System Charge Kit -
p by
co Vo
by lksw
VAS6096- coolant reservoir fills with coolant.
Prote
cted AG.
agen
– Close the valve -A- again.

– Leave the valve -B- open another two minutes.
• A further vacuum is created in the cooling system by the suc‐
tion jet pump.
– Close the valve -B-.

– Remove the pressure hose.
– Watch the pressure gauge. The vacuum may go down only to
0.4 bar (5.8 psi). Check the coolant system for leaks if the
vacuum continues to fall.
Note
♦ The cooling system does not have any leaks if the vacuum
falls but then stabilizes at minimum 0.4 bar (5.8 psi).
♦ Perform the next filling »slowly«.
– Open the valve -A- slowly.

• Coolant is extracted from the Cooling System Charge Kit -
VAS6096- coolant reservoir by pressure in the coolant system
and the system is filled.
– Remove the Cooling System Charge Kit - VAS6096- from the
Cooling System Tester - Adapter - VAG1274/8- on coolant
expansion tank.

– Check the coolant level inside the reservoir. Fill or drain if nec‐
essary.
– Check the coolant freeze point. Refer to
⇒ “1.7 Fill Quality, Checking, High Temperature Circuit”, page
197 .
1.5.2 Coolant, Draining and Filling, Low Tem‐

perature Circuit agen
AG. Volkswagen AG d
oes
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Special tools and workshop equipment required d byV gu
ara
ise nte
r
♦ Cooling System Tester - Adapter - VAG1274/8- ut
ho eo
ra
s a c
s
♦ Cooling System Charge Kit - VAS6096-
ce
le
un
pt
an
d

itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
Draining
rrectne
Note
Collect escaping coolant for disposal.
ss o
cial p
f inform
mer
WARNING
atio
om
n
c
i
or
n thi
te
sd
a
♦ The cooling system is under pressure when the engine is

iv
o
pr
warm.
um
r
fo
en
ng
t.
yi
♦ Cover the coolant reservoir cap with a cloth and carefully
Co
op py
open it to reduce the pressure.
. C rig
ht ht
rig by
copy Vo
by lksw
cted agen
Prote AG.
– Disconnect the coolant hoses -arrows- and allow the coolant
to drain.
Filling:
• The ignition is off.
Caution
Only mix distilled water with coolant additives. Using distilled

water provides optimum corrosion protection.

Note
♦ The mixture of the water used greatly influences the effective‐

ness of the coolant. The water quality to be used is based on
the contents, which can be specific to a country or even a re‐
gion. Distilled water fulfills all requirements. For this reason,
use distilled water when adding coolant or filling coolant for the
first time.
♦ Use only coolant additives listed. Refer to the Parts Catalog.
Other coolant additives may above all reduce the corrosion
protection effect significantly. The damage resulting from this
may lead to loss of coolant and consequently to severe engine
damage.
♦ Coolant with the correct mixture ratio prevents freezing and
corrosion damage and calcium deposits. Additionally, the boil‐
ing temperature will be raised. Foragthis reason
en AG. Volkswathe
gen cooling
AG do
olksw additive year-round. es not
system must be filled with coolant
yV gu b ara
ed
♦ Because of its high boiling
tho
ris point, the coolant contributes to nte
e
engine reliability under
au heavy engine loads, particularly in
or
ac
ss
countries with tropical climates.
ce
e
nl
pt
du
♦ The Refractometer - T10007A- MUST be used to determine
an
itte
y li
the current freeze protection value.
erm
ab
ility
ot p
♦ Protection against frost must be assured down to minimum -25
wit
, is n
°C (-13 °F) (in arctic climatic countries down to approximately
h re
-36 °C (-32.8 °F)). The freeze protection may only be in‐
hole
spec
creased, when stronger freeze protection is needed due to the
es, in part or in w
climate. But only down to -48 °C (-54 °F), otherwise the effec‐
t to the co
tiveness of the coolant decreases.
♦ The coolant concentration must not be reduced by adding wa‐
ter even in warmer seasons and in warmer countries. The frost rrectness of i
protection must be at least -25 °C (-13 °F).
l purpos
♦ Read the freeze protection value on the scale for the coolant
additive that has been added.
nf
ercia
or
♦ The temperature on the Refractometer - T10007A- corre‐

m
m
atio
sponds to the »freezing point«. At this temperature, ice crys‐

om
n in
tals may begin to form in the coolant.

or c
thi
te
♦ Do not reuse used coolant.

sd
iva
o
r
rp
cu
♦ Only use water/coolant additive to lubricate the coolant hoses.

o
m
f
en
ng
t.
yi Co
Cop py
t. rig
gh
– Connect the coolant hoses -arrows-.
ht
pyri by
Vo
co lksw
by
cted
– Fill the coolant reservoir on the Cooling System Charge Kit -
agen
Prote AG.
VAS6096- with at least five liters (5.28 quarts) of premixed
coolant with the proper mixture ratio:
protection down to -25 ºC (-13 °F)
protection down to -36 ºC (-32.8 °F)
• Coolant additive. Refer to the Parts Catalog.

– Install the Cooling System Tester - Adapter - VAG1274/8- on

– Secure the Cooling System Charge Kit - VAS6096- on the
adapter.
– Close valves -A and B- by turning lever at a right angle to the
flow direction.
– Place the drain hose -1- in a small container -2-.
Note
A small amount of coolant which should be collected is drawn off

with the discharged air.
– Connect the hose -3- to compressed air.

• Pressure: 6 to 10 bar (87 to 145 psi) positive pressure.
– Open the valve -B- by turning the lever in the flow direction.
olks
wage es n
ot g
V
by ua
• A further vacuum is created in the cooling system riseby
d the suc‐ ran
tee
tion jet pump. The needle on the instrument display
ut
ho
must travel or
into the green region. ss
a ac
ce
le
un
– Briefly open the valve -A- by turning the lever in the flow di‐
pt
an
d
rection so that the coolant reservoir hose on the Cooling

itte
y li
erm
System Charge Kit - VAS6096- fills with coolant.
ab
ility
ot p
– Close the valve -A- again.
wit
is n
h re
ole,
– Leave the valve -B- open another two minutes.
spec
• A further vacuum is created in the cooling system by the suc‐
t to the co
tion jet pump. Needle on the instrument display must still
remain in the green region.
rrectne
– Close the valve -B-.
s
• The needle on display must remain in the green range. Only
s o
then is there enough vacuum in the coolant system for the
cial p
filling. f inform
mer
atio
om
n
c
Note
i
or
n thi
te
sd
va
♦ Repeat the procedure if the needle goes below the green

i
o
pr
cum
r
range.
fo
en
ng
t.
yi Co
♦ If the pressure falls, check the coolant system for leaks. Cop py
t. rig
gh ht
pyri by
Vo
o
– Remove the pressure hose.
c by lksw
cted agen
Prote AG.
– Open the valve -A- slowly.
• Coolant is extracted from the Cooling System Charge Kit -
VAS6096- coolant reservoir by pressure in the coolant system
and the system is filled.
– Remove the Cooling System Charge Kit - VAS6096- from the
Cooling System Tester - Adapter - VAG1274/8- on coolant
expansion tank.

– Install the Cooling System Tester - Adapter - VAG1274/10- on

the adapter.
– Fill with coolant until the coolant system tester tube is full. Fill
again during the bleeding procedure if necessary.
– Remove the engine covers -1 and 2- upward.
Note
Place a cloth under the bleeder valve to catch any coolant drip‐
ping out.
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss
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e
nl
pt
du
an
itte
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erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
– Open the bleeder valve -arrow- until the coolant starts to come
out.
– Close the bleeder valve.
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
– Open the bleeder screws -1 and 2- one after the other until
yi Co
op
coolant starts to come out.
C py
t. rig
gh ht
yri by
– Close the bleeder screws. cop Vo
by lksw
cted agen
Prote AG.

– Extract coolant until the level is between the MIN and MAX
markings.
– Close coolant reservoir cap.
– Install the noise insulation. Refer to ⇒ Body Exterior; Rep. Gr.
50 ; Overview - Noise Insulation . . Volkswage AG n AG d
agen oes
olksw not
yV gu
db ara
rise nte
tho eo
s au ra
c
s
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
1.6 Engine Coolant System, Draining, High
ot p
wit
, is n
Temperature Circuit
h re
hole
spec
es, in part or in w
t to the co
♦ Spring Clip Pliers - VAS6499-
rrectness of i
♦ Hose extension diameter 20 mm
l purpos
♦ Compressed air gun
nf
ercia
– Drain the coolant for the high temperature coolant circuit. Re‐
or
fer to
m
m
atio
om
n in
cuit”, page 188 .
or c
thi
te
– Close the coolant reservoir.
sd
iva
o
r
rp
cu
– Remove the left front wheel. Refer to ⇒ Rep. Gr. 44 .
o
m
f
en
ng
t.
yi Co
– Remove the left front wheel housing liner. Refer to ⇒ Body Cop py
Exterior; Rep. Gr. 66 .
t. rig
gh ht
pyri by
Vo
co
Drain the Engine Coolant Pipes
by lksw
cted agen
Prote AG.
– Open the clamps and remove the coolant hoses -A and B-.
– Attach a hose -2- to the line -B- to lengthen it and place the
one end in the Shop Crane - Drip Tray - VAS6208- .
– Apply maximum 1 bar (14.5 psi) compress air across the line
-A- using a compressed air gun -1- until the circuit is com‐
pletely empty.
Drain the Heater Coolant Pipes

– Attach a hose -1- to the line -A- to lengthen it and place the
one end in the Shop Crane - Drip Tray - VAS6208- .
– Apply maximum 1 bar (14.5 psi) compress air across the line
-B- using a compressed air gun -2- until the circuit is com‐
pletely empty.
– Connect the coolant hoses and the clamps.
1.7 Fill Quality, Checking, High Tempera‐

ture Circuit
Note
It is necessary to check the coolant concentration to determine if

there is air in the coolant system.
agen
AG. Volkswagen AG d
o
w es n
olks ot g
byV ua
Special tools and rworkshop
ise
d
equipment required ran
tee
tho or
♦ Cooling System
ss
au
Tester - VAG1274B- ac
ce
le

un
pt
an
d
itte
y li

rm
ab
pe
ility

ot
wit
, is n
Cooling System Tester - Adapter - VAG1274/8- on the coolant

h re
reservoir.
hole
spec
es, in part or in w
– Generate approximately 1 bar (14.5 psi) pressure using the

t to the co

– Check the coolant level inside the reservoir.
rrectness of i
Caution
l purpos
There are no leaks in the coolant system if the coolant level

nform
ercia
goes down by only maximum 25 mm. If the level goes down

significantly or if the coolant evaporates from the reservoir, this
m
a
com
means there are air bubbles in the coolant system.

ion in
r
te o
thi
s
iva
do
Coolant Level OK
r
rp
cum
fo
en
g
– Perform a road test until the engine operating temperature is

n
t.
yi Co
op
reached. C py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
The Coolant Level Significantly Goes Down
Prote AG.
– Drain the coolant system. Refer to

⇒ “1.6 Engine Coolant System, Draining, High Temperature
Circuit”, page 196 .
– Fill the coolant system.
– Check the coolant concentration one more time. Refer to
⇒ “1.7 Fill Quality, Checking, High Temperature Circuit”, page
197 .

2 Coolant Pump/Thermostat
⇒ “2.1 Overview - Coolant Pump/Thermostat”, page 198
⇒ “2.2 Electric Coolant Pump, Removing and Installing”,
page 199
⇒ “2.3 Coolant Pump, Removing and Installing”, page 201
⇒ “2.4 Coolant Thermostat, Removing and Installing”, page 202
⇒ “2.5 Coolant Thermostat, Checking”, page 202
⇒ “2.6 Engine Coolant Temperature Sensor G62 , Removing and
Installing”, page 203
Removing and Installing”, page 204
2.1 Overview - Coolant Pump/Thermostat
1 - Bolt
❑ 9 Nm
2 - Bolt
❑ 20 Nm
n AG . Volkswagen AG
3 - Ribbed Belt Pulley wage does
Volks not
❑ For the coolantedpump
by gu
ara
is nte
or
4 - Coolant Pump au
th eo
ra
ss c
❑ With seal
ce
le
un
pt

an
d
itte
ling. Refer to
y li
rm
ab
⇒ “2.3 Coolant Pump,

pe
ility

ot
wit
, is n
ling”, page 201 .

h re
hole
spec
5 - Bolt
es, in part or in w
❑ 9 Nm
t to the co
6 - Bolt
rrectness of i
-item 2-
l purpos
⇒ Item 2 (page 42) .

7 - Washer
nform
ercia
8 - Idler Roller
m
❑ For the ribbed belt

com
tion in
r
te o
9 - Connection
thi
s
iva
do
❑ For coolant hose

r
rp
cum
fo
10 - Seal
en
ng
t.
yi Co
op
❑ Replace C py
t. rig
gh ht
yri
11 - Seal
p by
co Vo
by lksw
cted
❑ Coolant thermostat
agen
Prote AG.
component
12 - Coolant Thermostat
❑ Removing and installing. Refer to ⇒ “2.4 Coolant Thermostat, Removing and Installing”, page 202 .
❑ Check. Refer to ⇒ “2.5 Coolant Thermostat, Checking”, page 202 .

Note
When removing and installing the

coolant thermostat, make sure that
the thermostat needle is installed
correctly (conical end is inserted in
the coolant thermostat wax thermo‐
static element). If necessary, push
the thermostat needle all the way in‐
to the wax thermostatic element.
13 - Bolt
❑ 9 Nm
14 - Coolant Regulation Valve - N515-
2.2 Electric Coolant Pump, Removing and

Installing swa
gen AG
. Volkswagen AG
does
k not
g Vol
⇒ “2.2.1 Low Temperature Circuit d b Coolant Pump V468 , Remov‐ uara
y
se nte
ing and Installing”, page 199
tho
ri
eo
au ra
⇒ “2.2.2 High Temperature
ss Circuit Coolant Pump V467 , Remov‐ c
ce
le

un
pt
an
d
itte
2.2.1 Low Temperature Circuit Coolant Pump
y li
erm
ab
ility
- V468- , Removing and Installing
ot p
wit
is n
h re
ole,
spec
t to the co
Removing:
– Drain the coolant for the low temperature coolant circuit. Refer
rrectne
to
cuit”, page 192 .
ss o
cial p
– Disconnect the connector -1- and remove the coolant hoses

inform
-2-.
mer
atio
m
– Remove the bolts -arrows- and remove the mounting strap.

o
n
c
i
or
Installing:
thi
te
sd
iva
o
r

p
cum
r
fo
en
ng
t.
yi Co
op
to C py
t. rig
gh ht
pyri by
cuit”, page 192 .
o Vo
by c lksw
cted agen
Prote AG.
2.2.2 High Temperature Circuit Coolant Pump

- V467- , Removing and Installing
Component location: behind the right engine support
2. Coolant Pump/Thermostat 199

Removing:
WARNING

warm.

fer to
cuit”, page 188 .
– Remove the right front wheel.
Note
Loosening the tie rod improves accessibility.
– Loosen nut of track rod ball joint, but do not unscrew yet.
AG. Volkswagen AG d
Caution agen oes
olksw not
V gu
d by ara
e nte
To protect thread, screw nut ton
ho pin a few turns.
ris
eo
au ra
ss c
ce
le
un
pt
– Remove the tie rod from the wheel bearing housing using the
an
d
itte
Puller - Ball Joint - T10187- and remove the nut.

y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
– Remove the connector -arrow- from the pump.

t to the co

– Remove the coolant hoses -1 and 2- and let the remaining
rrectne
coolant drain.
ss o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.

AG. gen AG Volkswa
– Remove the bolt -arrow- and then remove agen does
olkswthe coolant pump. not
V y gu
db ara
Installing: rise nte
tho eo
s au while noting the following:
ra
c
s
ce
e
nl
pt
du
an
itte
y li
erm
ab
to
ility
ot p
wit
, is n
cuit”, page 188 .
h re
hole
spec
es, in part or in w
50 ; Overview - Noise Insulation .
t to the co
2.3 Coolant Pump, Removing and Installing
rrectness of i
l purpos
nform
ercia
Removing:
m
at
– Loosen the left front coolant pipes and move them to the side.
om
io
Refer to
n
c
in t
or
⇒ “3.3 Coolant Pipes for Low Temperature Coolant Circuit,
his
ate
Removing and Installing”, page 208 . The coolant hoses can
do
riv
remain attached.
p
cum
for
en
ng
t.
– Remove the supercharger ribbed belt.
yi Co
Cop py
t. rig
– Remove the ribbed belt. Refer to gh ht
yri by
⇒ “1.5 Ribbed Belt, Removing and Installing”, page 45 . cop Vo
by lksw
cted agen
Prote AG.
– Remove the bolts for the coolant pump ribbed belt pulley by
counterholding with a Wrench - Pin Type - 3212- .
– Remove the ribbed belt pulley.
Note
Place a cleaning cloth underneath to catch any escaping coolant.
– Remove the hose -A- and remove the bolts -arrows-. Remove
the coolant pump.
Installing
– Install the left front coolant pipes. Refer to
to
cuit”, page 188 .

2.4 Coolant Thermostat, Removing and In‐

stalling
Removing
fer to
cuit”, page 188 .
page 210 .
Note

– Remove the coolant thermostat with the connections.
Installing
olkswagen AG
en AG. V
Install in reverse order of removal while notingolkthe
swa following:
g does
not
yV gu
db ara
rise nte
tho eo
Note au ra
c
ss
ce
le
un
♦ Replace the seals.

pt
an
d
itte
y li
♦ When installing the coolant thermostat, make sure that the

rm
ab
pe
thermostat needle is installed correctly (conical end is inserted

ility
ot
in the coolant thermostat wax thermostatic element). If nec‐

wit
, is n
essary, push the thermostat needle all the way into the wax
h re
hole
thermostatic element.
spec
es, in part or in w
t to the co
– Install front coolant pipe. Refer to

page 210 .
rrectness of i

l purpos

nform
ercia
to
m
a
com
ti
cuit”, page 188 .

on in
r
te o
thi
s
iva
2.5 Coolant Thermostat, Checking

do
r
rp
cum
fo
– Heat up the removed thermostat in water.

en
ng
t.
yi Co
Cop py
Opening Begins Opening Ends Opening Lift
t. rig
gh ht
pyri by
Vo
o
approximately 87 °C approximately 102 by c
minimum 8 mm
lksw
cted agen
(188.6 °F) ℃ (215.6 °F) 1)
Prote AG.
• 1) Cannot be tested.

2.6 Engine Coolant Temperature Sensor -

G62- , Removing and Installing
Removing:
• The engine is cold.
– Briefly open the coolant reservoir cap to reduce the residual
pressure in the coolant system.
page 37 .
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
rrectness o
cial p
f inform
– Disconnect the connector -1- on the Engine Coolant Temper‐
mer
ature Sensor - G62- .
atio
om
n
c
i
or
n thi
te
Note
sd
iva
o
pr
cum
r
fo
♦ Place a cleaning cloth underneath to catch any escaping cool‐

en
ng
t.
yi
ant.
Co
Cop py
t. rig
gh ht
♦ Ignore -arrow-. yri
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⇒ “3.1 Overview - Coolant Pipes”, page 205
⇒ “3.2 Coolant Pipes for Engine Oil Cooler, Removing and Instal‐
ling”, page 206
⇒ “3.3 Coolant Pipes for Low Temperature Coolant Circuit, Re‐
moving and Installing”, page 208
⇒ “3.4 Front Coolant Pipe, Removing and Installing”, page 210
⇒ “3.5 Upper Coolant Pipe, Removing and Installing”, page 211
⇒ “3.6 Compressor Coolant Pipes, Removing and Installing”,
page 213
3.1 Overview - Coolant Pipes

M6 bolts: 10 Nm
M8 bolts: 20 Nm
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6 - Clip
7 - T-Connection
❑ To the Electric Drive Power and Control Electronics - JX1-
8 - Return Pipe for Engine Oil Cooler
⇒ “3.2 Coolant Pipes for Engine Oil Cooler, Removing and Installing”, page 206 .
9 - Supply Pipe for Engine Oil Cooler
⇒ “3.2 Coolant Pipes for Engine Oil Cooler, Removing and Installing”, page 206 .
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move the bolts and the coolant pipe.
Installing
⇒ “3.1 Overview - Coolant Pipes”, page 205 .
Note
♦ Replace the O-rings.

– Clean or smooth O-ring sealing surface before installing.

– Coat the O-ring with coolant and slide it onto the coolant pipe.
– Install the engine support. Refer to
⇒ “2.1 Overview - Subframe Mount”, page 32 .
– Install the A/C compressor. Refer to ⇒ Heating, Ventilation
to
cuit”, page 188 .
3.3 Coolant Pipes for Low Temperature

Coolant Circuit, Removing and Installing
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– Disconnect the coolant hoses -arrows- and remove the upper

coolant hose -1- from the brackets.
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3.4 Front Coolant Pipe, Removing and In‐

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– Remove the front left coolant pipes. Refer to
– Remove the coolant hose -arrow- from the front coolant pipe
by lifting the retaining clamp.

– Press the locking mechanism -arrows- together and remove

the Coolant Regulation Valve - N515- -1- in direction of.
– Disconnect the secondary air hose -1- and coolant hose

-arrow-.
– Loosen the hose clamp -1- and disconnect the connector -2-
from the Engine Coolant Temperature Sensor - G62- .
– Remove the bolt -3- and the bolts -arrows-.
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– Unclip the line -1-. Remove the nuts -arrows- and remove the
protective plate -2-.
– Remove the right lower section of the intake manifold. Refer
to
– Remove the front secondary air injection hose -arrow- from its
bracket and disconnect it; do to so press the release buttons.
– Free up the hose for the secondary air and vacuum hoses and
move them to the side.
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♦ Install the noise insulation. Refer to ⇒ Body Exterior; Rep. Gr.

4 Radiator/Coolant Fan
⇒ “4.1 Overview - Radiator/Coolant Fan”, page 215
⇒ “4.2 Radiator, Removing and Installing”, page 216
⇒ “4.3 Radiator, Disassembling”, page 221
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4. Radiator/Coolant Fan 215

Connect the Coolant Hose to the Connector Coupling

– Remove the old O-ring -2- in the coolant hose -3-.
– Coat the new O-ring with coolant and install it in the coolant
hose.
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audibly.
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⇒ “4.6 Fan Shroud, Removing and Installing”, page 223 .
– Drain the coolant from the high temperature coolant circuit.
Refer to
cuit”, page 188 .
– Place the Used Oil Collection and Extraction Unit -
SMN372500- under the separating point on the transmission
fluid cooler.

– Remove the bolt -A- and the connections on the transmission

fluid cooler. Catch any fluid coming out.
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– Remove the radiator grill -1-. Refer to ⇒ Body Exterior; Rep.

Gr. 66 .
– Remove the license plate holder -2- and the center air grille
-3-. Refer to ⇒ Body Exterior; Rep. Gr. 63 .

– Remove the center radiator for the charge air cooling circuit
from the radiator module by removing the brackets -1 and 2-.
The coolant hoses -arrows- remain connected.
– Open the clip -1- and disconnect the upper coolant hose from
the radiator.
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Installing
⇒ “4.1 Overview - Radiator/Coolant Fan”, page 215 .
– Install the radiator module.
– Mount the upper radiator mount and tighten it.
– Install the radiator module into the upper radiator mount -A-
and install the locking bolt -B-.

– Install the lower radiator mount into the radiator module and
tighten it.
– Push the clips -arrows- on the upper air guide into the radiator.
– Install the radiator -1- grille. Refer to ⇒ Body Exterior; Rep.

Gr. 66 .
– Install the license plate holder -2- and the center air grille -3-.
Refer to ⇒ Body Exterior; Rep. Gr. 63 .
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4.3 Radiator, Disassembling
Note
The radiator module consists of the radiator (high temperature),

the condenser, and the transmission fluid cooler.
Conditions
• The radiator module is removed. Refer to
⇒ “4.4 Center Radiator for Charge Air Cooling Circuit, Remov‐
ing and Installing”, page 221 .
– Remove the bolts -1 and 2-.
– Turn the radiator module around. Press the retainer -1- and
remove the transmission fluid cooler in direction of -arrow-.
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Removing
– Remove the bumper cover. Refer to ⇒ Body Exterior; Rep.
Gr. 63 .
– Slightly pry off the mounting tabs -1 and 2- and remove the air
shroud in the direction of the -arrow-.

– Remove the lower coolant hose -1- and drain the coolant. Re‐
move the upper coolant hose.
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4.6 Fan Shroud, Removing and Installing

Removing
– Loosen the coolant expansion tank for the low temperature
coolant circuit -1-, remove the connector -2- and move the
coolant expansion tank upward.

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Engine Mechanical, Fuel Injection and Ignition o(Hybrid) oes
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– Remove the coolant pipe bolts -1- from the fanho shroud.
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Installing
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Install in reverse order of removal.

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5 Special Tools

equipment required
♦ Cooling System Tester -
Adapter - VAG1274/8-
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20 – Fuel Supply
1 Fuel Tank
⇒ “1.1 Overview - Fuel Tank”, page 228
⇒ “1.2 Fuel Tank, Draining”, page 230
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During all repair procedures on the fuel tank, be aware of the
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EVAP system, coolant, refrigerant, brake fluid, vacuum)
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and wires so that the original routing is restored.
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tube and body is securely fastened, to prevent electro‐
static charging.
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♦ Make sure that there is sufficient clearance to all moving

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228 Rep. Gr.20 - Fuel Supply

1 - Fuel Filler Neck

❑ Tighten to the body to 10
Nm
❑ With a connection for
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2 - Breather
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5 - Fuel Tank
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❑ Support with the Engine

and Gearbox Jack -
VAS6931- when remov‐
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6 - Locking Ring
❑ 145 Nm
❑ Remove and install with the Wrench - Fuel Sending Unit - T10202-
7 - Fuel Filter
❑ Flange installed position. Refer to ⇒ Fig. ““Location of Flange on Fuel Reservoir”“ , page 230
❑ Always replace the flange seal
❑ Fuel Filter, Replacing. Refer to ⇒ “3.1 Fuel Filter, Removing and Installing”, page 245
8 - Heat Shield
9 - Mounting Strap
10 - Bolt
❑ 33 Nm
11 - Protective Cover
❑ For the bottom of the fuel tank
12 - Line Coupling
❑ To loosen, squeeze the button the line coupling
1. Fuel Tank 229

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13 - Fuel Delivery Unit
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❑ Flange individual parts, right side. Refer to
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❑ Flange installed position. Refer to ⇒ Fig. ““Location of Flange on Fuel Reservoir”“ , page 230
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❑ Fuel Pump, Checking. Refer to ⇒ “7.1 Fuel Pump, Checking”, page 260 .
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Individual Components of Flange, Right Side
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– Install the flanges in direction of travel -arrow-.
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The tab -2- must be between the tongues -1 and 3- on the fuel
tank.
1.2 Fuel Tank, Draining

♦ Fuel Extraction Unit - VAS5190-
♦ Wrench - Fuel Sending Unit - T10202-
Caution
The intake hose from the fuel siphoning device could damage
the fuel filler tube flap. The fuel tank may only be drained via
the flange.
Procedure
– Read the Safety Precautions before starting. Refer to
⇒ “1.1 Safety Precautions, Working on Fuel Supply System”,
page 1 .
– Follow the rules of cleanliness. Refer to
⇒ “3.1 Guidelines for Clean Working Conditions”, page 5 .
– Remove the rear bench seat. Refer to ⇒ Body Interior; Rep.
Gr. 72 ; Rear Bench Seat, Removing and Installing ,

– Fold the right carpet to the side.

– Loosen the nuts -1 through 4- on the flange cover.
– Remove the flange cover.
– Remove the bleed line -1-.
Note
Squeeze the button on the line couplings.
WARNING
The fuel lines are under pressure.

Fuel poses a risk of injury to the eyes and skin.
Wear protective eyewear and protective clothing to avoid injury
and contact with the skin. Place a cleaning cloth around the
connection point before loosening hose connections. Carefully
open the connection points to release the pressure.
– Place a cloth around the fuel supply line connection -2- and
remove the hose coupling.
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– Insert the Fuel Extractor Unit - VAS5190- suction hose as far

as possible into the fuel tank and extract the fuel.
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– Remove the fuel filter to extract the fuel from the fuel tank and
to be able to work on the left side of the fuel tank.
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Refer to
⇒ “3.1 Fuel Filter, Removing and Installing”, page 245 .
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– Then insert the Fuel Extractor Unit - VAS5190- suction hose

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as far as possible into the fuel tank and extract the fuel.
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For additional work on components inside of fuel tank, sensor

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– Replace the seals for the sensor flanges.

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231
Prote AG.
1. Fuel Tank

The tab on the flange -2- must be between the tongues
-1 and 3- on the fuel tank.
– Tighten the locking ring to 145 Nm using the Wrench - Fuel

Sending Unit - T10202- . agen
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1.3 Fuel Tank, Removing and Installing
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Caution
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following:
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♦ Route all the various lines (e.g. for fuel, EVAP system, or
m
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♦ Fuel Extraction Unit - VAS5190-
♦ Engine and Gearbox Jack - VAS6931-
Requirements
• The fuel tank must be empty. Refer to
⇒ “1.2 Fuel Tank, Draining”, page 230 .
Removing
page 1 .

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– Follow the guidelines for clean
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– Remove the rear axle. Refer to ⇒ Suspension, Wheels, Steer‐
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Protection .
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– Remove the fuel filler door. Refer to ⇒ Body Exterior; Rep.
hole
Gr. 55 ; Fuel Filler Door Unit .
spec
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– Remove the rubber seal from the fuel filler tube.
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– Remove the bolts -1- from the filler tube and disconnect the
ground wire -2-.
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1. Fuel Tank 233

Note
WARNING

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– Disconnect the connector -arrow- from the sensor flange.

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– Remove the right rear wheel housing liner. Refer to ⇒ Body

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Exterior; Rep. Gr. 66 ; Wheel Housing Liner, Removing and

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– Remove the stone chip protective molding -arrows-.
– Unclip the breather lines that are secured on the longitudinal

member with clips from the fuel tank.
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1. Fuel Tank 235

– Remove the filler neck bolt -arrow- in the wheel housing.

– Remove the breather lines from the EVAP canister. Refer to
⇒ “5.1 Overview - EVAP System”, page 251 .
– Remove securing straps with covers on left and right below
fuel tank.
– Support the fuel tank with the Engine and Gearbox Jack -
VAS6931- and remove the mounting strap in the center of the
fuel tank.
– Carefully lower the fuel tank a little.
– Disconnect the connector from the Fuel Pump Control Module
- J538- . Refer to -item 4- ⇒ Item 4 (page 229) .
– Disconnect the bleed line at the coupling. Refer to -item 12-
⇒ Item 12 (page 229) .
Note
– Lower the fuel tank.

Installing
♦ Connections for breather and fuel lines must engage audibly
when joined.
♦ Make sure ventilation and fuel lines are not kinked when in‐
stalled.
♦ The flange seal should be replaced each time it is opened.
♦ Secure fuel hoses with spring-type clamps.
♦ Make sure the connectors and the fuel hoses are secure.
♦ The ground wire on the fuel filler tube must be securely at‐ agen AG. Volkswagen AG do
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Rep. Gr.20 - Fuel Supply Prote
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2 Fuel Delivery Unit/Fuel Level Sensor

⇒ “2.1 Overview - Fuel Delivery
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❑ Replace
6 - Fuel Filter
❑ Left side
❑ Fuel Filter, Replacing.
Refer to
⇒ “3.1 Fuel Filter, Re‐
page 245
7 - Fuel Level Sensor 2 - G169-
❑ Left side
❑ Flat, rectangular floater
❑ Clipped in the retaining
ring on the bottom of the
reservoir -item 8-
⇒ Item 8 (page 237)
⇒ “2.3 Fuel Level Sensor 2 G169 and Suction Jet Pumps, Removing and Installing”, page 241 .
8 - Retaining Ring
❑ Welded to the fuel tank
❑ For the Fuel Level Sensor 2 - G169- and the suction jet pump retainers
9 - Suction Jet Pump
❑ Clipped to the retaining ring -item 8- ⇒ Item 8 (page 237) .
2. Fuel Delivery Unit/Fuel Level Sensor 237

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❑ Right side
❑ Round, spherical floater
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13 - Fuel Delivery Unit
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❑ Always replace the flange seal
❑ Individual components. Refer to ⇒ Fig. ““Individual Components of Flange, Right Side”“ , page 230
❑ Pay attention to the fuel tank installation position. Refer to
⇒ Fig. ““Location of Flange on Fuel Reservoir”“ , page 230
15 - Connector
❑ For the fuel pump
16 - Connector
2.2 Fuel Delivery Unit/Fuel Level Sensor,

♦ Elbow Assembly Tool - T10118-
Procedure:
Note

location.

page 1 .


– Remove the flange with the fuel filter on the left side. Refer to
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– Siphon the fuel if necessary. Refer to

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Touareg 2010 ➤ , Touareg 2015au➤ t ra
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Engine Mechanical, Fuel Injection
s and Ignition (Hybrid) - Edition 07.2015
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– Disconnect fuel pump connector -1- from flange.
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– Remove fuel level sensor connector -2- from flange.
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– Remove the sensor flange.
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– Remove the sensor flange with the fuel filter fuel line through
the right opening in the fuel tank.
t to the co
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mer
– Unclip the black filler hoses -1 and 2- off the fuel delivery unit
atio
housing.
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– Remove the fuel line -3- for the suction jet pumps.
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– Remove the connecting line -4- from the fuel filter/fuel pump.
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Note
♦ To do this, press red buttons on hose coupling together.

♦ Insert the Elbow Assembly Tool - T10118- to do this.
– Rotate the fuel delivery unit approximately 15° to the left and
remove it from the bottom of the fuel tank.
Note
The fuel delivery unit housing is filled with fuel. Fuel may run out
if the housing is tipped or tilted.
– Remove the fuel level sensor.

Installing

The tab on the flange -2- must be between the tongues
-1 and 3- on the fuel tank.


Sending Unit - T10202- .
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2.3 Fuel Level Sensor 2 - G169- and Suction
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Jet Pumps, Removing and Installing
es, in part or in w
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Removing:
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– Follow the rules of cleanliness. Refer to Prote
cted agen
AG.

– Remove the flange with the fuel filter on the left side of the fuel
tank. Refer to
– Unclip the Fuel Level Sensor 2 - G169- -1- and then remove
it from the fuel tank.

– Press the tab -1-.

If you want to remove the suction jet pumps, proceed as follows:

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– Remove the bleed line -1-. by
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– Disconnect the connector -3- from the fuel level sensor and pyri by
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– Disconnect fuel pump connector -1- from flange.

– Remove fuel level sensor connector -2- from flange.
– Remove the sensor flange.
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– Remove the sensor flange with the fuel filter fuely Vline
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the right opening in the fuel tank. ise
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– Unclip the black filler hoses -1 and 2- off the fuel delivery unit
hole
spec
housing.
es, in part or in w
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– Remove the fuel line -3- to the suction jet pumps.
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Press the locking ring to release the fuel line.
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– Remove the retainer -2- for the suction jet pumps -3- on the
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The rear suction jet pump -item 10- ⇒ Item 10 (page 238) is not cted agen
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shown in the illustration.
– Press the tab -1- to remove the suction jet pumps.

Remove suction jet pumps together with filler hoses and pump
fuel line from left opening in fuel tank.
Installing

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Note
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Make sure the connectors and the fuel hoses are secure.
cial p
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3 Fuel Filter
⇒ “3.1 Fuel Filter, Removing and Installing”, page 245
3.1 Fuel Filter, Removing and Installing

Note
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Fuel filter iselocated
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in left fuel tank opening, when gu viewed
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rection ofhortravel.
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Removing
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page 1 .
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– Remove the rear bench seat. Refer to ⇒ Body Interior; Rep. t to the co
– Fold the carpet to the side.
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– Disconnect the connector -arrow- from the fuel filter flange.
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3. Fuel Filter 245

– Remove the locking ring from the flange using the Wrench -
Fuel Sending Unit - T10202- .
– Lift the fuel filter flange and disconnect the connector -1- from
the fuel level sensor.
Note
♦ Siphon the fuel if necessary. Refer to

♦ The ground wire -2- can remain connected.
– Remove the fuel lines -1 and 2- from the fuel filter housing.
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Squeeze the button on the line couplings. ss c
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– Remove the fuel filter through the opening in the fuel tank.
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– Drain the fuel filter housing. ab

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– Replace the flange seal.

– Make sure the fuel level sensor connector, the ground wire
and the fuel lines are secure.
rrectness of i
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– Install the fuel filter flange in direction of travel -arrow-.

The tab -2- must be between the tongues -1 and 3- on the fuel
nform
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tank.
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3. Fuel Filter 247

Engine Mechanical,
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AG. VoInjection
lkswagen Aand
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4 EVAP System
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⇒ “4.1 Overview - EVAP System”, page 248
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⇒ “4.2 Fuel System, Checking for Leaks”, page 248
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4.1 Overview - EVAP System
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1 - Breather Line
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❑ From the fuel tank
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2 - Breather Line
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Purge Regulator Valve

1 - N80-
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3 - Bleed Connection
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4 - EVAP Canister
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7 - Rubber Bushing
4.2 Fuel System, Checking for Leaks

♦ K-Jetronic Fuel System Tester - VAG1371-
Procedure
– Remove the right rear wheel and wheel housing liner

– Disconnect the vent line -arrow- to solenoid valve inside the

engine compartment.
– Connect the K-Jetronic Fuel System Tester - VAG1371- to the

vent line -arrow- as shown.
– Connect the valve on the K-Jetronic Fuel System Tester -
VAG1371- to the tire valve.
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– Remove the cover -arrow- from the vent connection on the
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EVAP canister and then seal off the opening with a plug.
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– Set pressure to 35 mbar (0.5 psi) using valve -A-. After the atio
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pressure has stabilized, it must not drop below 30 mbar (0.43

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If pressure does not build up or if positive pressure is not main‐

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tained for at least 5 minutes, locate leak as follows:

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Note
Also check the fuel cap for leaks.
Only if no error has been detected up to this point:
4. EVAP System 249

– Check the vent line and the EVAP canister for leaks. To do
this, disconnect the vent line -1- from the EVAP canister and
seal off the connection with a plug.
– Repeat the pressure test.
If the Pressure Still Drops, Search for the Leak on the EVAP Can‐
ister or the Vent Line:
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– With valve -A- open, check the following lines and components s
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for leaks by listening, touching, using standard leak detection

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spray or using the Ultrasonic Measuring Device - VAG1842- .
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♦ Line from engine compartment to EVAP canister.
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♦ EVAP Canister
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If Pressure No Longer Falls Now, Search for Leak on the Fuel
spec
Tank:
es, in part or in w
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– To do this, connect the vent line to the EVAP canister.
rrectness of i
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– With valve -A- open, check the fuel tank for leaks by listening,
touching, using standard leak detection spray or using the Ul‐
nform
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trasonic Measuring Device - VAG1842- .

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After completing work, check tire pressure!

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5 EVAP Canister System, Engine

Code CGFA
⇒ “5.1 Overview - EVAP System”, page 251
⇒ “5.2 Fuel System, Checking for Leaks”, page 252
5.1 Overview - EVAP System
1 - Vacuum Line
❑ For the vacuum supply
to the Leak Detection
Pump - V144-
❑ To vacuum connection
on the intake manifold
2 - Bolt
❑ 9 Nm
3 - Breather Line AG. Volkswagen AG d
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❑ 5 Nm
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❑ 9 Nm
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7 - Breather Line
Purge Regulator Valve
rrectness of i
1 - N80-
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8 - Bolt
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❑ 5 Nm
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9 - Bolt
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❑ 9 Nm
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10 - EVAP Canister
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❑ Installed location: inside

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11 - Rubber Bushing opyri
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❑ Replace if damaged
12 - Connecting Hose
❑ Between the air filter and Leak Detection Pump - V144-
13 - Leak Detection Pump - V144-
❑ Fuel System, Checking for Leaks. Refer to ⇒ “5.2 Fuel System, Checking for Leaks”, page 252
❑ Black 3-pin connector
5. EVAP Canister System, Engine Code CGFA 251

5.2 Fuel System, Checking for Leaks

♦ Evaporative Emissions Tester - KLI9210-
♦ Evaporative Emissions Tester - Adapter 55 - KLI9210/55-3-
♦ Vehicle Diagnostic Tester
Test Conditions
• The Leak Detection Pump - V144- detected a leak.
• Guided Fault Finding was performed using the Vehicle Diag‐
nostic Tester .
Evaporative Emissions Tester - KLI9210- Preparation:
Note
Depending on the version, the appearance of the Evaporative

Emissions Tester - KLI9210- may vary.
AG. Volkswagen AG d
– Check on the Evaporative Emissions Tester - KLI9210- wheth‐lkswagen oes
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er there is enough fluid in the smoke generator. db
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– Set the valve -D- to “Hold”. utho eo
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– Open the nitrogen bottle -H-.
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– Connect the measuring hose -G- to the self-test connection
an
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-B-.
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– Set the valve -D- to “Test”.
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– Use the pressure reducer -J- to adjust the pressure to 10 in.
hole
spec
H2O (25 mbar).
es, in part or in w
t to the co
– Set the valve -D- to “Hold”.
– The pressure must now be maintained a minimum of 2 mi‐
nutes. If the pressure is not maintained, check the tester.
rrectness of i
Fuel System, Checking for Leaks:
l purpos
nform
mercia
a
com
tion in
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– Disconnect the breather line -arrow- to the EVAP Canister

s
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Purge Regulator Valve 1 - N80- in the engine compartment.

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– Connect the Evaporative Emissions Tester - Adapter 55 -

KLI9210/55-3- between the EVAP Canister Purge Regulator
Valve 1 - N80- and the vent line as shown.
– Connect the measuring hose -G- from the Evaporative Emis‐

sions Tester - KLI9210- to the Evaporative Emissions Tester
- Adapter 55 - KLI9210/55-3- .
– Set the valve -D- to “Hold”.
lkswage es n
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rrectness of i
– Connect the Vehicle Diagnostic Tester to the vehicle.

l purpos
– Start the engine and let it run in idle.

– Select the Guided Functions mode on the Vehicle Diagnos‐
nform
ercia
tic Tester.
m
at
– Select under Guided Functions “Check fuel tank ventilation

om
ion
system for leaks”.

c
in t
or
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te
– Start the test.

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– Watch the pressure gauge on the Evaporative Emissions

f
en
g
Tester - KLI9210- during the test.

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.
• The Leak Detection Pump - V144- must pump the fuel system
t rig
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up to minimum 7 in. Inflate H2O (17 mbar).
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The minimum pressure is not reached, but the pressure reached
AG.
does not decrease:

– Turn off the ignition and perform a pressure retention test. Re‐
fer to ⇒ page 254 . If no drop in pressure is detected: Check
the vacuum supply of the Leak Detection Pump - V144- . Refer
to
⇒ “5.2.3 Leak Detection Pump V144 , Checking Vacuum Sup‐
ply”, page 257 .
The minimum pressure is not reached and the pressure reached
decreases immediately:

– Clamp off the hose to the EVAP Canister Purge Regulator

Valve 1 - N80- with a hose clamp -arrow-.
– Repeat the test. If the minimum pressure is now reached: Re‐
place the EVAP Canister Purge Regulator Valve 1 - N80- .
If the minimum pressure is not reached again and the pressure
that is reached decreases immediately:
– Leak in fuel system, perform the “leak test in fuel system”. Re‐ wagen AG. Volkswagen AG does
fer to ⇒ “5.2.1 Fuel System Leak Detection”, page 255 . y Volks not
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If the Minimum Pressure Is Reached, Turn off the Ignition.
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The valve in the Leak Detection Pump - V144- is now
ss closed and
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the pressure is maintained.
un
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– Watch the pressure gauge:
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If the pressure does not decrease, perform a pressure retention
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is n
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spec
If the pressure falls, clamp off the hose to the EVAP Canister
Purge Regulator Valve 1 - N80- using a hose clamp -arrow-.
t to the co
– If the pressure stops falling, replace the EVAP Canister Purge
Regulator Valve 1 - N80- .
rrectne
If the pressure continues to fall, perform the “leak test in fuel sys‐
tem”. Refer to ⇒ “5.2.1 Fuel System Leak Detection”, page 255 .
ss o
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Pressure Retention Test
inform
mer
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– Set the valve -D- to “Test”. Increase the current pressure until
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ng
it reaches 10 in. H2O (25 mbar).

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– Watch the pressure gauge -C- and the flow meter -E-. The fuel
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system is filled if the flow quantity decreases and the pressure p by
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increases to 10 in. H2O (25 mbar).
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Note
Depending on the level in the fuel tank, this procedure may take
up to three minutes.
– After the pressure has stabilized, set the valve -D- to “Hold”.
• After five minutes the pressure must not drop below 8 in. H2O
(20 mbar).
If the Pressure Is Not Maintained for Five Minutes, the Leak
Should Be Localized as Follows:

– First check EVAP Canister Purge Regulator Valve 1 - N80- for

leaks. To do this, clamp off the hose to EVAP Canister Purge
Regulator Valve 1 - N80- -arrow-.
– Set the valve -D- to “Test” and repeat the pressure test.
– Watch the pressure gauge and the flow meter. The fuel system
is filled if the flow quantity decreases and the pressure increa‐
ses to 10 in. H2O (25 mbar). agen
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– After the pressure has stabilized, setedthe
by valve -D- to “Hold”.
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– If the pressure stops falling, replace
au
th the EVAP Canister Purge eo
ra
Regulator Valve 1 - N80- . ss c
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If the pressure continues to fall, perform the “leak test in fuel sys‐
du
an
itte
tem”. Refer to ⇒ “5.2.1 Fuel System Leak Detection”, page 255 .
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After completing the work, perform the “Check tank ventilation
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5.2.1 Fuel System Leak Detection

nf
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Test Conditions: orm

m
atio
• The procedure “Fuel System, Checking for Leaks” is per‐

om
formed. Refer to
n in
or c
⇒ “5.2 Fuel System, Checking for Leaks”, page 252 .

thi
te
sd
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• The Evaporative Emissions Tester - KLI9210- connected to

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the vehicle with the Evaporative Emissions Tester - Adapter

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55 - KLI9210/55-3- .
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– Connect the Evaporative Emissions Tester - KLI9210- to the
ht ht
rig by
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– Remove right rear wheel housing liner.
AG.
– Clamp off the hose between the Leak Detection Pump - V144-
-item 8- ⇒ Item 8 (page 257) and the air filter -item 7-
⇒ Item 7 (page 257) -arrow-.

– Set the valve -D- to “Test”.

– Watch the pressure gauge -C- and the flow meter -E-. The fuel
system is filled if the flow quantity decreases and the pressure
increases to 10 in. H2O (25 mbar).
– After the pressure has stabilized, set the valve -D- to “Hold”.
• After five minutes the pressure must not drop below 8 in. H2O
(20 mbar).
– If the pressure stops falling, replace the Leak Detection Pump
- V144- .
If the Pressure Is Not Maintained for a Minimum of Five Minutes
or If No Pressure Is Built up, Localize the Leak as Follows:
– Set the valve -D- to “Test” and fill the system with smoke.
– While fuel system is being filled, press smoke generator button
-I- for approximately one minute.
The fuel system is now under pressure and filled with smoke.
– Check all fuel system lines and hoses for escaping smoke.
Also check the fuel cap.
Note
♦ Illuminate the components and hoses with a strong flood light,

the smoke will be more visible.
♦ To check for leaks at accessible locations,aguse
en AGthe
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♦ Depending on how long fault
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t or
ac
ator button may need to bess pressed again. This ensures there
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♦ To check fuel pump and fuel filter flange, the assembly open‐
y li
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ings in the vehicle interior must be opened.

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– Replace any leaking hoses or components.

ole,
spec
After completing the work, perform the “Check tank ventilation

system for leaks” guided function. Refer to Vehicle Diagnostic
t to the co
Tester .
rrectne
5.2.2 EVAP System, Function Overview

ss o
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Engine Mechanical,
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1 - EVAP Canister ris
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2 - Component Location for ss
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Evaporative Emissions Tester
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- Adapter 55 - KLI9210/55-3-
pt
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❑ During the leak test in
rm
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fuel system
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3 - EVAP Canister Purge Reg‐ , is n
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ulator Valve 1 - N80-
hole
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4 - Breather Line
es, in part or in w
t to the co
❑ To the Intake Manifold
5 - Solenoid Valve
rrectness of i
❑ For the Leak Detection
Pump - V144-
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6 - Vacuum Line
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❑ To the Intake Manifold

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7 - Air Filter
com
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❑ For the Leak Detection
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Pump - V144-
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8 - Leak Detection Pump -
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5.2.3 Leak Detection Pump - V144- , Check‐

ing Vacuum Supply
♦ Turbocharger Tester Kit - VAG1397A-
♦ T-Connection - 251 201 346-

♦ 6 mm hose

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Leak Detection Pump
ss
a - V144- component location: inside the right ac
rear wheel housing under the wheel housing liner.
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– Remove the right rear wheel and wheel housing liner.
erm
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– Remove the vacuum line -1- from the Leak Detection Pump -
wit
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V144- .
h re
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– Connect the Turbocharger Tester Kit - VAG1397A- , with the
es, in part or in w
T-connection and the 6 mm diameter hose from between the
t to the co
vacuum line -1- and the Leak Detection Pump - V144- -2-.
– Turn on the measuring range I (absolute pressure measur‐
rrectness of i
ing).
l purpos
– Connect the Vehicle Diagnostic Tester and start the engine.

– Select the Guided Functions mode on the Vehicle Diagnos‐
nform
ercia
tic Tester.
m
at
– Select under Guided Functions “Check fuel tank ventilation
om
io
system for leaks”.
n
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– Start the test.

at
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– During the test, pay attention to the display on the Turbo‐ cum
for
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charger Tester Kit - VAG1397A- .

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– If the pressure rises above 0.700 (10.15 psi) bar during the
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test, the vacuum supply is too low. Make sure the vacuum line
to the intake manifold is not bent or plugged up.

6 Accelerator Mechanism
⇒ “6.1 Overview - Accelerator Pedal Module”, page 259
6.1 Overview - Accelerator Pedal Module
1 - Bracket
2 - Connector
❑ Black 6-pin
3 - Bolt
❑ 10 Nm
4 - Accelerator Pedal Position lkswage es n
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Sensor - G79- with Accelerator byV ua
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Pedal Position Sensor 2 - ir se tee
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G185- au ac
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❑ To remove the sensor,
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remove the cover in the
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6. Accelerator Mechanism 259

7 Fuel Pump
⇒ “7.1 Fuel Pump, Checking”, page 260
7.1 Fuel Pump, Checking

⇒ “7.1.1 Fuel Pressure, Checking”, page 260
⇒ “7.1.2 Residual Pressure, Checking”, page 264
⇒ “7.1.3 Fuel Delivery Rate, Checking”, page 265
7.1.1 Fuel Pressure, Checking

♦ Pressure Tester Kit - VAS6550-
♦ Pressure Tester Kit - Hose 2 - VAS6550/2-
♦ Pressure Tester Kit - Adapter Set - Fitting - VAS6550/3-1-
♦ Pressure Tester Kit - Adapter Set - Hose 2 - VAS6550/3-2-
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♦ Vehicle Diagnostic Tester utho eo
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♦ Wiring diagram
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Test Conditions
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• The engine control module DTC memory does not contain a
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malfunction related to the voltage supply of the fuel pump.
hole
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• Fuel Pump Control Module - J538- OK
es, in part or in w
t to the co
• Battery charger connected ⇒ Electrical Equipment; Rep. Gr.
27 ; Charging the battery .
rrectness of i
• Fuel pump fuse OK; for the fuse assignment. Refer to ⇒ Wiring
diagrams, Troubleshooting & Component locations.
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• The fuel filter is OK.

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• Fuel tank filled at least above the reserve.

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• The ignition is off

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– Follow all safety precautions. Refer to

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WARNING


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– Disconnect the fuel ris
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– Connect the Pressure Tester Kit - VAS6550- with the Pressure
Tester Kit - Hose 2 - VAS6550/2- , the Pressure Tester Kit -
l purpos
Adapter Set - Fitting - VAS6550/3-1- and the Pressure Tester

Kit - Adapter Set - Hose 2 - VAS6550/3-2- as shown.
nform
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Note
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♦ Secure the hose lines with the included clamps.
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Kit - VAS6550- in the direction of flow.
– Close cut-off tap “C”.
– Press the On/Off button to turn the Pressure Tester Kit -
VAS6550- on.
– Switch the ignition on.
– Connect the Vehicle Diagnostic Tester and conduct the guided
function “activate fuel pump”.
Note
♦ The fuel pump is now activated.

♦ The specified value will not be reached if the fuel pressure is
measured with the Guided Function “start fuel pump”.
♦ The specified value will not be reached if the fuel pressure is
measured without the battery charger connected.
– Read the pressure on the Pressure Tester Kit - VAS6550- .

Target value: > 5.5 bar (79.77 psi).
7. Fuel Pump 261

– Slowly close the shut-off valve “B” on the Pressure Tester Kit
- VAS6550- .
Target value: > 5.5 bar (79.77 psi).
– Switch off the ignition.
If the Specified Value Is Reached:
– Holding Pressure, Checking. Refer to
⇒ “7.1.2 Residual Pressure, Checking”, page 264 .
If Specified Value Is Not Obtained:
Note
If the Pressure Tester Kit - VAS6550- is to be removed, open cut-

off tap “C” and reduce the residual pressure. For this purpose,
hold the hose of cut-off tap “C” in a measuring container.
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– Remove the Pressure iTestersedb Kit - VAS6550- and then connect ara
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– Make sure the hoses clamp is securely fastened.
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– Remove the rear bench seat ⇒ Body Interior; Rep. Gr. 72 ;
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– Fold the right carpet cutout to the side.

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– Loosen the nuts -1 through 4- on the flange cover. spec

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– Disconnect the fuel supply line -2-.

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Press the button on the line coupling together for this purpose.
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Tester Kit - Adapter Set - Hose 4 - VAS6550/3-4- and the
Pressure Tester Kit - Adapter Set - Hose 3 - VAS6550/3-3- as
shown.
– Open the shut-off valves “A” and “B” on the Pressure Tester
– Perform the guided function “activate fuel pump” again.
Note
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– Read the pressure on the Pressure Tester Kit - VAS6550- . r ac
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Target value:
s > 5.5 bar (79.77 psi).
ce
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– Slowly close the shut-off valve “B” on the Pressure Tester Kit
an
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- VAS6550- .
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Specified value. Greater than 5.5 bar (79.77 psi).

h re
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If the Target Values Are Achieved:

– Check the fuel supply line from the fuel tank to the engine for
possible damage.
rrectne
If Specifications Are Not Obtained Again:

ss
– Make sure all couplings and fuel lines in the fuel tank and the
o
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fuel delivery unit are secure and not leaking.

inform
mer
If No Error Can Be Found:

atio
om
– Replace the fuel delivery unit. Refer to

c
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⇒ “2.2 Fuel Delivery Unit/Fuel Level Sensor, Removing and

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If the Pressure Tester Kit - VAS6550- is to be removed, open cut- cted agen
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7. Fuel Pump 263

7.1.2 Residual Pressure, Checking

Test Conditions
• The Pressure Tester Kit - VAS6550- must be connected. Refer
to ⇒ “7.1.1 Fuel Pressure, Checking”, page 260 .
• Fuel pressure approximately 5.0 bar (72.5 psi)
Test Sequence
– Observe the pressure drop on the pressure gauge. After 10
minutes the pressure must not drop below a 4.3 bar (62.3 psi)
decrease.
If the pressure drops below 4.3 bar (62.3 psi):
Note
The fuel pump is now activated.
The fuel pressure must increase up to a maximum pressure of >

5.5 bar (79.77 psi).
– Switch on the ignition and immediately close cut-off tap “B” of
the pressure tester. Cut-off tap “B” points perpendicular to the
direction of flow.
– Observe the pressure drop on the pressure gauge. After 10
minutes the pressure must not drop below a 4.3 bar (62.3 psi)
decrease.
If the Pressure Drops below 4.3 bar (62.3 Psi) Again:
(Leak on fuel tank side)
– Check the fuel tank connections for leaks.
If No Error Can Be Found: AG. Volkswagen AG d
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– Check the fuel line to the sensor flange -item 14- ised b ara
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– Check all additional fuel lines in fuel tank for leaks. s
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If No Faults Are Found on Fuel Line:

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– Replace the fuel delivery unit. Refer to

ility
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es, in part or in w
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Note

rrectness of i
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Rep. Gr.20 - Fuel Supply cted agen
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7.1.3 Fuel Delivery Rate, Checking

Test Conditions:
– The fuel pressure was checked and is OK. Refer to
⇒ “7.1.1 Fuel Pressure, Checking”, page 260 .
Test Sequence
AG. Volkswagen AG d
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A second mechanicaut is needed for the following task. ra
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WARNING
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– Disconnect the fuel supply hose -arrow- from the fuel supply
o
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line.
nform
mer

atio
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Tester Kit - Hose 2 - VAS6550/2- , the Pressure Tester Kit -

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Adapter Set - Fitting - VAS6550/3-1- and the Pressure Tester

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Kit - Adapter Set - Hose 2 - VAS6550/3-2- as shown.

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– Hold the end of the Pressure Tester Kit - Adapter Set - Hose
2 - VAS6550/3-2- in a measuring container -1-.
7. Fuel Pump 265

– Press the On/Off button to turn the Pressure Tester Kit -
VAS6550- on.
– Perform the guided function “activate fuel pump”.
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– Slowly close cut-off tap -B- until a counter pressure of 4 bar
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(58 psi) is achieved.
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– Empty the measuring container.
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Note
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– Switch off the ignition after 30 seconds.
nform
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• Target value: minimum delivery rate: > 1.5l/30 seconds.

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If the Target Value Is Not Reached, the Measurement at the Fuel
n
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Delivery Unit Flange Must Be Repeated:

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– Remove the Pressure Tester Kit - VAS6550- and then connect

the fuel supply line.
– Make sure the hose clamp is securely fastened.
– Remove the rear bench seat ⇒ Body interior; Rep. Gr. 72 ;
Removing and installing, Rear Bench Seat .
– Fold the right carpet cutout to the side.


– Disconnect fuel supply line -2-.
Note
Press the button on the line coupling together for this purpose.

Tester Kit - Adapter Set - Hose 3 - VAS6550/3-3- and the
Pressure Tester Kit - Adapter Set - Hose 4 - VAS6550/3-4- as
shown. agen
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– Hold the end of the ePressure
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yV Tester Kit - Adapter Set - Hose
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3 - VAS6550/3-3-horin a measuring container.
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7. Fuel Pump 267

– Perform the guided function “activate fuel pump”.
Note

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– Slowly close cut-off tap -B- until a counter pressure of 4 bar by V o gu
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(58 psi) is achieved. rised
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– Switch off the ignition. ss a ra
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– Empty the measuring container.
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Note
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– Switch off the ignition after 30 seconds.
l purpos
• Target value: minimum delivery rate: > 1.5l/30 seconds.

nform
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If the Specified Value Is Now Reached:

m
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– Check the fuel supply line to the engine for kinks and damage.
n
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If the Specified Value Is Not Reached Again:

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– Replace the fuel filter. Refer to
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– Repeat the test. t. C rig
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If the Specified Value Is Not Reached Again:
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– If the fuel pump is faulty, replace the fuel delivery unit. Refer
to
Note


8 Special Tools

equipment required
♦ Fuel Extraction Unit -
VAS5190-
♦ Wrench - Fuel Sending Unit
- T10202-
♦ Torque Wrench 1331
5-50Nm - VAG1331-
♦ Torque Wrench 1332
40-200Nm - VAG1332-
♦ Engine and Gearbox Jack -
VAS6931-
AG. Volkswagen AG d
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♦ Elbow Assembly Tool - T10118-

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♦ K-Jetronic Fuel System Tester - VAG1371-
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♦ Pressure Tester Kit - VAS6550- ss
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♦ Not illustrated.
♦ Pressure Tester Kit - Hose 2 - VAS6550/2-
♦ Pressure Tester Kit - Adapter Set - Fitting - VAS6550/3-1-
♦ Measuring Container
♦ Wiring diagram
♦ Evaporative Emissions Tester - KLI9210-
♦ Evaporative Emissions Tester - Adapter 55 - KLI9210/55-3-

21 – Turbocharger,
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⇒ “1.1 Overview - Charge Air Cooler”, page 271
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⇒ “1.2 Charge Air Pressure Sensors G31 and G447 , Removing
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⇒ “1.3 Charge Air Cooler, Removing and Installing”, page 273
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1.1 Overview - Charge Air Cooler
hole
spec
es, in part or in w
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1 - Seal
❑ Replace
rrectness of i
2 - O-Ring
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❑ Replace
❑ Coat with engine oil
nform
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when installing the

charge air cooler
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3 - O-Ring
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❑ Coat with engine oil

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4 - Supercharger Housing rig ht
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5 - Seal cted agen
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❑ Replace
6 - Right Charge Air Cooler
ling. Refer to
⇒ “1.3 Charge Air Cool‐
7 - Bolt
❑ 10 Nm
❑ Replace
❑ Self-locking
8 - Seal
❑ Not available separate‐
ly.
❑ May not be removed
from the charge air cool‐
er
❑ Coat with engine oil when installing the charge air cooler
9 - Bolt
❑ 10 Nm
❑ Replace
❑ Self-locking
10 - Left Charge Air Cooler
❑ Removing and installing. Refer to ⇒ “1.3 Charge Air Cooler, Removing and Installing”, page 273 .
1. Charge Air System 271

11 - Seal
❑ Not available separately.
❑ May not be removed from the charge air cooler
❑ Coat with engine oil when installing the charge air cooler
1.2 Charge Air Pressure Sensors - G31-

and - G447- , Removing and Installing
Removing
Charge Air Pressure Sensor - G31- , Removing:
– Disconnect the connector -arrows-.
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– Remove the bolts and nuts -arrows-. Remove the bracket

-A-.
rrectness o
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– Remove the bolts -arrows- and remove the charge air pres‐
Co
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272 Rep. Gr.21 - Turbocharger, Supercharger

Charge Air Pressure Sensor 2 - G447- , Removing:

– Free up the vacuum hose -1-.
– Remove the screws -arrows- and remove the cover -2-.
– Remove the bolts -arrows- and remove the charge air pres‐
sure sensor.
Installing
⇒ “2.1 Overview - Supercharger”, page 277 .
Note
♦ Replace the self-locking screws and the O-ring.

♦ Clean the threaded holes for the charge air pressure sensor
inside the supercharger housing with a thread tap before as‐
sembling.
1.3 Charge Air Cooler, Removing and In‐

stalling
Special tools and workshop equipment
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♦ Arbor - 2033-y Volks not
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♦ Seal Installer
horis - Valve Stem Seal Tool - 2036- nte
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♦ Camber
ss Adjustment Tool - VAG1942- c
ce
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nl
pt
Removing
du
an
itte
y li
• Supercharger secured on the Engine and Gearbox Bracket -

erm
ab
ility
VAS6095A- for repair work. Refer to

ot p
⇒ “2.6 Supercharger, Securing to Engine/Transmission Holder

wit
, is n
h re
for Repair Work”, page 288 .

hole
spec
Left Charge Air Cooler

es, in part or in w
t to the co
Note
rrectness of i
Ignore -2-.
l purpos
– Unclip the bracket -1- for the vacuum hose.

nform
mercia
at
om
ion
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ate
do
priv
cum
for
en
ng
t.
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Cop py
t. rig
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cted agen
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1. Charge Air System
– Remove the Charge Air Pressure Sensor 2 - G447- . Refer to

⇒ “1.2 Charge Air Pressure Sensors G31 and G447 , Remov‐
ing and Installing”, page 272 .
Right Charge Air Cooler

– Remove the Throttle Valve Control Module - J338- . Refer to
⇒ “4.3 Throttle Valve Control Module J338 , Removing and
AG. Volkswagen AG d
Installing”, page 307 . lksw
agen oes
n o ot g
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– Remove the Charge Air Pressure Sensor - G31- . Refer
ris
ed to
b ran
tee
⇒ “1.2 Charge Air Pressure Sensors G31 and G447 th , Remov‐
o
or
ing and Installing”, page 272 . au ac
ss
ce
le
un
pt
an
d
itte
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rm
ab
pe
ility
ot
wit
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hole
Continuation for Both Sides
spec
es, in part or in w
t to the co
– Remove the bolts -1 and 2- and the coolant pipes on the com‐
pressor.
rrectness of i
l purpos
nform
mercia
a
com
tion in
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thi
s
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do
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– Remove the screws on the left -1 and 2- and right -3 and 4-

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charge air coolers.

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t.
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– Attach the Seal Installer - Valve Stem Seal Tool - 2036- to the
compressor with Seal Installer - Valve Stem Seal Tool Adapter
Plates - 2036/1- as illustrated.
– Position the Arbor - 2033- on the front of the charge air cooler.
– Slowly remove the charge air cooler with even pressure from
the supercharger housing olkstoward
wage the rear using the esTire
not Pry
Lever - VAG1942- . d by V gu
ar
e an
ris tee
Installing tho or
au ac
ss
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nl
⇒ “1.1 Overview - Charge Air Cooler”, page 271 .
pt
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erm
ab
ility
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Note
wit
, is n
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♦ Replace the seals, O-rings and self-locking screws.
hole
spec
es, in part or in w
♦ Always clean the threaded holes inside the supercharger
t to the co
housing with a thread tap before assembling.
rrectness of i
– Check the seal -5- on the charge air cooler -4-.
l purpos
• The seal must not be cracked or damaged.

– Slide the seal -1- onto the charge air cooler.
nform
ercia
– Insert the O-ring -2- into the opening in the supercharger

m
at
om
housing -3-.
ion
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ate
do
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for
en
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rig ht
py by
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– Coat the sealing surface -arrow A- and the charge air cooler
seal -arrow B- -1- with engine oil.
– Coat the inner sealing surface inside the supercharger hous‐
ing with engine oil.
1. Charge Air System 275

. Volkswage
n AG n AG d
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d by (Hybrid) - Edition 07.2015
V gu
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ho
– Make sure the seals are opposite the openings
au
t
in the super‐ or
ac
ss air cooler
charger housing when installing the charge
ce
le
-arrows-.
un
pt
an
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itte
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erm
ab
Caution
ility
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Danger of causing damage to the charge air cooler.
h re
ole,
spec
♦ Install the charge air cooler by hand only.
t to the co
rrectne
– Install the charge air cooler all the way into the supercharger
ss
housing by hand in direction of -arrow A-. When doing this, let
o
cial p
f i
the front of the charge air cooler slide into the hole -arrow B-
nform
inside the supercharger housing.
mer
atio
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Note
thi
te
sd
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pr
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Holding the supercharger housing perpendicular in the Engine
um
r
fo
and Gearbox Bracket - VAS6095A- makes it easier to install and
en
ng
t.
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remove the charge air cooler. ht. Cop py
rig
rig ht
py by
co Vo
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cted agen
Prote AG.
– Manually guide the charge air cooler by hand through the su‐
percharger housing openings -arrows-, if necessary.
– As soon as it is possible, install the two bolts loosely by hand
to help guide the charge air cooler.
Caution
Danger of causing damage to the charge air cooler.

♦ The charge air cooler may not be installed by using the
bolts.
♦ Install the charge air cooler by hand only until there is
maximum 1 mm between the sealing flange and the seal
and the supercharger housing. Only then should the bolts
be tightened as follows:
– Tighten the bolts for the left -1 and 2- and right -3 and 4- charge
air coolers in a diagonal sequence and in small steps.
– Install the coolant pipes to the supercharger. Refer to
page 213 .
– Install the Throttle Valve Control Module - J338- .
– Check the supercharger for leaks. Refer to
⇒ “2.4 Supercharger, Checking for Leaks”, page 283 .

2 Supercharger
⇒ “2.1 Overview - Supercharger”, page 277
⇒ “2.2 Overview - Drive Head”, page 279
⇒ “2.3 Supercharger, Removing and Installing”, page 280
⇒ “2.4 Supercharger, Checking for Leaks”, page 283
⇒ “2.5 Drive Head and Decoupling Spring, Removing and Instal‐
ling”, page 285
⇒ “2.6 Supercharger, Securing to Engine/Transmission Holder for
Repair Work”, page 288
⇒ “2.7 Supercharger, Securing to Engine/Transmission Holder for
Leak Test”, page 288
2.1 Overview - Supercharger
1 - Engine Lifting Eye

2 - Bolt
❑ 27 Nm
3 - Supercharger
❑ With charge air coolers
❑ Supercharger, Remov‐
ing and installing. Refer
AG. Volkswagen AG d
to ksw
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not
l
⇒ “2.3 Supercharger, by
Vo gu
ara
Removing and Instal‐ rised
nte
ling”, page 280 . aut
ho eo
ra
s c
❑ Overview - Charge Air s
ce
le
Cooler. Refer to
un
pt
an
d
⇒ “1.1 Overview -
itte
y li
Charge Air Cooler”,
rm
ab
pe
page 271 .
ility
ot
wit
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h re
ling. Refer to
hole
spec
es, in part or in w
Removing and Instal‐ t to the co

ling”, page 280 .
❑ Secured on the Engine
and Gearbox Bracket -
rrectness of i
VAS6095A- for repair

l purpos
work. Refer to
Securing to Engine/
nform
ercia
Transmission Holder for

Repair Work”,
m
a
com
ti
page 288 .
on in
r
te o
❑ Secured on the Engine

thi
s
and Gearbox Bracket -

iva
do
r
VAS6095A- for leak

rp
cum
fo
test. Refer to
en
ng
t.
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Co
op py
Securing to Engine/
t. C rig
gh ht
yri
Transmission Holder for p by
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Leak Test”, page 288 .
lksw
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Prote AG.
4 - Insulation Plate
5 - Bolt
❑ 5 Nm
2. Supercharger 277
6 - Rubber Grommet
❑ Quantity: 2
7 - Intermediate Flange
8 - Bolt
❑ 10 Nm
9 - Throttle Valve Control Module - J338-
⇒ “4.3 Throttle Valve Control Module J338 , Removing and Installing”, page 307 .
10 - O-Rings
❑ Replace
11 - Connection
12 - Bolt
❑ 10 Nm
13 - Bracket
❑ For change-over valves agen
AG. Volkswagen AG d
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14 - Bolt ed by
V gu
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❑ 9 Nm ut
hor eo
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15 - Bolt s
ce
le
un
pt
❑ 10 Nm
an
d
itte
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16 - Intermediate Flange
erm
ab
ility
ot p
17 - Control Valve Control Unit - J808-
wit
is n
h re
ole,
spec
⇒ “4.4 Regulating Flap Control Unit J808 , Removing and Installing”, page 309 .
t to the co
18 - Bleeder Valve
❑ 1.5 to 3.0 Nm
❑ For the left charge air cooler
19 - Bolt rrectness
❑ 10 Nm
o
cial p
f i
❑ Replace
nform
mer
❑ Self-locking
atio
m
❑ Always clean the threaded holes with a thread tap before assembling
o
n
c
i
or
n thi
e
20 - Intake Air Temperature Sensor - G42-

t
sd
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pr
21 - O-Rings
um
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en
ng
❑ Replace
t.
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22 - Nut
rig
gh ht
pyri by
Vo
❑ 20 Nm
o
by c lksw
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23 - O-Ring
❑ Replace
24 - Threaded Pin
❑ 17 Nm
25 - Bolt
❑ 10 Nm
❑ Replace
❑ Self-locking
❑ Always clean the threaded holes with a thread tap before assembling

26 - Charge Air Pressure Sensor

❑ Cylinder bank 1 (right) Charge Air Pressure Sensor - G31- , cylinder bank 2 (left) Charge Air Pressure
Sensor 2 - G447-
⇒ “1.2 Charge Air Pressure Sensors G31 and G447 , Removing and Installing”, page 272 .
27 - Seals
❑ Replace
28 - O-Ring
❑ Replace
29 - Connection
❑ For the crankcase ventilation
❑ Installed position. Refer to ⇒ Fig. ““Installing the Crankcase Ventilation Connector”“ , page 166
30 - O-Rings
❑ Replace
2.2 Overview - Drive Head en AG. Volkswagen AG

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1 - Bolt ris nte
tho eo
❑ 25 Nm ss
au ra
c
❑ Replace
ce
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nl
pt
du
an
❑ Always clean the threa‐
itte
y li
ded holes with a thread
erm
ab
tap before assembling
ility
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❑ Self-locking
h re
hole
2 - Drive Head
spec
es, in part or in w
❑ Oil capacity: 150 ml (5 t to the co

oz) Compressor Oil - G
070 000-
rrectness of i

ling. Refer to
l purpos
⇒ “2.5 Drive Head and

Decoupling Spring, Re‐
nf
ercia
page 285 .
rm
m
atio
m
3 - Decoupling Spring
o
n in
or c

thi
e
ling. Refer to
t
sd
iva
⇒ “2.5 Drive Head and

r
rp
cu
o
Decoupling Spring, Re‐

f
en
ng
t.
yi Co
op
page 285 .
C py
ht. rig
rig ht
py by
4 - Supercharger Housing co Vo
by lksw
cted agen
Prote AG.
2. Supercharger 279
2.3 Supercharger, Removing and Installing

Removing:
Note
Follow the guidelines for clean working conditions. Refer to


page 43 .
– Loosen the hose clamps -arrows-, clamp off the coolant hoses
with the Hose Clamps - Up To 25mm - 3094- and remove them
from the coolant pipes on the supercharger.
AG. Volkswagen AG d
agen oes
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ility

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t to the co
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mer
– Disconnect the electrical connector -1- on EVAP Canister

atio
m
Purge Regulator Valve 1 - N80- and disconnect the vacuum

o
n
c
i
or
hose -2- by pressing the release buttons.

thi
te
sd
va
– Remove the EVAP Canister Purge Regulator Valve 1 - N80-

i
o
pr
cum
r
from the bracket and lay it aside with the hose connected.
fo
en
ng
t.
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Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

– Disconnect the connector -arrow- from the Throttle Valve Con‐

trol Module - J338- .
– Disconnect the connector -arrow- on the Regulating Flap Con‐

trol Unit - J808- .
– Disconnect the connectors -1, 2 and 3-.
Note
Mark the vacuum hoses for reinstallation.
– Disconnect the vacuum hoses -4 through

wage
7-.
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un
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– Disconnect the connector -1- on the Intake Air Temperature

erm
ab
Sensor - G42- / Manifold Absolute Pressure Sensor - G71- .

ility
ot p
wit
is n
h re
ole,
Note
spec
t to the co

rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
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cum
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fo
en
ng
t.
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Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
2. Supercharger 281
– Free up the vacuum hose -1-.

– Remove the screws -arrows- and remove the cover -2-.
– Disconnect the connector -arrows-.
– Remove the bolts and nuts -arrows-. Remove the bracket

-A-.
AG. Volkswagen AG d
agen oes
olksw not
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pt
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erm
ab
ility
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, is n
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hole
spec
es, in part or in w
t to the co

rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
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Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

– Free up the brake booster vacuum hose -2- on the bracket

-1-.
– Disconnect the connectors -1 and 2-.
– Remove the nuts -arrows- and remove the supercharger with
the charge air coolers upward.
– Seal off the openings on the supercharger and on the charge

air circuit with the Engine Bung Set - VAS6122- .
Installing
⇒ “2.1 Overview - Supercharger”, page 277 .
Note

. Volkswagen AG
gen AG d
♦ The hose connectionsVoas well
lksw
a
as the air duct pipes
oes
nand
ot hoses
must be free of oiledand
by grease before installing. gu
ara
nte
ris
o eo
♦ Secure all hose
aut connections with hose clamps that are specific
h
ra
to that model.
ss Refer to the Parts Catalog. c
ce
e
nl
pt
♦ In order to be able to securely mount the air guide hoses on

du
an
itte
their connectors, spray the screws on the previously used

y li
erm
ab
clamps with a rust remover.

ility
ot p
wit
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h re
– Make sure the crankcase ventilation support is installed cor‐

hole
spec
rectly when mounting the compressor. Refer to

es, in part or in w
⇒ Fig. ““Installing the Crankcase Ventilation Connector”“ ,

t to the co
page 166 .
rrectness of i

page 43 .
l purpos
– Fill with coolant. Refer to

nform
ercia
cuit”, page 192 .

m
at
om
ion
c
in t
or
his
ate
do
riv
2.4 Supercharger, Checking for Leaks

p
cum
for
en
ng

t.
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Cop py
t. rig
♦ Turbo System Tester Kit - VAG1687- with Turbo System Test‐ yri
gh by
ht
er Kit - Adapter 10 - VAG1687/10- , Turbo System Tester Kit cop Vo
by lksw
- Adapter 13-1 - VAG1687/13-1- , Turbo System Tester Kit - cted agen
Prote AG.
Adapter 13-2 - VAG1687/13-2- and Turbo System Tester Kit
- Adapter 13-3 - VAG1687/13-3-
Procedure
• Supercharger secured on the Engine and Gearbox Bracket -
VAS6095A- for the leak test. Refer to
2. Supercharger 283

• Regulating Flap Control Unit - J808- is installed. Refer to
⇒ “4.4 Regulating Flap Control Unit J808 , Removing and In‐
– Secure the Turbo System Tester Kit - Adapter 13-1 -
VAG1687/13-1- on the bottom of the supercharger housing.
– Secure the hose connections with hose clamps.
. Volkswage AG n AG d
agen oes
olksw not
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db ara
Note rise nte
tho eo
s au ra
c
The supercharger is illustrated
s without the transmission holder.
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
VAG1687/13-3- on the top of the supercharger housing.
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva

r
rp
cu
o
VAG1687/13-2- with Turbo System Tester Kit - Adapter 10 -

f
en
ng
t.
VAG1687/10- to the supercharger housing.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
Prepare the Turbo System Tester Kit - VAG1687- as follows:

– Completely remove the pressure regulating valve -2- and
close the valves -3 and 4-.
Note
Pull the knob in order to rotate the pressure regulating valve.

– Connect the Turbo System Tester Kit - VAG1687- as shown

to the compressed air -1- and to the Turbo System Tester Kit
- Adapter 10 - VAG1687/10- .
– If there is water in the viewing glass, open the water drain plug
-6- and drain the water.
– Open the valve -3-.
Caution
Volkswagen AG
Damage could result if the pressure is set too high.
ksw
agen
AG. does
not
Vol gu
♦ The pressure must not exceed 0.5 sedbar
by (7.2 psi)! ara
nte
ri
ho eo
aut ra
ss c
– Set the pressure to 0.5 bar (7.2 psi) using the pressure control
ce
le
un
pt
valve -2-.
an
d
itte
y li
rm
– Open the valve -4- and wait until the test circuit is filled. Reg‐
ab
pe
ility
ulate the pressure to 0.5 bar (7.2 psi) again if necessary.
ot
wit
, is n
– Close the valve -3- and observe the pressure gauge.
h re
hole
spec
• The drop in pressure must not exceed 0.1 bar (1.45 psi) in 30
es, in part or in w
seconds.
t to the co
– Inspect the charge air system for poorly sealed areas by lis‐
tening, feeling, using commercially available leak detection
rrectness of i
spray or by using the Ultrasonic Tester - VAG1842S- .
l purpos
Note
nform
ercia
♦ Refer to the Owner's Manual for information on using the Ul‐

m
a
com
trasonic Tester - VAG1842S- .

ion in
r
te o
♦ Release the pressure in the test circuit by pulling off the hose
thi
s
iva
coupling before removing the adapter.

do
r
rp
cum
fo
en
ng
t.
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2.5 Drive Head and Decoupling Spring, Re‐ Cop py
t. rig
gh
ht
pyri by
Vo
co lksw
by
cted agen
Prote
AG.

♦ 150 ml (5 oz) Compressor Oil - G 070 000-
♦ Expanding pliers (commercially available)
Removing
• Compressor secured to the Engine and Gearbox Bracket -
VAS6095A- . Refer to
2. Supercharger 285
– Remove the coolant pipes from the compressor. Refer to

page 213 .
– Hold the supercharger perpendicular on the engine/transmis‐
sion holder.
• The drive head faces up.
Caution
♦ To prevent the bearing cap -1- from coming loose and

having to be sealed again, do not use a hammer to remove
the drive head -2-, but rather only use the expanding pliers
-arrows-, as shown in the following illustration.
– Carefully remove the drive head from the bearing cap.
– Remove the decoupling spring.
olks
wage es n
ot g
yV ua
db ran
ir se tee
ho
aut or
ac
ss
ce
e
nl
pt
du
an
itte
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erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
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rp
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o
m
f
en
ng
t.
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Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

– Extract all the oil for the compressor drive from the bearing
cover as well as from the oil pockets -arrows- between the ribs
using the Used Oil Collection and Extraction Unit -
SMN372500- .
Installing
⇒ “2.2 Overview - Drive Head”, page 279 .
Note
♦ Replace the bolts for the drive head.

♦ Insert the self-locking bolts or the bolts with bolt-locking com‐
pound. Refer to Parts Catalog.
– Clean the sealing surfaces; they must

swa
be
gefree
n AG.of oil and grease.
Volkswagen AG
does
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Vol gu
– Clean the threaded holes forethe
d b drive head inside the bearing
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cap with a thread tap before
tho assembling.
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– Fill 150 ml (5 oz) of Compressor
ss Oil - G 070 000- into the c
ce
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bearing cap.
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Checking the oil level later is not possible.
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– Install the decoupling spring into the decoupling element.
• The end -1- of the spring must fit into the hole -arrow- inside
rrectness of i
the decoupling element.
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– Lightly apply the sealant to the sealing surface on the drive

head.
nform
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– Install the drive head on the supercharger housing. Pay at‐

tention to the alignment bushings.
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– Turn the ribbed belt pulley at the same time until the other end Prote
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of the decoupling spring engages in the hole in the front de‐
AG.
coupling element.
– Check the supercharger for leaks. Refer to
⇒ “2.4 Supercharger, Checking for Leaks”, page 283 .
– Install the coolant pipes to the supercharger. Refer to
page 213 .
2. Supercharger 287
2.6 Supercharger, Securing to Engine/

Transmission Holder for Repair Work
Note
The openings on the bottom of the supercharger housing should

make it possible to see and reach the charge air cooler.

♦ Gearbox Support - T40206-
Procedure
• Supercharger removed. Refer to
– Insert the Gearbox Support - T40206- with Gearbox Support
- T40206/1- in the Engine and Gearbox Bracket - VAS6095A- .
– Secure the supercharger on the transmission holder as
shown. For the bolted connections -1-, use the holes “1”, “4”,
“9”, “11” and “13”.
– Attach the Gearbox Support Supplement - T40206/2- directly
to the compressor housing at the front and on the right side
using the bolt -2-.
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Installation position of the Gearbox Support Supplement -

T40206/2- :
t to the co
• The seals -arrow 1- on the support must face downward.

rrectne
• It is possible to see and reach the charge air cooler through

the openings -arrow 2- inside the supercharger housing.
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2.7 Supercharger, Securing to Engine/

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Transmission Holder for Leak Test
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Note Prote AG.
The seals on the Gearbox Support Supplements - T40206/2-

should seal off the openings in the supercharger housing during
the leak test.


Procedure
• Supercharger removed. Refer to
– Insert the Gearbox Support - T40206- with Gearbox Support
- T40206/1- in the Engine and Gearbox Bracket - VAS6095A- .
– Secure the supercharger on the transmission holder as
shown. For the bolted connections -1-, use the holes “1”, “4”,
“9”, “11” and “13”.
– Attach the Gearbox Support Supplement - T40206/2- directly
to the supercharger housing at the right front using the bolt
-2-.
Installation Position of the Gearbox Support Supplement -

T40206/2-
• The seals on the supports seal off the openings in the super‐
charger housing.
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2. Supercharger
3 Special Tools
♦ Turbo System Tester Kit - VAG1687- with Turbo System Test‐

er Kit - Adapter 10 - VAG1687/10- , Turbo System Tester Kit
- Adapter 13-1 - VAG1687/13-1- , Turbo System Tester Kit - lkswage es n
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Adapter 13-2 - VAG1687/13-2- and Turbo System Tester Kit d by Vo ua
ran
- Adapter 13-3 - VAG1687/13-3- o
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♦ Arbor - 2033-
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♦ Seal Installer - Valve Stem Seal Tool - 2036-
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♦ Camber Adjustment aTool
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24 – Multiport Fuel
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⇒ “1.1 Vacuumss System, Checking”, page 293
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⇒ “1.2 Overview - Vacuum System”, page 293
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1.1 Vacuum System, Checking
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♦ Hand Vacuum Pump - VAS6213-
spec
Procedure
t to the co
– Check all vacuum lines in the vacuum system for:
rrectne
♦ Cracks
♦ Damage caused by animals
ss o
♦ Pinching
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♦ Porous locations and other leaks
mer
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– Check the vacuum lines leading both to and from the solenoid
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valve to the respective component.
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– If there is a DTC memory entry, check all the vacuum lines for
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the named component, but also all the vacuum lines to the
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other components.
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AG.
1.2 Overview - Vacuum System
1. Injection System 293

1 - Retaining Plate
2 - Bolts
❑ 9 Nm
3 - Distribution Piece
❑ For pressure
4 - To the Brake Booster
5 - To the Coolant Valves
6 - To the Vacuum Pump
7 - Secondary Air Injection Sol‐
enoid Valve - N112-
❑ To remove, squeeze the
tabs on the retaining
plate
8 - Intake Manifold Runner
Control Valve - N316-
❑ Bolted to the retaining
plate, tightening specifi‐
cation 5 Nm
9 - Secondary Air Injection Sol‐
enoid Valve 2 - N320-
❑ To remove, squeeze the
tabs on the retaining
plate
10 - Right Combination Valve
11 - Left Combination Valve
12 - T-Connection
❑ Connection for the vac‐
uum adjusting element
13 - Check Valve AG. Volkswagen AG d
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❑ For Coolant Regulation Valve - N515- rise nte
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15 - Hose ss c
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❑ To the coolant pump

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Rep. Gr.24 - Multiport Fuel Injection Prote AG.
2 Fuel Injectors
⇒ “2.1 Fuel Injectors, Removing and Installing”, page 295
2.1 Fuel Injectors, Removing and Installing

♦ Injector/Combustion Chamber Seal Tool Set - T10133B-
Removing
– Remove the supercharger. Refer to
– Remove the applicable intake manifold lower section. Refer to
– Guide the Injector/Combustion Chamber Seal Tool Set - Puller
- T10133/2A- in the groove on the fuel injector.
– Position the Injector/Combustion Chamber Seal - Removal
Tool - T10133/16A- on the puller and remove the fuel injector
by turning the screw -1-. . Volkswage AG n AG d
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– Remove the support ring -4-, O-ring -3- and ris spacer ring -2- nte
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from the fuel injector -1-. s au ra
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– Remove the seal -5-.
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– Carefully remove the old combustion chamber seal -6- by cut‐
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ting the sealing ring with a knife and prying it open with a small
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screwdriver.
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– Make sure that the groove of the fuel injector does not become
spec
damaged. If the groove is damaged, the fuel injector must be
es, in part or in w
t to the co
replaced.
Installing
rrectness of i
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Note
♦ Replace combustion chamber seal and O-ring.

nf
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orm
♦ Replace the spacer ring if damaged.

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♦ Lightly moisten fuel injector O-rings with clean engine oil.

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♦ Install the cylinder at same cylinder.

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2. Fuel Injectors 295

– Clean the hole in the cylinder head using the Brush -

T10133/4- .
– Place the Injector/Combustion Chamber Seal - Assembly

Cone - T10133/5- with the new combustion chamber seal -1-
onto the fuel injector -2-.
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– Slide the combustion chamber seal with the Injector/Combus‐ lksw
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tion Chamber Seal - Assembly Sleeve - T10133/6- onto by the
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ed - nte
T10133/5- as far as possible. au
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– Turn the Assembly Sleeve Injector/Combustion Chamber Seal
ce
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- Assembly Sleeve - T10133/6- and slide the combustion
du
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chamber seal into the seal groove.
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Note
h re
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spec
When pushing the combustion chamber seal onto the fuel injec‐
es, in part or in w
tor, the seal spreads open. Therefore after pushing it on, it must
t to the co
be tightened again in two steps, as follows. rrectness of i
– Push the Injector/Combustion Chamber Seal - Calibration

l purpos
Sleeve - T10133/7- with a slight turning motion (approximately

180°) all the way onto the fuel injector.
nform
ercia
– Pull off the Calibration Sleeve Injector/Combustion Chamber

Seal - Calibration Sleeve - T10133/7- again using turning mo‐
m
at
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tion in opposite direction.

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296 Rep. Gr.24 - Multiport Fuel Injection

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Engine Mechanical, Fuel Injection
sw agen AGand Ignition (Hybrid)
does - Edition 07.2015
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– Push the Calibration Sleeve -T10133/8- with ris a slight turning
e nte
tho
motion (approximately 180°) all the wayauonto the fuel injector. eo
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– Pull off Injector/Combustion Chamber Seal - Calibration
ce
le
un
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Sleeve - T10133/8- again using turning motion in opposite di‐
an
d
itte
rection.
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– Install the components from the repair set on the fuel injector
-1-:
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2 - Spacer ring, shoulder faces the fuel injector
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3 - O-ring
mer
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4 - Support Ring
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5 - Sealing washer
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– Lightly coat the new O-ring with clean engine oil before instal‐
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The combustion chamber seal -8- must not be oiled.
– Push the fuel injector all the way into the hole in the cylinder
head using the Injector/Combustion Chamber Seal - Assembly
Mandrel - T10133/9- .
Note
The fuel injector must not be difficult to install. If necessary, wait

as the combustion chamber seal continues to pull itself together.
– Make sure the fuel injector is positioned correctly in the cylin‐

der head:
• The connection of the fuel injector must engage in the intended
recess in the cylinder head.
– Install the intake manifold lower section. Refer to
2. Fuel Injectors 297

3 Air Filter
⇒ “3.1 Overview - Air Filter Housing”, page 298
⇒ “3.2 Air Filter Element, Removing and Installing”, page 299
⇒ “3.3 Air Filter Housing, Removing and Installing”, page 301
3.1 Overview - Air Filter Housing
1 - Water Drain
❑ Clean
2 - Air Guide
❑ From the lock carrier
3 - Bolt
❑ 9 Nm
4 - Air Filter Lower Section
❑ Clean off dirt, leaves
and salt residue.
ling. Refer to
⇒ “3.3 Air Filter Housing,
ling”, page 301 .
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5 - Air Duct Pipe olksw not
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❑ Clean off dirt, leaves orise nte
and salt residue. auth eo
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6 - Air Filter Element
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❑ Use an original air filter
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element. Refer to the
erm
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Parts Catalog.
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❑ Replacement intervals.
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Refer to the Mainte‐ h re

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nance Tables spec

es, in part or in w

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ling. Refer to
⇒ “3.2 Air Filter Element,
rrectness of i
ling”, page 299 .

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7 - Vent Hose
❑ Not installed
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8 - Air Filter Upper Section

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❑ Clean off dirt, leaves and salt residue.

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❑ Removing and installing. Refer to ⇒ “3.2 Air Filter Element, Removing and Installing”, page 299 .
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9 - O-Ring
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10 - Hose
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11 - Rubber Grommet
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3.2 Air Filter Element, Removing and Instal‐
Vol
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– Remove the right engine compartment cover. Refer to
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page 37 .
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– Loosen the clamp -1- and remove the air guide hose -2-.
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– Open the hose clamps -arrows-.
– Remove the air filter housing upper section -1- from the air filter
housing lower section -2- and pull it out of the openings for the
tabs -arrows-.
3. Air Filter 299

Touareg 2010 ➤ , Touareg 2015 agen➤
AG. Volkswagen AG d
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Engine Mechanical, Fuel
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– Remove the air filter -arrow-.
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Installing
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Note
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♦ Always use an Original air filter.
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spec
♦ Air filter housing must always be clean.
es, in part or in w
t to the co
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♦ Note the following when cleaning the air filter housing with
pressurized air: To prevent malfunctions, cover the critical air
l purpos
flow components, such as air guide pipes, etc., with a clean

cloth.
nf
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♦ Follow all disposal regulations.
orm
m
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– Remove any salt residue, dirt or leaves from the air filter hous‐
o
n in
or c
ing upper and lower sections.
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– Clean out the water drain -arrow- in the bottom of the air filter
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housing with compressed air.

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– Check air duct from lock carrier to air filter housing for dirt and
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– Install the air filter -arrow-.
– Carefully place the air filter housing upper section -1- on the
air filter housing lower section -2-.
– Make sure that the air guide hoses are attached securely to
the air filter upper section.

3.3 Air Filter Housing, Removing and Instal‐

ling
♦ Pry Lever - 80-200-
Removing
– Remove the air filter. Refer to
⇒ “3.2 Air Filter Element, Removing and Installing”,
page 299 .
– Remove the right front wheel housing liner. Refer to ⇒ Body
– From the wheel housing side, remove the air guide -1- from
the air filter housing lower section.
– Remove the bolt -1-. Remove the air filter housing out of the
rubber bushings.
Installing
♦ Air filter housing must always be clean. AG. Volkswagen AG d
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♦ Insert the air guide to the lock carrier into the air filter housing. by
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♦ Pay attention to the water drain hose routing. ut
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♦ Note the following when cleaning the air filter housing s with
ce
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pressurized air: To prevent malfunctions, cover the critical air

un
pt
an
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flow components, such as air guide pipes, etc., with a clean

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cloth.
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♦ Install the right front wheel housing liner. Refer to ⇒ Body

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spec
♦ Install the air filter. Refer to
⇒ “3.2 Air Filter Element, Removing and Installing”,

t to the co
page 299 .
rrectness o
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3. Air Filter 301

4 Intake Manifold
⇒ “4.1 Overview - Intake Manifold Lower Section with Fuel Rail”,
page 302
AG. Volkswagen AG d
⇒ “4.3 Throttle Valve Control Module J338 , Removing wagand
en In‐ oes
olks not
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⇒ “4.4 Regulating Flap Control Unit J808ut,hoRemoving and Instal‐ eo
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4.1 Overview - Intake Manifold Lower Section with Fuel Rail
pt
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1 - Bolts
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❑ 2.5 Nm
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spec
2 - Intake Manifold Runner Po‐
es, in part or in w
sition Sensor
t to the co
❑ On the right side, Intake
Manifold Runner Posi‐
rrectness of i
tion Sensor - G336-
❑ On the left side, Intake
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Manifold Runner Posi‐

tion Sensor 2 - G512-
nform
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ling. Refer to
m
at
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i
⇒ “4.5 Intake Manifold
on
c
Flap Vacuum Actuator,
in t
or
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Removing And Instal‐

at
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ling”, page 310 .

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4 - Sleeve
5 - Fuel Pressure Sensor -
G247-
❑ 22 Nm
❑ Oil the threads
6 - Bracket
7 - Bolt
❑ 9 Nm
8 - High Pressure Pipe
❑ Connectors should not
show any signs of dam‐
age
❑ Do not change the shape.
❑ Removing and installing. Refer to ⇒ “7.3 High Pressure Pipe, Removing and Installing”, page 319 .
❑ Counterhold the threaded connections when loosening and tightening fuel line
❑ Union nut tightening specification 27 Nm
❑ Tighten fuel line threaded connections before installing the fuel line
9 - Bolt
❑ 9 Nm

10 - Nut
❑ 9 Nm
11 - Bolt agen
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13 - Retaining Bracket for Fuel Rail du
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14 - Threaded Connection
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❑ 40 Nm
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❑ If the threaded connections on the fuel rail were loosed, they must be replaced.
hole
spec
15 - Fuel Rail
es, in part or in w
t to the co
16 - Seal
❑ Replace
rrectness of i
17 - Intake Manifold Lower Section
l purpos

⇒ “4.2 Intake Manifold Lower Section with Fuel Rail, Removing and Installing”, page 304 .
nform
ercia
❑ After replacing the Control Valve Control Unit - J808- , perform the “adaptation” in “Guided Functions”
using the Vehicle Diagnostic Tester .
m
at
om
io
18 - Seal
n
c
in t
or
❑ Replace
his
ate
do
riv
19 - Support Ring
p
cum
for
en
g
❑ Check for proper seating

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❑ The fuel rail wields force via the support ring to hold the fuel injector tightly in the cylinder head.
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20 - O-Ring
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❑ Replace
Prote AG.
❑ Coat with clean engine oil

21 - Spacer Ring
22 - Fuel Injector
Removing and installing. Refer to ⇒ “2.1 Fuel Injectors, Removing and Installing”, page 295 .
23 - Sealing Washer
❑ Replace
24 - Combustion Chamber Seal
❑ Replacing. Refer to ⇒ “2.1 Fuel Injectors, Removing and Installing”, page 295 .
❑ Do not grease or treat with any other lubricants
25 - Gasket
❑ To replace, lift out using a screwdriver.
❑ To install, press in by hand
26 - Release Lever
❑ For the vacuum actuator
27 - Vacuum Hose
❑ To the Intake Manifold Runner Control Valve - N316-
28 - Vacuum Actuator for Intake Flap Control
⇒ “4.5 Intake Manifold Flap Vacuum Actuator, Removing And Installing”, page 310 .
4. Intake Manifold 303

Lower Intake Manifold Section - Tightening Specification and Se‐

quence
– Tighten the bolts and nuts -arrows- in a diagonal sequence on
the intake manifold lower section and in steps.
• 10 Nm
4.2 Intake Manifold Lower Section with Fuel

Rail, Removing and Installing
♦ Torque Wrench 1331 Insert - Ring Wrench - 11mm & 17mm -
VAG1331/2-
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Note aut ra
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The following removal and installation procedure is for the left
an
d
itte
lower section of the intake manifold. The procedure for the other
y li
rm
ab
side is identical.
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ility
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es, in part or in w
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rrectness of i
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tion in
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– Push the vacuum hoses to the side.
WARNING

nection point and carefully open the connection point.
– Counterhold the threaded connection and loosen the union nut

-1-.
– Disconnect the connector -4- from the Fuel Pressure Sensor
- G247- .
– Remove the screws and nuts -arrows- and remove the lower
intake manifold section and fuel rail.
– Disconnect the connector -2- from the intake manifold runner
position sensor and remove the vacuum hose -3-.
lkswage es n
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Caution byV ua
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ir se tee
tho
or
There is a risk of destroying the engine. au ac
ss
ce
le
♦ Cover the intake ducts with a clean cloth to prevent small

un
pt
an
d
particles from getting into the engine through the intake

itte
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channels in the cylinder heads.
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ility
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Installing
ole,
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t to the co
Note
rrectne
♦ Replace the O-rings.
ss
♦ Coat the fuel injector O-rings thinly with clean engine oil.
o
cial p
f inform
♦ If the threaded connections -item 14- ⇒ Item 14 (page 303)
mer
were loosened or removed, they must be replaced.

atio
om
♦ When installing the intake manifold lower section, the intake

c
i
or
manifold flaps must be opened, otherwise they may jam with

thi
te
sd
a
the baffles in the cylinder head.

iv
o
pr
cum
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fo
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t.
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co lksw
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Prote AG.

– Before installing the intake manifold lower section, loosen the

bolt -arrow- and move the fuel rail -1- back and forth in direction
of -arrows-.
• If the fuel rail -1- cannot be moved, remove the fuel rail retain‐
ing bracket -2- and clean
– Reassemble the fuel rail retaining bracket -2- and fuel rail -1-
and install the bolt -arrow- only hand-tight.
AG. Volkswagen AG d
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– Open the intake manifold flaps by connecting
ut the Hand Vac‐
ho eo
ra
uum Pump - VAS6213- to the connection sfor
s the intake flap
a c
control vacuum actuator, as shown in illustration.
ce
e
nl
pt
du
an
– Create a vacuum using the Hand Vacuum Pump - VAS6213- .
itte
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ility
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, is n
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es, in part or in w
t to the co
rrectness of i
• The intake manifold flaps are opened.
l purpos
– Press the intake manifold lower section evenly onto the fuel
injectors.
nform
ercia
– Tighten the intake manifold lower section bolts and nuts to the
m
at
om
i
tightening specification in a diagonal sequence.
on
c
in t
or
• Tightening specification of the intake manifold lower section -

his
ate
overview. Refer to
do
priv
⇒ Fig. ““Lower Intake Manifold Section - Tightening Specifica‐

um
for
en
g
tion and Sequence”“ , page 304 .

n
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Cop py
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Prote AG.

– Tighten the bolt -arrow- to 1 Nm.

– Remove the hand vacuum pump from the connection on the
intake manifold runner control vacuum actuator.
– Install the connector -4- on the Fuel Pressure Sensor - G247- .

– Counterhold the threaded connection and tighten the union
nut -1-.
Tightening specifications. Refer to
⇒ “4.1 Overview - Intake Manifold Lower Section with Fuel Rail”,
page 302 .
– Pay attention that the high pressure pipe sits free of tension.
AG. Volkswagen AG d
agen oes
olksw not
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4.3 Throttle Valve Control Module - J338- , ris nte
ho eo
ut ra
Removing and Installing s a c
s
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nl
pt
du
Removing: an
itte
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ility
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wit
page 37 .
, is n
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hole

spec
es, in part or in w
t to the co
rrectness of i
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nform
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om
ion
c
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or
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ate
do
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for
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– Remove the bolts -arrows- and remove the Throttle Valve
Control Module - J338- with the intermediate flange.
Caution
There is a risk of destroying the engine.

AG. Volkswagen
♦ Cover the intake channel with a clean wagecloth to prevent does n
n AG
olks
small particles from getting dinto
by the compressor.
V ot g
ua
r e an
ris tee
tho or
au ac
Installing ss
ce
le
un
pt
Install in reverse order of removal while noting the following: an
d
itte
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erm
ab
ility
ot p
Note
wit
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spec
t to the co
– Insert the intermediate flange -2- with new O-rings into the su‐
percharger -1- -arrows-.
rrectne
– Position the Throttle Valve Control Module - J338- -3- onto the
intermediate flange -arrows-.
ss o
cial p
• Tightening specification: 10 Nm.

f inform
mer
– If the throttle valve control module was replaced, adapt the

atio
engine control module. Refer to Vehicle Diagnostic Tester in

om
“Guided Functions”.
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
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Cop py
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4.4 Regulating Flap Control Unit - J808- ,

Removing
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss
ce
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nl
pt
du
an
itte
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erm
ab
ility
ot p
wit
, is n
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hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
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cted agen
Prote AG.
– Remove the connector -3- from the Regulating Flap Control

Unit - J808- .
– Remove the bolts -5 and 6-.
– Remove the connecting pipe -1- with the adapter (intermediate
flange) -2- and Regulating Flap Control Unit - J808- -4-.
Installing
Note

– Install the connecting pipe -1- with the adapter (intermediate

flange) -2- and Regulating Flap Control Unit - J808- -4- with
new O-rings.
– Hand-tighten the bolts -5 and 6-.
– First tighten the bolts -6- to the tightening specification.
• Tightening specification: 10 Nm.
– Then tighten the bolts -5- to the same tightening specification.
– Reattach the connector -3-.
G. Volkswagen AG d
– Tighten the fuel pipe -arrows-.
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agen
A
oes
not
o
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– If the Regulatingrised Flap Control Unit - J808- was replaced,
b ara adapt
nte
the engine ut
h control module. Refer to Vehicle Diagnostic Tester
o eo
ra
in “Guided
ss a Functions”. c
ce
e
nl
pt
du
an
itte
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erm
ab
ility
ot p
wit
, is n
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hole
spec
es, in part or in w
t to the co
4.5 Intake Manifold Flap Vacuum Actuator,

rrectness of i
Removing And Installing

l purpos
Caution
nf
ercia
orm
Do not actuate the vacuum adjusting element by hand. Danger

m
atio
m
of causing damage to the membrane. Use the Hand Vacuum

o
n in
c
Pump - VAS6213- for a function test.

or
thi
te
sd
iva
o
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rp
cu
Right Intake Manifold Flap Vacuum Actuator, Removing and In‐

o
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f
en
ng
stalling
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Cop py
.
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by
bracket and disconnect it; do to so press the release buttons. copy Vo
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Prote
Left Intake Manifold Flap Vacuum Actuator, Removing and In‐
AG.
stalling
page 210 .
Continuation for Both Sides
– Remove the bolts -2- and the intake manifold runner position
sensor -3-.
– Remove the ball cup -4- from the actuator lever -5-.

– Remove the vacuum adjusting element -1- and seal -7-.
Installing
– Lubricate the seal -7- lightly and install it on the vacuum ad‐
justing element.
– Push the vacuum adjusting element -1- and seal -7- onto the
actuator lever.
– Push the ball socket -4- onto the ball head on the actuator
lever.
– Install the intake manifold runner position sensor -3-. Tighten‐
ing specification. Refer to -item 1- ⇒ Item 1 (page 302) .
– Perform a function test by connecting the Hand Vacuum Pump

- VAS6213- to the connection for the intake flap control vac‐
uum actuator, as shown in illustration.
. Volkswag
– Use the Hand Vacuum Pump - VAS6213-ktoswacreate a vacuum. does no
gen AG
en AG
The operating lever must move. by
Vol t gu
a d ran
ise
Assembly is performed in reverse torder.
ho
r tee
or
au ac
ss
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e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
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Prote AG.

5 Sensors
⇒ “5.1 Intake Air Temperature Sensor G42 / Manifold Absolute
Pressure Sensor G71 , Removing and Installing”, page 312
⇒ “5.2 Intake Manifold Runner Position Sensor G336 / Intake
Manifold Runner Position Sensor 2 G512 , Removing and Instal‐
ling”, page 312
5.1 Intake Air Temperature Sensor - G42- /

Manifold Absolute Pressure Sensor -
Removing
– Remove the bolts -arrows- and remove the Intake Air Tem‐
perature Sensor - G42- / Manifold Absolute Pressure Sensor
- G71- .
Installing
Install in reverse order of removal. Note the following:
• Tightening specification. Refer to -item 19-
⇒ Item 19 (page 278) .
Note
5.2 Intake Manifold Runner Position Sensor

- G336- / Intake Manifold Runner Posi‐
. Volkswagen AG
gen AG
tion Sensor 2 - G512- y, VRemoving
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and does
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ut or
Procedure. Refer to ss
a ac
⇒ “4.5 Intake Manifold Flap Vacuum Actuator, Removing And In‐
ce
le
un
pt

an
d
itte
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erm
ab
ility
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is n
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spec
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
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or
n thi
te
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6 Engine Control Module

⇒ “6.1 Engine Control Module J623 , Removing and Installing”,
page 313
6.1 Engine Control Module - J623- , Remov‐

ing and Installing
Note
AG. Volkswagen AG d
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If the engine control module is to be replaced,by V connect the Vehicle
ol not
gu
Diagnostic Tester and perform the guided rised function “Replace En‐ ara
nte
gine Control Module”. ut
ho eo
ra
s a c
s
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le

un
pt
an
d
itte
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♦ Hot Air Gun from Wiring Harness Repair Set - VAS1978B- .
rm
ab
pe
ility
♦ Attachment nozzle from Wiring Harness Repair Set -
ot
wit
VAS1978B- .
, is n
h re
hole
♦ Locking pliers
spec
es, in part or in w
Removing
t to the co
rrectness of i
– Remove the wiper arms. Refer to ⇒ Electrical Equipment;
Rep. Gr. 92 ; Windshield Wiper System; Wiper Arms, Re‐
l purpos
moving and Installing .

– Remove the plenum chamber cover. Refer to ⇒ Body Exterior;
nform
ercia

m
a
com
– Cover the engine compartment in the area near the engine
tion in
control module to prevent scratching the paint.
r
te o
thi
s
– Remove the bolts and the engine control module.
iva
do
r
rp
cum
fo
en
ng
t.
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Note
Co
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The threads of the shear bolts are equipped with locking com‐ co Vo
by lksw
pound. By heating the shear bolts using a hot air gun, the adhe‐ cted agen
Prote AG.
sive effect of the locking compound is lowered.
Caution
Make sure the parts cannot get burned.

By heating the shear bolts, parts of the protective housing are
heated intensely. Wear safety gloves to prevent injuries.
– Warm the shear bolt -arrows- with a hot air gun.

– Loosen the bolt -1- with locking pliers.
6. Engine Control Module 313

– Bend the edges of the housing down and remove the bolts.
Installing
– Replace the protective housing.
– Install a new protective housing with new shear bolts.
– Tighten the shear bolts evenly until the bolt head shears off.
– Install the engine control module into the plenum chamber.
– Install the plenum chamber cover. Refer to ⇒ Body Exterior;
– Install the wiper arms. Refer to ⇒ Electrical Equipment; Rep.
Gr. 92 ; Windshield Wiper System; Wiper Arms, Removing
and Installing .
AG. Volkswagen AG d
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nl
pt
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ility
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hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
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AG. Volkswagen AG d
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7 High Pressure Pump d by
Volksw not
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⇒ “7.1 Overview - High Pressure Pump”, page
ut
ho 315 eo
ra
s a c
s
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e
nl
page 316
pt
du
an
itte
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⇒ “7.3 High Pressure Pipe, Removing and Installing”, page 319
erm
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ility
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7.1 Overview - High Pressure Pump
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1 - Bolt
es, in part or in w
t to the co
⇒ Fig. ““High Pressure
rrectness of i
Pump - Tightening
Specification and Se‐
l purpos

2 - High Pressure Pump
nform
ercia
❑ With Fuel Pressure

m
at
Regulator Valve - N276-
om
ion
c
in t
or
his
e
ling. Refer to
at
do
riv
⇒ “7.2 High Pressure

p
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or
Pump, Removing and

f
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❑ Do not disassemble
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3 - Threaded Connection by c lksw
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Prote AG.
❑ 40 Nm
❑ Counterhold the threa‐
ded connections when
loosening and tighten‐
ing the high pressure
pipe
❑ If the threaded connec‐
tions were loosed, they
must be replaced.
❑ Tighten before installing
the fuel supply line
threaded connection
❑ Tighten using the Tor‐
que Wrench 1331 Insert
- Open Ring Wrench -
14mm - VAG1331/8-
4 - Connection
❑ 27 Nm
5 - Hose Clamp
6 - High Pressure Pipe
❑ 25 Nm
❑ Removing and installing. Refer to ⇒ “7.3 High Pressure Pipe, Removing and Installing”, page 319 .
❑ Do not change the shape.
❑ Check for damage before installing
❑ Counterhold the threaded connections when loosening and tightening the high pressure pipe
❑ Coat the threads on the union nut with fuel.
7 - Fuel Supply Line
❑ Check for damage before installing
7. High Pressure Pump 315

8 - Low Fuel Pressure Sensor - G410-

❑ 15 Nm
9 - Nut
❑ 9 Nm
10 - Seal
❑ Replace
11 - Housing
12 - O-Ring
❑ Replace
13 - Camshaft Position Sensor - G40-
⇒ “1.5 Camshaft Position Sensor G40 and G163 , Removing and Installing”, page 361 .
14 - Bolt
15 - Bolt
❑ 9 Nm
16 - Nut
❑ 9 Nm
17 - Protective Plate
❑ For the high pressure pipe.
❑ Depending on the version, it may look different
18 - Roller Tappet
❑ Can be installed in one position only Volkswa
n AG. gen AG
❑ Coat the O-rings with clean wage
olks engine oil before installing
does
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19 - O-Ring ris
ed nte
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❑ Replace au
t ra
c
ss
❑ Coat the O-rings with clean engine oil before installing
ce
le
un
pt
an
d
itte
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erm
ab
High Pressure Pump - Tightening Specification and Sequence

ility
ot p
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– Tighten bolts in two stages as follows:

h re
ole,
spec
Step Bolts Tightening Specification

t to the co
1. -arrows- Install alternately by hand all the way

2. -arrows- In steps to 20 Nm
rrectness o
cial p
f inform
mer
atio
m
7.2 High Pressure Pump, Removing and In‐

o
n
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or
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Note
Co
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If the threaded connections -item 3- ⇒ Item 3 (page 315) were
p by
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loosened or removed, they must be replaced. Prote
cted AG.
agen


AG. Volkswagen AG d
Removing agen oes
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– Remove the right engine compartment cover.
oris Refer to
e nte
⇒ “3.1 Engine Compartment Cover, Removing
aut
h and Installing”, eo
ra
page 37 . ss c
ce
le
un
pt
– Loosen the clamp -1- and remove the air guide hose -2-.
an
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itte
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rm
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ility
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, is n
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es, in part or in w
t to the co
rrectness of i
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nform
ercia
lease buttons -1-.
m
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com
tion in
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te o
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Prote AG.
– Open the hose clamps -arrows-.
– Remove the air filter housing upper section -1- from the air filter
housing lower section -2- and pull it out of the openings for the
tabs -arrows-.

– Remove the nuts and bolts -arrows- and remove the protective
plate -A-.
WARNING

nection point -1- and carefully open the connection point.
– Remove the bolt -arrow-.

– Remove the hose -2-.

wage
– Remove the bolts -arrows- and remove the high pressure y Vo lks es n
ot g
pump with roller tappet. ir se
d b ua
ran
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th or
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ss
Note
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nl
pt
du
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Do not change the shape of the high pressure pipe.
erm
ab
ility
ot p
wit
, is n
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hole
spec
es, in part or in w
t to the co
Installing
– Check the roller tappet -1- for damage and replace it if nec‐
rrectness of i
essary.
l purpos
– Coat the roller tappet with engine oil and insert it with the tab
-arrow A- into the guide -arrow B-.
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
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co lksw
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Prote AG.

– Insert the Crankshaft Socket - T40058- guide pins as follows:

AG. Volkswagen AG d
agen oes
olksw not
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d by ara
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or eo
h
ut ra
– Turn the crankshaft in the direction
ss a of engine rotation -arrow- c
using the Crankshaft Socket - T40058- and the offset open-
ce
le
un
pt
end wrench. While doing so, push the roller tappet into the
an
d
itte
housing, until it has reached the lowest point.
y li
erm
ab
ility
– Only lift the high pressure pipe slightly to insert the high pres‐
ot p
sure pump. Do not bend it.
wit
is n
h re
ole,
– Replace the O-ring and install the high pressure pump.
spec
t to the co
• Refer to ⇒ “7.1 Overview - High Pressure Pump”, page 315 .
• Refer to
rrectne
⇒ Fig. ““High Pressure Pump - Tightening Specification and
ss o
– Refer to
cial p
f in
⇒ Fig. ““High Pressure Pump - Tightening Specification and
form
mer
atio
om
– Refer to
n
c
i
or
n
⇒ “7.3 High Pressure Pipe, Removing and Installing”,
thi
te
sd
page 319 .
iva
o
pr
cum
r
fo
en
ng
7.3 High Pressure Pipe, Removing and In‐

t.
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op py
stalling
t. C rig
gh ht
pyri by
Vo
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by c lksw
cted agen
Prote AG.
Note
If the threaded connections -item 14- ⇒ Item 14 (page 303) were

loosened or removed, they must be replaced.

♦ Torque Wrench 1331 Insert - Open Jaw - 17mm - VAG1331/6-
Removing:

– Remove the bolts -arrows- and move the Intake Manifold Run‐
ner Position Sensor - G336- with the intake manifold flap
vacuum actuator to the side.
Note
♦ Ignore -1-.
♦ Cylinder bank 2 (left) is shown in the illustration.
AG. Volkswagen AG d
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– Remove the nuts and bolts -arrows- and remove theuprotective
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Installing
• Tightening specifications. Refer to rrectness of i
⇒ “4.1 Overview - Intake Manifold Lower Section with Fuel
l purpos
Rail”, page 302 and

⇒ “7.1 Overview - High Pressure Pump”, page 315 .
nform
mercia
Note
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♦ High pressure pipe connections must not show any signs of

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– Tighten the union nut with the Torque Wrench 1331 5-50Nm
- VAG1331- and Torque Wrench 1331 Insert - Open Jaw -
17mm - VAG1331/6- . To do so, counterhold using an open-
end wrench on the threaded connection hex fitting.
– First tighten the bolt of the mounting tab, after that, the high
pressure pipe is tightened.

8 Heated Oxygen Sensors

⇒ “8.1 Overview - Heated Oxygen Sensor”, page 322
⇒ “8.2 Heated Oxygen Sensor G39 , Removing and Installing”,
page 323
⇒ “8.3 Oxygen Sensor after Three Way Catalytic Converter
G130 , Removing and Installing”, page 325
⇒ “8.4 Heated Oxygen Sensor 2 G108 , Removing and Installing”,
page 326
⇒ “8.5 Oxygen Sensor 2 after Catalytic Converter G131 , Re‐
8.1 Overview - Heated Oxygen Sensor

Oxygen Sensor Connectors
Po‐ Heated Oxygen Heating Connector
si‐ Sensor
tion
1 Oxygen Sensor Heater For Oxy‐ 4-pin, black lkswage es n
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after Three Way gen Sensor 1 after d byV
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Catalytic Convert‐
Catalytic Convert‐ o
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2 Heated Oxygen Oxygen Sensor 6-pin, black
ce
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nl
Sensor - G39- Heater - Z19-
pt
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3 Oxygen Sensor 2 Heater for Oxygen 4-pin, brown
erm
ab
after Catalytic Sensor 2 after
ility
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Converter - G131-Catalytic Convert‐
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h re
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4 Heated Oxygen Oxygen Sensor 2 6-pin, brown
es, in part or in w
Sensor 2 - G108- Heater - Z28-
t to the co
Cylinder Bank 1 (Right) Heated Oxygen Sensors Component Lo‐
cation
rrectness of i
1- Oxygen Sensor after Three Way Catalytic Converter -
l purpos
G130- with Heater for Oxygen Sensor 1 after Catalytic

Converter - Z29-
nf
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2- Heated Oxygen Sensor - G39- with Oxygen Sensor Heater
rm
m
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- Z19-
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Component Location: Cylinder Bank 2 (Left) Heated Oxygen Sen‐

sors
1- Heated Oxygen Sensor 2 - G108- with Oxygen Sensor 2
Heater - Z28-
2- Oxygen Sensor 2 after Catalytic Converter - G131- with
Heater for Oxygen Sensor 2 after Catalytic Converter - Z30-
Note
♦ Coat new oxygen sensors with an assembly paste. Paste must

not get on to slits of sensor body.
♦ For a used heated oxygen sensor, only coat the threads with
hot bolt paste. This paste must not come into contact with
sensor slots. Hot bolt paste. Refer to the Parts Catalog.
♦ The heated oxygen sensor wire must always be attached at
the same location when installing. This way the wire does not
come into contact with the exhaust pipe.
Heated Oxygen Sensor - G39- and Oxygen Sensor Heater - Z19- ,

removing and installing. Refer to
⇒ “8.2 Heated Oxygen Sensor G39 , Removing and Installing”,
page 323 .
Oxygen Sensor after Three Way Catalytic Converter - G130- and
Heater for Oxygen Sensor 1 after Catalytic Converter - Z29- , re‐
moving and installing. Refer to
G130 , Removing and Installing”, page 325 .
swage es n
Heated Oxygen Sensor 2 - G108- with Oxygen Sensor 2byHeaterVolk ot g
ua
- Z28- . Refer to ir se
d ran
tee
⇒ “8.4 Heated Oxygen Sensor 2 G108 , Removing and
uth Installing”,
o
or
page 326 . ss
a ac
ce
e
nl
Oxygen Sensor 2 after Catalytic Converter - G131- with Heater
pt
du
an
for Oxygen Sensor 2 after Catalytic Converter - Z30- . Refer to
itte
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⇒ “8.5 Oxygen Sensor 2 after Catalytic Converter G131 , Re‐
erm
ab
ility
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8.2 Heated Oxygen Sensor - G39- , Remov‐ h re

hole
spec
ing and Installing
es, in part or in w
t to the co

rrectness of i
♦ Ring Wrench 7-Piece Set - 3337-

l purpos
Removing
nform
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page 37 .
m
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or
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ate
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8. Heated Oxygen Sensors 323

AG. Volkswagen AG d
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nform
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m
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ion
c
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ate
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for
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by c lksw
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– Disconnect the connector -2- for the Heated Oxygen Sensor -

G39- and free up the wire.

– Remove the heated oxygen sensor -2- using the Ring Wrench
Set - Oxygen Sensor Probe Socket - 3337/7- :
Installing
♦ Tightening specifications: Overview - Heated Oxygen Sen‐
sors. Refer to
⇒ “8.1 Overview - Heated Oxygen Sensor”, page 322 .
8.3 Oxygen Sensor after Three Way Cata‐

lytic Converter - G130- , Removing and
Installing
Removing
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– Remove the engine Vol
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notto
⇒ “3.1 Engine ed bCompartment Cover, Removing and
y gu
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an
page 37 h. oris tee
t or
au ac
– Remove
ss the rear engine cover -2- upward.
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nl
pt
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ate
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es, in part or in w
– Disconnect the connector -1- for the Oxygen Sensor after
t to the co
Three Way Catalytic Converter - G130- and free up the wire.
rrectness of i
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7-Piece Set - Wrench - 3337/1/2- :
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sors. Refer to
8.4 Heated Oxygen Sensor 2 - G108- , Re‐

Removing
WARNING

trical shock! Before starting, visually inspect the high voltage
components in the work area. Note the general warnings. Re‐
fer to ⇒ Electrical Equipment Hybrid; Rep. Gr. 93 ; High
Voltage Electrical System General Safety Precautions .


page 37 .
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t to the co
– Disconnect the connector -4- for the Heated Oxygen Sensor
2 - G108- and free up the wire.
rrectness of i
– Loosen the power steering fluid reservoir and move it to the
l purpos
side.
nform
mercia
a
com
tion in
r
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thi
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Set - Oxygen Sensor Probe Socket - 3337/7- .
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sors. Refer to
8.5 Oxygen Sensor 2 after Catalytic Con‐

verter - G131- , Removing and Installing

Removing:
WARNING


page 37 .
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form
mer
ening the hose clamps -arrows-. atio

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– Disconnect the connector -3- for the Oxygen Sensor 2 after

Catalytic Converter - G131- and free up the wire.

7-Piece Set - Wrench 1 - 3337/1- :
Installing
sors. Refer to
lkswage es n
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ate
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9 Special Tools
♦ Injector/Combustion Chamber Seal Tool Set - T10133B-
♦ Torque Wrench 1331 5-50Nm - aVAG1331-

gen AG
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♦ Torque Wrench 1331 Insert - Open Jaw - 17mm - VAG1331/6-

rrectness of i
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rig ht
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♦ Hot Air Gun from Wiring Harness Repair Set - VAS1978B- .
♦ Pry Lever - 80-200-

AG. Volkswagen AG d
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♦ Not illustrated: C py
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♦ Attachment nozzle from Wiring Harness Repair Set - cop Vo
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VAS1978B- . cted agen
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♦ Locking pliers
♦ Torque Wrench 1331 Insert - Ring Wrench - 11mm & 17mm -
VAG1331/2-

26 – Exhaust System, Emission Controls

1 Exhaust Pipes/Mufflers
⇒ “1.1 Overview - Muffler”, page 332
⇒ “1.2 Exhaust Pipes/Mufflers, Disconnecting”, page 333
⇒ “1.3 Tail Pipes, Replacing”, page 334
⇒ “1.4 Exhaust System, Installing without Tension”, page 334
⇒ “1.5 Exhaust System, Checking for Leaks”, page 335
1.1 Overview - Muffler
1 - Bolt
❑ 23 Nm
2 - Mount
3 - Mount
4 - Bolt
❑ 23 Nm
5 - Mount
6 - Nut
❑ 35 Nm
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7 - Front Clamping Sleeves Volkswa not
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❑ Replace db ara
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❑ Installed position. tho eo
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⇒ Fig. ““Installed Posi‐

nl
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tion of Front Clamping

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Sleeves”“ , page 333

erm
ab
ility
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❑ Before tightening, align

wit
exhaust system so that

, is n
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it is tension-free. Refer
hole
spec
to
es, in part or in w
⇒ “1.4 Exhaust System,

t to the co
Installing without Ten‐

sion”, page 334
❑ Tighten threaded con‐
rrectness of i
nections evenly.
l purpos
8 - Nut
❑ 35 Nm
nf
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or
9 - Front Clamping Sleeves

m
m
atio
m
❑ Replace
o
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or c
❑ Installed position. Refer to ⇒ Fig. ““Installed Position of Front Clamping Sleeves”“ , page 333
thi
te
sd
iva
❑ Before tightening, align exhaust system so that it is tension-free. Refer to

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⇒ “1.4 Exhaust System, Installing without Tension”, page 334

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❑ Tighten threaded connections evenly.
Co
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10 - Center Muffler
gh ht
pyri by
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co
❑ Original equipment as one unit with the rear muffler. If a repair is required replace each separately
by lksw
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Prote AG.
332 Rep. Gr.26 - Exhaust System, Emission Controls

❑ Separating point. Refer to ⇒ “1.2 Exhaust Pipes/Mufflers, Disconnecting”, page 333 .
❑ Exhaust System, Installing without Tension. Refer to
⇒ “1.4 Exhaust System, Installing without Tension”, page 334 .
11 - Mount AG. Volkswagen AG d
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❑ Replace ifydamaged not
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12 - Bolt thoris e or
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❑ 23 ss Nm
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13 - Left Tail Pipe
pt
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❑ Tightening specification: 60 Nm
erm
ab
❑ Aligning. Refer to ⇒ “1.3 Tail Pipes, Replacing”, page 334 .
ility
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14 - Rear Muffler
h re
ole,
❑ Original equipment as one unit with center muffler
spec
❑ If a repair is required, the center muffler, rear muffler and tail pipes can be replaced separately
t to the co
❑ Center muffler/rear muffler separating point. Refer to
⇒ “1.2 Exhaust Pipes/Mufflers, Disconnecting”, page 333 .
rrectne
ss
15 - Right Tail Pipe
o
cial p
f in
❑ Tightening specification: 60 Nm
form
mer
❑ Aligning. Refer to ⇒ “1.3 Tail Pipes, Replacing”, page 334 .

atio
om
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Installed Position of Front Clamping Sleeves

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• Threaded connections point toward outside.

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1.2 Exhaust Pipes/Mufflers, Disconnecting

♦ A separating point has been provided in the connecting pipe
for individual replacement of the center or rear muffler.
♦ The separating point is marked by an indentation around the
circumference of the exhaust pipe.
♦ Chain Pipe Cutter - VAS6254-
Procedure
⇒ “1.1 Overview - Muffler”, page 332 .
1. Exhaust Pipes/Mufflers 333

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Engines aMechanical, Fuel Injection and Ignition (Hybrid) o-r aEdition
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– Separate the exhaust pipes at the separating points -arrow-
pt
du
an
using a Chain Pipe Cutter - VAS6254- .
itte
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ility
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t to the co
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– When installing, position clamping sleeves -arrows- centrally
nform
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on separation point.
m
at
om
i
– Install the clamping sleeves so that the bolt ends do not project
on
c
in t
over lower edge of the clamping sleeves. The clamping sleeve
or
his
e
must not touch other components, even at extreme move‐

at
do
riv
ments of the exhaust system.

p
cum
for
en
g
– Install the exhaust system without tension. Refer to

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⇒ “1.4 Exhaust System, Installing without Tension”, Cop py
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page 334 . opyri
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1.3 Tail Pipes, Replacing

Procedure
– Remove the tail pipe -arrow-.
– Attach end pipe to rear muffler and align.

– Check distance of left and right tail pipes to bumper:
• Dimension -a- = 20 mm minimum
• -b- = align evenly
– Center the tail pipe inside the cut-out in the bumper.
1.4 Exhaust System, Installing without Ten‐

sion
• Align the exhaust system when cold.


⇒ “1.1 Overview - Muffler”, page 332 .
– Loosen the screws on the front clamping sleeves.
– Loosen the threaded connections on the repair clamps, if
equipped.
– Press exhaust system forward -arrow- under the following ten‐
sions are adjusted on the individual retaining loops:
• Front retaining loop: dimension -a- = 2 mm.
AG. Volkswagen AG d
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• Center retaining ed byloop: dimension -a- = 15 mm. gu
ara
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ility
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es, in part or in w
t to the co
rrectness of i
• Rear retaining loop: dimension -a- = 12 mm.

l purpos
– Hold exhaust system in this position and tighten clamping

sleeve screws evenly to 35 Nm.
nf
ercia
orm
Note
m
atio
om
n in
or c
♦ A second technician is needed to align the exhaust system

thi
te
with repair sleeves between front and rear mufflers.

sd
iva
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cu
♦ If all adjustment dimensions are not achieved, loosen the af‐

o
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f
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fected bracket from body and shift accordingly.

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1.5 Exhaust System, Checking for Leaks
by c lksw
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Prote AG.
– Start the engine and let it run at idle.

– Seal off the tail pipes with cloths for the duration of the leak
test.
– Check for leaks by listening at connection areas of cylinder
head/exhaust manifold, exhaust manifold/front exhaust pipe
etc.
– Repair the detected leaks.
1. Exhaust Pipes/Mufflers 335

2 Emissions Control
⇒ “2.1 Overview - Emissions Control”, page 336
⇒ “2.2 Catalytic Converter, Removing and Installing, Left (Bank
2)”, page 337
⇒ “2.3 Catalytic Converter, Removing and Installing, Right (Bank
1)”, page 340
2.1 Overview - Emissions Control
1 - Left Front Muffler

2 - Seal
❑ Replace
3 - Nut
❑ 23 Nm
❑ Replace
4 - Oxygen Sensor 2 after Cat‐
alytic Converter - G131-
5 - Catalytic Converter
❑ For cylinder bank 2 (left)
❑ Protect from shocks and
impact stress
ling. Refer to
⇒ “2.2 Catalytic Con‐
verter, Removing and
Installing, Left (Bank 2)”,
page 337 .
❑ Exhaust System, Instal‐
ling without Tension. wage
es n
s
Refer to yV
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ua
⇒ “1.4 Exhaust System, ir se
d b ran
tee
Installing without Ten‐ utho
or
sion”, page 334 . ss
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6 - Nut
un
pt
an
d
itte
❑ 23 Nm
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❑ Replace
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7 - Seal
h re
ole,
❑ Replace
spec
8 - Left Catalytic Converter

t to the co
Support
9 - Bolt
rrectne
❑ 23 Nm
s
10 - Right Catalytic Converter Support

s o
cial p
f i
11 - Nut
nform
mer
❑ 23 Nm
atio
m
❑ Replace
o
n
c
i
or
n thi
e
12 - Seal
t
sd
iva
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r
❑ Replace
p
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Cop py
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Vo
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Prote AG.

13 - Oxygen Sensor after Three Way Catalytic Converter - G130-

14 - Catalytic Converter
❑ For cylinder bank 1 (right)
❑ Protect from shocks and impact stress
⇒ “2.3 Catalytic Converter, Removing and Installing, Right (Bank 1)”, page 340 .
15 - Nut
❑ 23 Nm
❑ Replace
16 - Seal
❑ Replace
17 - Right Front Muffler
18 - Bolt
❑ 23 Nm
19 - Bolt
❑ 23 Nm
20 - Right Front Muffler Support
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26 - Left Clamping Sleeve
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2.2 Catalytic Converter, Removing and In‐

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2. Emissions Control 337

control electronics and remove it. Release and remove the
high voltage cables -2, 3 and 4- in sequence.
– Remove the power steering fluid reservoir and move it to the
side. The hoses remain connected.
– Unclip the connector -A- and remove the bracket for the high
voltage cables -arrows-. Move the high voltage cables with the
bracket to the side.
– Remove the Oxygen Sensor 2 after Catalytic Converter -
G131- .
– Remove the nut -2- accessible from above using the Socket
and Jointed Extension - 12mm - T40220- .
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– Remove the left front muffler -A-.
– Remove the heat shield -1- for the universal joint -2-.
Caution
♦ Separate universal joint from steering gear only when front

wheels are in straight ahead position.
♦ Do not change steering wheel position and steering gear
position any more, secure steering wheel with adhesive
tape.
– Remove the universal joint -1- from the steering gear.
Note
Have the drip tray for the coolant ready.
– Remove the hoses from the coolant pipes -2-.

– Remove the coolant pipes from the transmission. AG. Volkswagen AG d
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– Remove nuts -1- and -3- (accessible from the bottom) from
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Refer to ⇒ “2.1 Overview - Emissions Control”, page 336 .
hole
spec
• Steering column tightening specifications. Refer to ⇒ Sus‐
es, in part or in w
pension, Wheels, Steering; Rep. Gr. 48 .
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– During installation, all cable ties must be installed at the same
location.
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⇒ “1.4 Exhaust System, Installing without Tension”,
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page 334 .
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2.3 Catalytic Converter, Removing and In‐

stalling, Right (Bank 1)
Removing:
page 37 .
– Remove the Oxygen Sensor after Three Way Catalytic Con‐
verter - G130- . Refer to
G130 , Removing and Installing”, page 325 .
– Remove the nut -2- accessible from above using the Socket
and Jointed Extension - 12mm - T40220- .
Note
To provide a better illustration, component location is shown from

behind with engine removed.


– Remove the right front muffler -B-.

– Remove the front driveshaft. Refer to ⇒ Transfer Case and
Rear Final Drive; Rep. Gr. 39 ; Driveshaft; Front Driveshaft,
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– Remove nuts -1 and 3- (accessible from thethobottom) from front
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– During installation, all cable ties must be installed at the same
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page 334 .
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2. Emissions Control 341

3 Secondary Air System

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3.1 Overview - Secondary Air Injection System
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1 - Vacuum Hose
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❑ From the Secondary Air

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⇒ “3.5 Right Secondary
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and Installing”,
page 346 .
3 - Bolts
❑ 9 Nm
4 - Secondary Air Injection
Sensor 1 - G609-
❑ Only engine code CGFA
ling. Refer to
⇒ “3.6 Secondary Air In‐
jection Sensor 1 G609 ,
ling”, page 347 .
5 - O-Ring
❑ Replace
6 - Bolts
❑ 5 Nm
7 - Left Secondary Air Injection Combination Valve
❑ Check. Refer to
⇒ “3.3 Secondary Air Injection Combination Valves, Checking for Function and Leaks”, page 344 .
⇒ “3.4 Left Secondary Air Injection Combination Valve, Removing and Installing”, page 345 .

8 - Vacuum Hose
❑ From Secondary Air Injection Solenoid Valve 2 - N320-
9 - Seal
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⇒ “3.2 Secondary Air Injection Pump Motor V101 , Removing and Installing”, page 343 .
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❑ Check in “Guided Functions”. Refer to Vehicle Diagnostic Tester .
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13 - Bracket
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14 - Nut
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15 - O-Rings
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3.2 Secondary Air Injection Pump Motor -

V101- , Removing and Installing
Removing
– Loosen the coolant expansion tank for the low temperature
circuit -1- and move it upward.
3. Secondary Air System 343

– Press the release buttons and remove the secondary air in‐
jection hoses -1 and 2-. Disconnect the connector -arrow- and
free up the cable.
– Remove the nuts -arrows- and remove the secondary air in‐
jection pump upward.
Installing
⇒ “3.1 Overview - Secondary Air Injection System”,
page 342 .
The secondary air injection hoses must engage audibly.
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the secondary air injection (AIR) pump via the secondary air
spec
injection (AIR) relay. Air reaches the secondary air injection
combination valves.
t to the co
♦ The secondary air injection solenoid valve is activated in par‐
allel and this allows the vacuum to reach the secondary air
rrectne
injection combination valves. The respective secondary air in‐
jection combination valve thereby opens the path for secon‐
s
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spec
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-1- Secondary Air Injection Solenoid Valve - N112- for Bank 1
(right).
-2- Secondary Air Injection Solenoid Valve 2 - N320- for Bank 2
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– Connect the Hand Vacuum Pump - VAS6213- to the vacuum

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– Operate the hand vacuum pump.

• The relevant combination valve must open, it must be possible
to blow through.
– If the secondary air injection combination valve does not open,
replace it. Refer to left
moving and Installing”, page 345 and right
Assembling
Assembly is performed in reverse order of removal.
3.4 Left Secondary Air Injection Combina‐

tion Valve, Removing and Installing
Removing
– Remove the left catalytic converter. Refer to
(Bank 2)”, page 337 .

– Remove the bolts -arrows- and the heat shield -1-.

– Remove the vacuum line -2- from the secondary air injection
combination valve.
– Remove the bolts -1-.
– Pull the combination valve slightly upward and remove the

bolts -3- for the secondary air pipe.
Installing
– Replace the seal.
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– First attach the secondary air pipe and then tighten the com‐
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(Bank 2)”, page 337 .
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3.5 Right Secondary Air Injection Combina‐
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tion Valve, Removing and Installing
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Removing
– Remove the right catalytic converter. Refer to
nf
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⇒ “2.3 Catalytic Converter, Removing and Installing, Right orm

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(Bank 1)”, page 340 .

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– Remove the bolts -arrows- and the heat shield -1-.

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– Remove the bolts -3-, pull out the combination valve and re‐
move the bolts -1- for the secondary air pipe.
Installing
– Replace the seal.
– First attach the secondary air pipe and then tighten the com‐
bination valve.
page 342 .
♦ Install the right catalytic converter. Refer to
(Bank 1)”, page 340 .
3.6 Secondary Air Injection

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Touareg 2010d b➤ y V, Touareg 2015 ➤
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Engine Mechanical,
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jection Sensor 1 - G609- .
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2 - Bracket for Heat Shield
3 - Exhaust Manifold
❑ Removing and Instal‐
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Left. Refer to
Removing and Installing,
Left (Bank 2)”,
page 350 .
Right. Refer to
Removing and Installing,
Right (Bank 1)”,
page 352 .
4 - Seal
❑ Replace
5 - Heat Shield
6 - Bolt
❑ 10 Nm
7 - Heated Oxygen Sensor
❑ Before catalytic converter
❑ Removing and installing. Refer to ⇒ “8 Heated Oxygen Sensors”, page 322 .
8 - Front Exhaust Pipe with Catalytic Converter
❑ Protect from shocks and impact stress
4. Exhaust Manifold 349

9 - Nut
❑ 23 Nm
❑ Replace
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Right Exhaust Manifold - Tightening Specification and Sequence

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4.2 Exhaust Manifold, Removing and Instal‐

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Removing
WARNING

Note

location.
– Remove the electric drive power and control electronics. Refer

to ⇒ Electrical Equipment Hybrid; Rep. Gr. 93 ; Hybrid Spe‐
cific Components; Electric Drive Power and Control Electron‐
ics - JX1- .

– Loosen the power steering fluid reservoir and move it to the

side.
– Remove the left catalytic converter (bank 2) from the exhaust
manifold.
– Remove the rear bracket from the catalytic converter and pull
the catalytic converter slightly toward the rear.
– Remove the Heated Oxygen Sensor 2 - G108- -arrow-.
– Remove the bolts -1 through 4- and remove the heat shield.
– Remove the nuts -1 and 2- and remove the heat shield bracket.
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1. Tighten the nuts hand-tight.
2. Pre-tighten to 15 Nm.
3. Tighten to 25 Nm.
⇒ “4.1 Overview - Exhaust Manifold”, page 349 .
4.3 Exhaust Manifold, Removing and Instal‐

ling, Right (Bank 1)
Removing
Note

location.
– Remove the right catalytic converter (bank 1). Refer to

(Bank 1)”, page 340 .
– Remove the air filter housing. Refer to
⇒ “3.3 Air Filter Housing, Removing and Installing”,
page 301 .
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– Remove the nuts -1 through 7- and remove the exhaust mani‐

fold.
Installing
– Position the exhaust manifold with the seal, coat the nut
threads with hot bolt paste and position them.
– Mount the bracket for the heat shield with the nuts -1 and 2-.
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⇒ “4.1 Overview - Exhaust Manifold”, page 349 .
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5 Special Tools
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28 – Ignition/Glow Plug System

1 Ignition System
⇒ “1.1 Overview - Ignition System”, page 355
⇒ “1.2 Test Data and Spark Plugs”, page 357
⇒ “1.3 Ignition Coils with Power Output Stages , Removing and
⇒ “1.4 Knock Sensor 1 and 2 G61 and G66 , Removing and In‐
⇒ “1.5 Camshaft Position Sensor G40 and G163 , Removing and
⇒ “1.6 Engine Speed Sensor G28 , Removing and Installing”,
page 362
1.1 Overview - Ignition System
WARNING

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1. Ignition System 355

1 - Bolt
❑ 9 Nm
2 - Camshaft Position Sensor -
G40-
ling. Refer to
⇒ “1.5 Camshaft Posi‐
tion Sensor G40 and
G163 , Removing and
3 - O-Ring
❑ Replace
4 - Knock Sensor
❑ Knock Sensor 1 - G61-
(right), Knock Sensor 2 -
G66- (left)
ling. Refer to
⇒ “1.4 Knock Sensor 1
and 2 G61 and G66 ,
ling”, page 360 .
5 - Bolt
❑ 20 Nm
6 - Spark Plug
❑ 30 Nm
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❑ Remove and install with

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8 - Bolt
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9 - Wiring Harness
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11 - Bolt
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13 - Camshaft Position Sensor 2 - G163-

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14 - Bolt Prote AG.
❑ 9 Nm
356 Rep. Gr.28 - Ignition/Glow Plug System

AG. Volkswagen AG d Touareg 2010 ➤ , Touareg 2015 ➤
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Engine Code CGFA
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Ignition sequence 1-4-3-6-2-5
Spark Plugs
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VW/Audi. Refer to 1). 101 905 611 G
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Electrode gap Maximum 1.1 mm

Tightening Specification 30 Nm
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1) Refer to the Parts Catalog for the current spark plugs.
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Ignition Coils with Power Output

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Stages , Removing and Installing

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Note
♦ Follow all safety precautions. Refer to

⇒ “1.4 Ignition System Safety Precautions”, page 2 .
♦ To remove the spark plugs, place the Puller - Ignition Coil -
T40039- on topmost thick rib -arrow- of the Ignition coil with
power output stage.
♦ The lower ribs may be damaged if they are used.
Right Ignition Coils with Power Output Stages (Bank 1), Remov‐
ing:
page 37 .

– Remove the engine cover -2- upward.
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– Release the clips -arrows- and remove the air filter upper sec‐
tion.

– Remove the bolts -arrows- and disconnect the connectors on

the ignition coils.
– Remove the ignition coils using the Puller - Ignition Coil -

T40039- .
Left Ignition Coils with Power Output Stages (Bank 2), Removing:
WARNING

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– Unclip the high voltage cablesisefrom the bracket -arrows-.
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– Press the connector locks -arrows- one after another and re‐
move the connectors -1- from the ignition coils with power
output stages.
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– If necessary, push the high voltage cables to the side and re‐
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move the ignition coils using the Puller - Ignition Coil -
T40039- .
t to the co
Installing:
– Insert all ignition coils loosely into the spark plug shaft.
– Align the ignition coils and push them all the way onto the spark rrectnes
plugs by hand.
s o
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⇒ “1.1 Overview - Ignition System”, page 355 .

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1.4 Knock Sensor 1 and 2 - G61- and -

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– Remove the compressor. Refer to cop Vo
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– Remove the applicable intake manifold lower section. Refer to

– Remove the connector -3- (green) for the Knock Sensor 1 -
G61- from the bracket.

– Remove the connector -2- (gray) for the Knock Sensor 2 - G66-
from the bracket and disconnect it.
– Remove the screw -1- for Knock Sensor 1 - G61- and the
screw -2- for the Knock Sensor 2 - G66- and then remove the
knock sensors.
Installing
– Install the left and right intake manifold lower sections. Refer
to
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– Install the compressor.
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1.5 Camshaft Position Sensor - G40- and -
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Camshaft Position Sensor - G40- , Removing:

– Remove the secondary air pipe from the bracket.
– Remove the bolt -arrow- and the Camshaft Position Sensor -
G40- .
Camshaft Position Sensor 2 - G163- , Removing:
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– Remove the bolt -arrow- and the Camshaft Position Sensor 2 ss
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1.6 Engine Speed Sensor - G28- , Remov‐
nf
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Removing
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– Remove the noise insulation. Refer to ⇒ Body Front; Rep. Gr.

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– Disconnect the connector from the Engine Speed Sensor -

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– Remove the bolt -1- from the front final drive. Pry out the rubber
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– Remove the bolt -1- and the Engine Speed Sensor - G28- .
Installing
– Insert the Engine Speed Sensor - G28- -1- into the opening on
the engine and push it in until it stops.
Front final drive bolt: 90 Nm.
Engine Speed Sensor - G28- : 10 Nm
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2 Special Tools
♦ Puller - Ignition Coil - T40039-
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3 Revision History
DRUCK NUMBER: K0058965521
Fac‐ Edit Job Fee Notes Quality
tory Edi‐ Type dba Checke
Edi‐ tion ck d By
tion
07.2 07/2 Fac‐ N/A Eric P.

015 4/20 tory
15 Up‐
date
02.2 03/1 Fac‐ N/A Eric P.
015 1/20 tory
15 Up‐
date
09.2 11/0 Cor‐ N/A Removed fluid capacities, Eric P.
014 7/20 rec‐ and linked to fluid capaci‐
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3. Revision History 365

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Cautions & Warnings autho tee
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Please read these WARNINGS and CAUTIONS before proceeding with maintenance
rm
ab
pe
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and repair work. You must answer that you have read and you understand these
ot
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WARNINGS and CAUTIONS before you will be allowed to view this information.
h re
hole
spec
es, in part or in w
•= If you lack the skills, tools and equipment, or a suitable workshop for any procedure described in this manual, we
t to the co
suggest you leave such repairs to an authorized Volkswagen retailer or other qualified shop. We especially urge
you to consult an authorized Volkswagen retailer before beginning repairs on any vehicle that may still be covered
wholly or in part by any of the extensive warranties issued by Volkswagen.
rrectness of i
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•= Disconnect the battery negative terminal (ground strap) whenever you work on the fuel system or the electrical
system. Do not smoke or work near heaters or other fire hazards. Keep an approved fire extinguisher handy.
nform
ercia
•= Volkswagen is constantly improving its vehicles and sometimes these changes, both in parts and specifications,
m
a
com
t
are made applicable to earlier models. Therefore, part numbers listed in this manual are for reference only. Always
ion in
check with your authorized Volkswagen retailer parts department for the latest information.
r
te o
thi
s
iva
do
•=
r
Any time the battery has been disconnected on an automatic transmission vehicle, it will be necessary to
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reestablish Transmission Control Module (TCM) basic settings using the VAG 1551 Scan Tool (ST).
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•=
.
Never work under a lifted vehicle unless it is solidly supported on stands designed for the purpose. Do not support
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a vehicle on cinder blocks, hollow tiles or other props that may crumble under continuous load. Never work under acop Vo
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vehicle that is supported solely by a jack. Never work under the vehicle while the engine is running.
agen
Prote AG.
•= For vehicles equipped with an anti-theft radio, be sure of the correct radio activation code before disconnecting the
battery or removing the radio. If the wrong code is entered when the power is restored, the radio may lock up and
become inoperable, even if the correct code is used in a later attempt.
•= If you are going to work under a vehicle on the ground, make sure that the ground is level. Block the wheels to
keep the vehicle from rolling. Disconnect the battery negative terminal (ground strap) to prevent others from
starting the vehicle while you are under it.
•= Do not attempt to work on your vehicle if you do not feel well. You increase the danger of injury to yourself and
others if you are tired, upset or have taken medicine or any other substances that may impair you or keep you from
being fully alert.
•= Never run the engine unless the work area is well ventilated. Carbon monoxide (CO) kills.
•= Always observe good workshop practices. Wear goggles when you operate machine tools or work with acid. Wear
goggles, gloves and other protective clothing whenever the job requires working with harmful substances.
•= Tie long hair behind your head. Do not wear a necktie, a scarf, loose clothing, or a necklace when you work near
machine tools or running engines. If your hair, clothing, or jewelry were to get caught in the machinery, severe
injury could result.
•= Do not re-use any fasteners that are worn or deformed in normal use. Some fasteners are designed to be used
only once and are unreliable and may fail if used a second time. This includes, but is not limited to, nuts, bolts,
washers, circlips and cotter pins. Always follow the recommendations in this manual - replace these fasteners with
new parts where indicated, and any other time it is deemed necessary by inspection.
Page 1 of 3
© 2002 Volkswagen of America, Inc.
All rights reserved. Information contained in this document is based on the latest information available at the time of printing and is subject to the copyright and other intellectual property rights of
Volkswagen of America, Inc., its affiliated companies and its licensors. All rights are reserved to make changes at any time without notice. No part of this document may be reproduced, stored in a
retrieval system, or transmitted in any form or by any means, electronic, mechanical, photocopying, recording, or otherwise, nor may these materials be modified or reposted to other sites, without
the prior expressed written permission of the publisher.
Version 1.0
Cautions & Warnings
•= Illuminate the work area adequately but safely. Use a portable safety light for working inside or under the vehicle.
Make sure the bulb is enclosed by a wire cage. The hot filament of an accidentally broken bulb can ignite spilled
fuel or oil.
•= Friction materials such as brake pads and clutch discs may contain asbestos fibers. Do not create dust by
grinding, sanding, or by cleaning with compressed air. Avoid breathing asbestos fibers and asbestos dust.
Breathing asbestos can cause serious diseases such as asbestosis or cancer, and may result in death.
•= Finger rings should be removed so that they cannot cause electrical shorts, get caught in running machinery, or be
crushed by heavy parts.
•= Before starting a job, make certain that you have all the necessary tools and parts on hand. Read all the
instructions thoroughly; do not attempt shortcuts. Use tools that are appropriate to the work and use only
replacement parts meeting Volkswagen specifications. Makeshift tools, parts and procedures will not make good
repairs.
•= Catch draining fuel, oil or brake fluid in suitable containers. Do not use empty food or beverage containers that
might mislead someone into drinking from them. Store flammable fluids away from fire hazards. Wipe up spills at
once, but do not store the oily rags, which can ignite and burn spontaneously.
•= Use pneumatic and electric tools only to loosen threaded parts and fasteners. Never use these tools to tighten
fasteners, especially on light alloy parts. Always use a torque wrench to tighten fasteners to the tightening torque
listed.
•= Keep sparks, lighted matches, and open flame away from the top of the battery. If escaping hydrogen gas is
ignited, it will ignite gas trapped in the cells and cause the battery to explode.
•= Be mindful of the environment and ecology. Before you drain the crankcase, find out the proper way to dispose of
the oil. Do not pour oil onto the ground, down a drain, or into a stream, pond, or lake. Consult local ordinances that
govern the disposal of wastes. en AG. V
olkswagen AG
ag does
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•= The air-conditioning (A/C) system is filled with a b
chemical refrigerant that is hazardous. arThe
ise
d an A/C system should be
r tee
serviced only by trained automotive serviceutechnicians
tho using approved refrigerant recovery/recycling
or equipment,
a ac
trained in related safety precautions, andssfamiliar with regulations governing the discharging and disposal of
ce
e
automotive chemical refrigerants.

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•= Before doing any electrical welding on vehicles equipped with anti-lock brakes (ABS), disconnect the battery
erm
ab
ility
negative terminal (ground strap) and the ABS control module connector.
ot p
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•= Do not expose any part of the A/C system to high temperatures such as open flame. Excessive heat will increase
hole
spec
system pressure and may cause the system to burst.

es, in part or in w
t to the co
•= When boost-charging the battery, first remove the fuses for the Engine Control Module (ECM), the Transmission
Control Module (TCM), the ABS control module, and the trip computer. In cases where one or more of these
rrectness of i
components is not separately fused, disconnect the control module connector(s).

l purpos
•= Some of the vehicles covered by this manual are equipped with a supplemental restraint system (SRS), that
automatically deploys an airbag in the event of a frontal impact. The airbag is operated by an explosive device.
nform
ercia
Handled improperly or without adequate safeguards, it can be accidentally activated and cause serious personal
injury. To guard against personal injury or airbag system failure, only trained Volkswagen Service technicians
m
at
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io
should test, disassemble or service the airbag system.

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Page 2 of 3
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© 2002 Volkswagen of America, Inc. cop Vo
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Version 1.0
Cautions & Warnings
•= Do not quick-charge the battery (for boost starting) for longer than one minute, and do not exceed 16.5 volts at the
battery with the boosting cables attached. Wait at least one minute before boosting the battery a second time.
•= Never use a test light to conduct electrical tests of the airbag system. The system must only be tested by trained
Volkswagen Service technicians using the VAG 1551 Scan Tool (ST) or an approved equivalent. The airbag unit
must never be electrically tested while it is not installed in the vehicle.
•= Some aerosol tire inflators are highly flammable. Be extremely cautious when repairing a tire that may have been
inflated using an aerosol tire inflator. Keep sparks, open flame or other sources of ignition away from the tire repair
area. Inflate and deflate the tire at least four times before breaking the bead from the rim. Completely remove the
tire from the rim before attempting any repair.
•= When driving or riding in an airbag-equipped vehicle, never hold test equipment in your hands or lap while the
vehicle is in motion. Objects between you and the airbag can increase the risk of injury in an accident.
I have read and I understand these Cautions and Warnings.
AG. Volkswagen AG d
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Page 3 of 3
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© 2002 Volkswagen of America, Inc. by c lksw
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Prote AG.
Version 1.0

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Service

Service Department. Technical Information

26 - Exhaust System, Emission Controls

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Copyright © 2015 Volkswagen AG, Wolfsburg D3E802EBC6C

00 - General, Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

3.1 Engine Compartment Cover, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37

13 - Crankshaft, Cylinder Block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42

1 Cylinder Block, Belt Pulley Side . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42

1.1 Overview - Supercharger Ribbed Belt Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42

1.2 Supercharger Ribbed Belt, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43

1.4 Overview - Ribbed Belt Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44

1.6 Ribbed Belt Tensioner, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46

1.8 Sealing Flange, Removing and Installing, Belt Pulley Side . . . . . . . . . . . . . . . . . . . . . . . . 48

2 Cylinder Block, Transmission Side . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52

2.1 Overview - Drive Plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52

2.2 Drive Plate, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53

2.3 Sensor Wheel, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53

2.4 Sensor Wheel, Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54

3.4 Crankshaft, Measuring Radial Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61

15 - Cylinder Head, Valvetrain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75

3 Chain Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103

3.6 Drive Chain Balance Shaft, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112

4.3 Camshaft, Measuring Radial Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121 thi

4.4 Camshaft, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121

4.5 Camshaft Adjuster, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128

2.1 Engine Oil Cooler, AGRemoving

4 Oil Filter/Oil Pressure Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 168

4.2 Oil Pressure Switch F22 , Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 169

4.4 Oil Pressure, Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 171

19 - Cooling System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 177

1.4 Coolant System, Checking for Leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 185

1.6 Engine Coolant System, Draining, High Temperature Circuit . . . . . . . . . . . . . . . . . . . . . . 196

20 - Fuel Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 228

2.1 Overview - Fuel Delivery Unit/Fuel Level Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 237

1 Charge Air System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1.3 Charge Air Cooler, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 273

2.1 Overview - Supercharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 277

2.4 Supercharger, Checking for Leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 283

2.7 Supercharger, Securing to Engine/Transmission Holder for Leak Test . . . . . . . . . . . . . . . . 288

3 Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 290

24 - Multiport Fuel Injection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 293

1 Injection System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 293

1.1 Vacuum System, Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 293

26 - Exhaust System, Emission Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 332

1.1 Overview - Muffler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 332

1.2 Exhaust Pipes/Mufflers, Disconnecting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 333

2.1 Overview - Emissions Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 336

28 - Ignition/Glow Plug System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 355

00 – General, Technical Data

– Wear protective eyewear.

– Reduce the pressure: Lay clean cloths around the connection

Leaking Fuel Is a Fire Hazard.

When the battery is connected, the door contact switch activates

ignite and start a fire.

1.3 Safety Precautions, Road Test with

1.4 Ignition System Safety Precautions

– Switch off the ignition before connecting and disconnecting

– Switch off the ignition before an engine wash.

– Wear safety gloves.

cloth and carefully open.

2 Rep. Gr.00 - General, Technical Data

Vehicle data label locations. Refer to ⇒ Maintenance ; Booklet